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Polaris 120 XC SP - page 1
2003 120 X C SP Owner's Manual for V ehicle Maintenance and Safety 2003 120 X C SP Owner's Manual for V ehicle Maintenance and Safety ...
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Polaris 120 XC SP - page 2
Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. W ARNING The engine exhaust from this product contains chemicals known to cause cancer , birth de- fects or other reproductive harm. PROPOSITION 65 W ...
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Polaris 120 XC SP - page 3
1 What’ s the hottest thing on snow? Our new web site. It’ s designed just for YOU! S T echnical ti ps S New product introductions S Event schedules S Parts a nd Service M anual information S Exciting details a bout The W ay Out Check it out... www .polarisindustries.com/owner ...
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Polaris 120 XC SP - page 4
2 All infor mat ion in t hi s manual i s based upon t he l atest product dat a and speci fi cati ons avail abl e at the ti me of pri nti ng. Pol ari s Indust ri es Inc. reser ves the r ight t o make product changes and imp rov em en ts whic h ma y affec t illustra tion s or e xp lan atio ns. No part of thi s manual shall be repr oduced or used wit ...
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Polaris 120 XC SP - page 5
3 TABLE OF CONTENTS T able of C ontents 3 .......................... Wel com e 4 .................................. Introducti on 5 ............................... Important Notes for Owners and Drivers 6 ........... Preservation of the E nvironment 7 .................. V ehicle Identification N umbers 9 .................... Safety 10 ............. ...
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Polaris 120 XC SP - page 6
4 WELC OME Dear Par ents: W e be lieve your childre n should have the opportunity to e njoy The W ay Out e xperienc e a long with you. W e’ve pr ovided this owner ’ s manual to a ssist you and your c hildren in lea rning a bout the saf e opera tion and car e of your new Polaris snowmobile. Please re view the informa tion in this manual w ith an ...
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Polaris 120 XC SP - page 7
5 INTRODUCTION After r eading this manual, store it in the snowmobile for c onvenie nt ref ere nce . It should rema in with the snowmobile whe n sold. n This manual conta ins the latest information at the time of printing. W e reserve the right to make produc t changes and improve ments without notice. n The illustra tions and photos use d in this ...
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Polaris 120 XC SP - page 8
6 INTRODUCTION Impor tant Notes for Owner s and Dr ivers P ARENT S: Do not allow anyone unde r the age of six (6) to operate this mach ine. Revie w the infor mation in this manua l with a ny child who may b e operati ng t he sno wmo bil e. It is up t o you t o teach any opera tor the proper and sa fe way to ride a snowmobile. Y ou must set boundari ...
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Polaris 120 XC SP - page 9
7 INTRODUCTION Pr eservation of the E nvironm ent T each your child t o drive their s nowmobile w i th consi deration for th e protec tion and pr eser vation of the environme nt. Noise Level One of the most publicize d subjec ts with rega rd to snowmobile s is noise. The Society of Automotive Engine ers (SAE) , which is the standar d-se tting body ...
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Polaris 120 XC SP - page 10
8 INTRODUCTION Pr eservation of the E nvironm ent Environm ental Protection As part of the continuing environmenta l education ca mpaign, we are enc ouraging state a nd provincia l governme nts across the snowbelt to adopt rigorous sa fety tr aining progr ams which a lso enc ourage protec tion of our environme nt, wildlife and vege tation. Snowmobi ...
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Polaris 120 XC SP - page 11
9 INTRODUCTION V ehicl e Identification N umber s The fra me vehicle ide ntifica tion number (VIN) a nd engine seria l number a re impor tant for model identific ation w hen re gister ing your vehi cle, when o btai ni ng in suran ce, and w hen orderi ng rep lacem ent parts. In the eve nt your vehicle is stolen, these numbers are e ssential to the r ...
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Polaris 120 XC SP - page 12
10 SAFE TY Equipm ent Modifi cations All Polaris snowmobiles ha ve be en designe d and te sted to pr ovide saf e operat io n when us ed as di rected. F ail ure of crit ical m achi ne compone nts may re sult from oper ation w ith any modific ation; espec ially those that increa se speed or power . There’ s a significant possibility of loss of cont ...
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Polaris 120 XC SP - page 13
11 SAFE TY Maintenance Pr ogram As with all snowmobiles, caution must be obse rve d to ensure opera tor safe ty . Par ticular c aution must be take n to make sure that the snowmobile is in e xce llent oper ating c ondition at a ll times. W e strongly re comme nd that the ope ra tor , as we ll as an a dult, chec k major and vi tal safet y component ...
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Polaris 120 XC SP - page 14
12 SAFE TY Safety Decals Safet y and warn ing d ecals h ave been pl aced on th e vehi cle for th e opera tor ’ s protec tion. Make sure the oper ator under stands the info rmat io n on all d ecals . If any d ecal becom es illegible or come s of f, contact your P olari s dealer for a replacement . Any safety decal needi ng rep lacem ent wi ll b e ...
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Polaris 120 XC SP - page 15
13 SAFE TY The following signa l words and symbols a ppea r throughout this manual a nd on your vehic le. Y our safe ty is involved whe n these wor ds and symbols are use d. Become f amilia r with their mea nings befor e rea ding the manual. The safety aler t sy mbol , on y our vehic le or in this manual, alert s you t o the pot ential f or pers on ...
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Polaris 120 XC SP - page 16
14 YOU TH SECT IO N Know Y our S nowm obile Befor e you have an adult star t the engine for you for the first time, let’ s lear n about the c ontrols on your ne w mac hine. 1. Engine St op Switc h - When the engine is running, you ca n push this button down and the e ngine w ill stop. The stop sw itch must be in the UP position to start the engin ...
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Polaris 120 XC SP - page 17
15 YOU TH SECT IO N Know Y our S nowm obile 6. Bra ke L ever - S qu eeze the b rake lev er to ward t he han dleb ar to make your snowmobile slow down or stop. 7. Ignit ion Swit c h - The ignition sw itch ke y must be turne d ON befor e pulling on the recoil star ter ha ndle to start your snowmobile. Y ou can a lso use this key to tur n of f the e n ...
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Polaris 120 XC SP - page 18
16 YOU TH SECT IO N Know Y our S nowm obile Let’ s l ea rn more about the parts of your snowmobile befo re we talk about riding. 1 2 3 4 5 6 9 8 10 7 ...
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Polaris 120 XC SP - page 19
17 YOU TH SECT IO N Know Y our S nowm obile 1. Hood - The hood covers the moving and hot parts of t he engine and must be secure ly latche d befor e you ride the snowmobile. 2. Headlight - The he adlight is always on when the engine is running. It helps other s see you whe n you’re riding during daylight, but it’ s not supposed to be str ong en ...
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Polaris 120 XC SP - page 20
18 YOU TH SECT IO N Know Y our S nowm obile Let ’ s review t he t hree w ays to stop yo ur sn ow mob il e: 1. Push the stop switch dow n. 2. Pull of f the te ther stra p. 3. T urn the key of f . 1 2 3 ...
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Polaris 120 XC SP - page 21
19 YOU TH SECT IO N Pre-Rid e Chec k Y ou’re a lmost rea dy to have an a dult start your snowmobile . Before the snowmobile is starte d for the fir st time, you must do a PRE-RIDE CHECK. In fa ct, eve ry time you r ide your snowmobile you must have an adul t hel p you ch eck thes e thi ngs b efore st arti ng it . Let’ s l earn about these thing ...
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Polaris 120 XC SP - page 22
20 YOU TH SECT IO N Pre-Rid e Chec k n Have an adult che ck the gas leve l to see if your snowmobile ne eds more. Childre n should neve r add the ir own gasoline . This must always be done by an adult. Before anyone a dds gasoline to your snowmobile they must r ead the instructions a nd war nings on page 46 in this Owne r ’ s Manua l. n Have an a ...
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Polaris 120 XC SP - page 23
21 YOU TH SECT IO N Ridi ng Rules Now you’re rea dy to lear n about driving your Pola ris snowmobile. There a re some things you can do and there ar e some things you must never do. Rules are ve ry importa nt when you’re driving a snowmobile. Adults have r iding rules, too. The rules he lp keep us sa fe whe n we ride. Y ou m us t be at leas t s ...
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Polaris 120 XC SP - page 24
22 YOU TH SECT IO N Ridi ng Rules " Always wear the right kind of clothing when you’re riding your snowmobile. Y ou’ll nee d a good helme t with a f ac e shield or goggles. W ear a w arm jacke t and snowpants. Make sure your cloth- ing fits prope rly . If it’ s too small, it could ke ep you fr om moving easily . If it’ s t oo big, it c ...
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Polaris 120 XC SP - page 25
23 YOU TH SECT IO N Ridi ng Rules " Always drive your snow mobile while sitting down. Keep both hands on the ha ndleba rs and ke ep both fe et on the r unning boards. " Neve r follow a nother snowmobile too c losely . Alwa ys allow lots of time an d space to stop your snowmobile . " Ride your snowmobile only where you know it’ s sa ...
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Polaris 120 XC SP - page 26
24 YOU TH SECT IO N Ridi ng Rules Lear n how to ride safe ly and c orre ctly . Lea rn how to use your hands and ar ms as signals. Read a nd understa nd your Owner’ s Manual. Left T urn Right T urn Stop ...
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Polaris 120 XC SP - page 27
25 ADULT SECTION Pre-Rid e Chec k It’ s up to you, t he adult, to t each your child th e proper and safe way to ride a snowmobile. Y ou must set boundaries and adhe re to them, keeping your child’ s safety f ore most in your mind. Never a llow your child to opera te this machine w ithout adult supervision. n Check the throttle f or prope r oper ...
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Polaris 120 XC SP - page 28
26 ADULT SECTION Pre-Rid e Chec k Befor e S tar ting The E ngine n Re ad a nd U nder st and Y our Owne r ’ s Manua l Read and make sure the oper ators under stand the Owner ’ s Manual comple tely bef ore allowing a nyone to operate this snowmobile. It’ s also a good ide a to re view it periodic ally to re infor ce the infor mation. It’ s ve ...
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Polaris 120 XC SP - page 29
27 ADULT SECTION Pre-Rid e Chec k n Check t hro ttl e safety sw it ch T est the throttle saf ety switch syste m on a daily basis befor e the machine is used. While se ate d in a normal riding position, and with the engine idling, hold the throttle leve r pin stationar y by exe rting pre ssure on the pivot pin in the dire ction show n in the illustr ...
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Polaris 120 XC SP - page 30
28 ADULT SECTION Pre-Rid e Chec k n Check en gi ne st op swi tch T est the engine stop switch bef ore each us e of t he sn owm obi le. T o stop the engine in an e mer genc y , push down on the stop switch (A) . This will ground out the ignition and bring the engine to a quick stop. T o resta rt the engine, the switch m u s tb ep u l l e du pt ot h ...
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Polaris 120 XC SP - page 31
29 ADULT SECTION Operation Warnings n Do n ot carry p assen gers This snowmobile is designed for a single opera tor . n Do n ot o p erate wi th in take si len cer removed n Stay cl ear of t rack n Do no t op erate wit h dri ve chain g uard remo ved If the engine is oper ated wit h the int ake silenc er remov ed, damage t o the engine may oc cur . D ...
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Polaris 120 XC SP - page 32
30 ADULT SECTION Operation Warnings n Do not touch the engine a ft er it ’ s be en running n Disab led o perat ors Hot com ponents c an cause s erious burns to sk in. Do not touc h engine and exhaust par ts af ter the engine has been running. W ARNING Safe oper ation of this r ider-ac tive v ehicle requir es good judgement and physic al skills. P ...
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Polaris 120 XC SP - page 33
31 ADULT SECTION Operation Warnings n Check b rake lever t ravel Measu re th e clearan ce betw een the l ever and brak e block. Inspec tion should be made with the lev er firmly de presse d. Distanc e A should be no more than 3/4 ″ (1.9 cm ). Exces si ve trav el i ndi cates a need t o adj us t t he brak e cable. Refer t o t he mech anical brak e ...
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Polaris 120 XC SP - page 34
32 ADULT SECTION Operation Warnings n Che ck s ur roundings to ve r ify c lea r oper at ing are a It’ s important to make sure ther e’ s a clear a rea a ll around the snowmobile, including an area c lea r of bystander s. Some sideways movement is possible when sta rting out, and debr is may be thrown by the t rack. T each t he op erato r to ch ...
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Polaris 120 XC SP - page 35
33 ADULT SECTION Operation Warnings n Stop engine be for e at tem pting adjus tm ent s n Alwa ys we a r clothing des igne d for snowm obiling Clothing designed f or snowmobiling is wa rm, comf orta ble and sa fe . The s nowmobile engine compar tment cont ains mov ing part s. Shields and guar ds have been prov ided for s afet y , but it is s till po ...
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Polaris 120 XC SP - page 36
34 ADULT SECTION Operation Warnings n Know limita tions of m ac hine and sk ills of driv er The opera tor should be aware tha t there ar e state and loca l laws governing snowmobile opera tion and tha t these la ws should be followe d. They ha ve bee n esta blished for the pro tection o f all snowmobile rider s. Most states of fe r a snowmobile saf ...
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Polaris 120 XC SP - page 37
35 ADULT SECTION Operation Warnings W i re fences are a s erio us h azard. T each your child to a lways be on the aler t for fences. S ing le s trand s are es pecial ly dang erous , s ince t here can b e a great distance betwe en posts. Guy wire s on utility poles a re a lso dif ficult to distinguis h. T each your chi ld to reduce sp eed when trav ...
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Polaris 120 XC SP - page 38
36 ADULT SECTION Operation Warnings Windchill/T emper ature Charts The following informa tion is provided as a guide to determine wha t temper ature s are danger ous when riding your snowmobile. WIND CHILL CHAR T ( ° F) Est i- m a t e d Actual Ther mometer Reading ( ° F) mate d Wind Speed i n M P H 50 40 30 20 10 0 -10 -20 -3 0 -4 0 -5 0 -6 0 in ...
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Polaris 120 XC SP - page 39
37 ADULT SECTION Operation Warnings WIND CHILL CHAR T ( ° C) Est i- m a t e d Actual Ther mometer Reading ( ° C) ma t e d Wind S p e e d 5 0 -5 -10 -15 -2 0 -25 -3 0 -35 -40 S pee d in KPH Equivalent T emperature ( ° C) 0 5 0 -5 -10 -15 -2 0 -25 -3 0 -35 -40 10 1 -4 -1 1 -16 -22 -2 7 -33 -3 8 -45 -50 20 -4 -9 -17 -23 -29 -3 6 -42 -4 8 -54 -61 30 ...
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Polaris 120 XC SP - page 40
38 ADULT SECTION Operation Warnings Cold Weather Dr ive - A way Whe neve r the mach ine has bee n parke d for some length of time, espec ially over night, always shake loose the skis and track for the opera tor bef ore atte mpting to put the machine into motion. The throttle will re quire some pre ssure to move the mac hine. T each t he opera tor n ...
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Polaris 120 XC SP - page 41
39 ADULT SECTION Operation Warnings Snow and Ice Build - Up Snow and ice buildup in the under hood ar ea c an inte rfe re with the st eering . Hard P acked Snow T each your child t o reduce speed as required to m aintai n control in al l driving conditions. If nec essar y , maximum spee d may be r egula ted by using the procedure outline d on page ...
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Polaris 120 XC SP - page 42
40 ADULT SECTION Operation Warnings Driving on Ice It is dangerous to opera te on ice or under slipper y conditions. If ice or slippery conditions ar e unavoida ble, use extreme c aution and ope rate a t speed s no fas ter th an a walk. Never att emp t an abru pt chan ge of direct io n on a s li ppery s urface. The chan ce of “sp in-o ut ” incr ...
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Polaris 120 XC SP - page 43
41 ADULT SECTION Operation Warnings Driving Downhill Whe n riding downhill, the oper ator must keep the speed a t a minimum. It is importa nt to apply just enough throttle to kee p the clutc h enga ged while desc ending the hill. This will allow use of the engine ’ s compr ession to help slow the mac hine, and ke ep the snowmobile f rom rolling f ...
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Polaris 120 XC SP - page 44
42 ADULT SECTION Com ponent Identification 1. Hood 8. Rear Suspension 2. Headlight 9. Nosepan 3. W indshield 10. T railing A rm 4. Handleba r 1 1. S kis 5. Seat 12. F ront Bumper 6. Storage (unde r seat) 13. Rear Bumper 7. T aillight 14. Snow Flap 8. T rack 2 1 3 4 5,6 7 8 9 10 11 12 14 13 8 ...
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Polaris 120 XC SP - page 45
43 ADULT SECTION Com ponent Identification 1. Stop Switch 2. T ethe r Strap 3. Thro ttle Control 4. R ecoi l S tart er Handl e 5. Hood Hold-Down 6. Choke Button 7. Gas Cap 8. Ignition Switc h 9. Console 10. Brak e Lever 1 1. T ether Switch 10 8 11 6 3 1 4 7 9 2 5 5 ...
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Polaris 120 XC SP - page 46
44 ADULT SECTION Br eak-In Per iod Engi ne Br eak- In The brea k-in period for your new snowmobile is def ined as the first ten hours of opera tion, or the time it takes to use the first two tanks full of gasoline. No single a ction on your part is as impor tant as a proper brea k-in pe riod. Care ful tr eatme nt of a new engine will r esult in mor ...
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Polaris 120 XC SP - page 47
45 ADULT SECTION Br eak-In Per iod Checking Engin e Oil Befo re c hec king or r ef illing engine oil, be sure the engine is stopped and the vehic le is positioned on a stable, level s urface. NOTE: Alw ays cha nge the oil if it’ s becom e con tam inat ed. 1. Remove the dipstic k and wipe it dry with a cle an shop towe l. 2. Inse rt the dipstick ( ...
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Polaris 120 XC SP - page 48
46 ADULT SECTION Operation Fuel When refuel in g, u se eit her lead ed or unl eaded gas ol ine wi th a minimum pump octane number of 87=( R+ M/2) octane. Fuel Safety Gasoline is highly f lammable and explos ive under c ertain conditi ons. S Always ex ercise ex tr eme caut ion whenever handling gas oline. S Always r efuel wit h the engine s topped, ...
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Polaris 120 XC SP - page 49
47 ADULT SECTION Operation Speed/Per form ance Regulation Adults have the re sponsibility for t eachin g chil dren t he prop er and safe way to ride a snowmobile. Please set boundarie s and adhere to them, keep ing your child’ s safe ty fore most in your mind. Never allow a child to operate this ma chine without adult superv ision. Under certai n ...
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Polaris 120 XC SP - page 50
48 ADULT SECTION Operation Sta rti ng the Engine Never sta rt the snowmobile without checking all compone nts to be sure of prope r oper ation. Refer to the Pre-Ride Chec k beginning on page 25. Star ting a Cold E ngine 1. T urn the key to O N. 2. Pull the engine stop switc h (shut-o f f switch) up to the RUN position. 3. Pull the choke lever c omp ...
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Polaris 120 XC SP - page 51
49 ADULT SECTION Operation Em er genc y Stoppi ng Pr ocedur es The following cha rt lists methods for stopping the engine in the event of an em ergency . SYSTEM WHA T IT DOES THROTTLE CONDITIO N Engine Stop Switc h Interr upts ig nition circuit All Ignitio n Sw itch Interr upts ig nition circuit All T ether Sw itch Interr upts ig nition circuit All ...
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Polaris 120 XC SP - page 52
50 ADULT SECTION Operation Pre - Ri de Warm - Up Always war m up the engine , drive train and tr ac k befor e oper ating the snowmobile. W ith the snowmobile sec ure ly supported b y the re ar bumper with a minimum clea ra nce of 4 ″ (10 cm) f rom the ground, use the following pr ocedur e to prope rly war m up the snowmobile. 1. Start the engine ...
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Polaris 120 XC SP - page 53
51 ADULT SECTION Maintenance Polaris R ecomm ended M aintenance Program Y our Polaris snowmobile ha s been e nginee red a nd manufa cture d by skilled Polaris personne l to t he highest degre e of perf ormanc e and relia bility possible. In or der to ma intain this leve l of quality , your mach ine must have regula r serv ice and ma intenanc e insp ...
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Polaris 120 XC SP - page 54
52 ADULT SECTION Maintenance Care ful periodic ma intenanc e will help keep your vehic le in the safest, most relia ble condition. In spection, ad justment and lubr ica tion of important c omponents ar e e xplained in the f ollowing cha rt and in the mainte nance se ction of this manual. Ser vice a nd adjustments ar e cr itica l. If you’re not fa ...
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Polaris 120 XC SP - page 55
53 ADULT SECTION Maintenance ITEM DAIL Y WEEKL Y OR BEFORE EXTEND ED PERIO D OF OPER A TIO N 50 HRS 100 HRS 150 HRS SEE PA G E Check tr ack ali gnment X 69 Che ck dr ive ch ain te nsio n X 60 Check and ti ghten any l oose suspensi on mount ing bol ts X 77 T i ghten ski saddle and spindl e bo lts if loo se X 74 Check fr ont and rear li mit er str ap ...
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Polaris 120 XC SP - page 56
54 ADULT SECTION Mai ntena nce Present this s ectio n of your manual t o your dealer each time your snowmobile is service d. This will provide you and future owner s with an accurate l og of mai nt enance and s ervi ces perform ed on t he snowmobile. 50 Hou r Init ial M aint enance In spect ion Auth ori zed Pol aris S ervi cin g Dealer Serv ici ng ...
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Polaris 120 XC SP - page 57
55 ADULT SECTION Maintenance Spa rk P lugs A new e ngine c an ca use te mporar y spark plug f ouling eve n though the heat ra nge is proper , due to the preserva tive whic h has been adde d during asse mbly of the e ngine to c ombat rust a nd cor rosion. A void prolonged idle speed s, as plug fouling and c arboniz ation w ill result. S Use BR6ES sp ...
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Polaris 120 XC SP - page 58
56 ADULT SECTION Maintenance Spa rk P lugs Spark Plug R emoval an d Rep lacement 1. Remove the spark plug ca p. 2. Using the spec ial wrenc h provided in the tool pouch, rotate the spark plug c ounterc lockwise to r emove. 3. Rever se the proce dure for spa rk plug installation. T orque to 12-14 ft. lbs. (16.6-19.3 Nm). Fuel V alve/Fuel L ines The ...
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Polaris 120 XC SP - page 59
57 ADULT SECTION Maintenance Car bur etor Proper c ar bure tor adjustment is critic al, since a mixture too lea n (too much a ir , too little fuel) w ill result in ove rhe ating of the combustion cha mber c ausing pr e-ignition of the fue l. This results in piston burning, bearing fa ilure , or complete engine fa ilure . A lean mixture ca n be the ...
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Polaris 120 XC SP - page 60
58 ADULT SECTION Maintenance Throttl e Cabl e Lubri cation W ith the engine of f, lubricate the thr ottle cable o ccasi onal ly . T urn t he han dl ebars to the lef t and lubric ate liberally with Po lari s All S easo n Grease. Choke /Ca ble Lubr icat ion Lubrica te the choke slide and ca bles occasional ly as s hown. Operate t he choke intermitte ...
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Polaris 120 XC SP - page 61
59 ADULT SECTION Maintenance Brake A djustment If excess iv e brake l ever t o brak e bl ock cl earance i s evi dent , t he b rake cab le should be adjusted. If prope r adjustment ca nnot be achie ved by using the following methods, check the brake ba nd for exc essive wea r . Y our snowmobile dealer c an install a new brake ba nd when nece ssary . ...
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Polaris 120 XC SP - page 62
60 ADULT SECTION Maintenance Chain T ensio ner Inspec t the chain. The cha in should have 1 ″ of deflec tion as shown. If not, loosen the nut on the cha in tensione r (A) and ra ise until 1 ″ (B) of defle ction is atta ined. T ighten nut to 15-18 ft. lbs. Whe n the c hain c omes within 1/8 ″ (C) of the muf fle r mount bracke t (D) on th e cha ...
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Polaris 120 XC SP - page 63
61 ADULT SECTION Maintenance Lubri cati on NOTE: Drive line noise is normal and inherent in a chain drive system such as t hi s mach ine us es. T o ensure long life of the snowmobile ’ s driveline, lubricate a s follows: S Lubrica te Point A eve ry 15 hours of ope ra tion with a sma ll amount of Pol aris P remi um Al l Seas on Grease. S Lubrica t ...
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Polaris 120 XC SP - page 64
62 ADULT SECTION Maintenance Oil Level Mainta in the oil leve l betw ee n the safe ma rks (A ) on the dipstick. Oil Chang e Change the oil af ter the initial 20 hours of operatio n and again after each 50 hours. W ashing Y our Snowm obile Keeping your snowmobile cle an w ill not only impr ove its a ppea ra nce but it can a lso exte nd the life of v ...
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Polaris 120 XC SP - page 65
63 ADULT SECTION Maintenance Controls and L inkage All bushings, spindle shafts, and tie r od ends should be coate d with a light coa t of oil or grea se. Thr ottle a nd br ake controls a nd c able s should be lubric ated with Pola ris Premium All Sea son Grea se. Force a small amount of lubrica nt down the c able . Bearings T o pre vent cor rosion ...
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Polaris 120 XC SP - page 66
64 ADULT SECTION Maintenance Engi ne Proper of f-sea son prepa ra tion of the e ngine and f uel system is vital to the pre vention of rust and co rrosion f ormation on pr ec ision engine parts during stor age. W ithout proper stora ge, jet re striction c an c ause le an c onditions and very poor slow spee d driving quality . When pr epa ring your s ...
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Polaris 120 XC SP - page 67
65 ADULT SECTION Maintenance Car buretor P rotection Dur ing Off -S eason Stor age When pr epa ring your snowmobile for of f-season stor age w e recomm end t hat y ou add a fuel co ndi ti oner/ st abil izer or P remi um Carbon Clea n (2871326) to the fuel tank. Follow the instruc tions on the can . Run the engine for five minute s to get additives ...
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Polaris 120 XC SP - page 68
66 ADULT SECTION Maintenance T ra nspor ting the Snow mobi le Whe neve r the snowmobile is transpor ted the following mea sure s should be taken: 1. T urn the fuel valve off . 2. Be sure the f uel cap is installe d corre ctly . 3. Alwa ys tie the snowmobile to the transporting unit secur ely using suitable str aps. NOTE: T ranspor tation to a nd fr ...
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Polaris 120 XC SP - page 69
67 ADULT SECTION Maintenance T ra ck and S uspensi on Under norma l conditions modera te tr ac k tension should be mainta ined dur ing summer st orage. The r ear of th e mach ine should be supported of f the gr ound to allow f ree hanging of the trac k. T rack T ension T rack adjustme nt is cr itica l for proper ha ndling. Always mainta in cor rec ...
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Polaris 120 XC SP - page 70
68 ADULT SECTION Maintenance T rack Adjustment If the tra ck nee ds adjustment: 1. Loosen rea r idler shaf t bolt (D). 2. Tight en or loo sen t he track adj us tin g screws (B ) as necess ary to provide equa l adjustment on both sides of the track. 3. Repea t measure ment on the other side of the track. NOTE: Check m ore frequ entl y wh en th e mac ...
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Polaris 120 XC SP - page 71
69 ADULT SECTION Maintenance T rack Alignment A periodic c hec k should be made to see that the trac k is center ed and running eve nly on the slide rails. Misalignmen t will cause exc essive wea r to the tra ck a nd slide r ail. 1. Safely support the rea r of the machine with the tra ck of f the ground using a jack stan d. 2. Start the engine and ...
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Polaris 120 XC SP - page 72
70 ADULT SECTION Maintenance T rack W arm Up When stor ing your snowmobile outside overnight, it is rec ommende d that the tra ck be warmed up pr ior to driving the snowmobile. This reduc es dr ive clut ch wear . T o warm up t he track , safe ly support the rear of the snowmobile of f the ground, start the engine and abruptly e ngage the clutch . A ...
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Polaris 120 XC SP - page 73
71 ADULT SECTION Maintenance T rack Inspection Using a hoist or jackstand, safe ly lift and suppor t the rea r of the snowmobile of f the ground. Rotate the tra ck by hand to che ck f or any pos si ble d amag e. T o in spect track ro ds , carefull y ex ami ne th e track along the entire le ngth of each rod, ben din g th e track and i nsp ecti ng fo ...
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Polaris 120 XC SP - page 74
72 ADULT SECTION Maintenance Hi - Fax Replacement The 120 XC S P uses XTR A Lit e st yl e Hi-F ax. When an y are a of the Hi-Fax is worn to 7/16 ″ (1.1 cm), it should be replaced . This wil l s ave wear on other vital compone nts. T h es l i d er a i li sd e s i g n e dt o opera te in conditions with adequa te snow cover to provide suf fic ient l ...
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Polaris 120 XC SP - page 75
73 ADULT SECTION Maintenance T ra ck Lubr icat ion T rack f ailure , loss of vehic le c ontrol and br aking a bility ca n re sult from exten ded us e of thi s veh icl e on surfaces p rovi di ng margi nal l ubri cati on betwee n hi-f ax and tr ac k guide clips. Example s of mar ginal lubrica tion would include la kes without snow c over , icy trails ...
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Polaris 120 XC SP - page 76
74 ADULT SECTION Maintenance Steering Inspection and Adjustment The ste er ing assembly of the mach ine should be chec ked periodic ally for loose nuts and bolts. Se e A,B,C,D,E, F , and G in illustra tion at right. W ith handleba rs in stra ight ahe ad position and me asur ing from the straight edge of the ski s, t he meas urem ent betwee n the sk ...
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Polaris 120 XC SP - page 77
75 ADULT SECTION Maintenance Handlebar Adjustment 6. Slide the handlebar pa d upward t o access t he adj ust er bolts. If additiona l room is requir ed, unzip one of the handleba r pa d zipper s and roll the pad to the side. 7. T o adjust, remove the upper flange nut and ca rria ge bolt. 8. Loosen the lower flange nut only enough so the br ac ket c ...
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Polaris 120 XC SP - page 78
76 ADULT SECTION Maintenance Ski S kags The s kag (A) i s a repl aceabl e bar atta che d to the underside of the ski. The purpose of the skag is to assist in tur ning the snowmobile and to preven t th e wearing away of th e ski caus ed by cont act wit h road s and other ba re te rra in. W e recomm end t hat skag s b e checked once a week to ma inta ...
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Polaris 120 XC SP - page 79
77 ADULT SECTION Maintenance Sus pension Lubr ic ation T o mainta in rider comfo rt and to re tar d wea r of the pivot shafts, the suspension pivot shaf ts should be lubric ate d with Polaris Pre mium All Season G re ase se ver al times dur ing the sea son and a gain bef ore sum mer s to rage each y ear . T he rid ing charact erist ics of t he snow ...
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Polaris 120 XC SP - page 80
78 ADULT SECTION Maintenance Suspe nsion C ompone nts Suspension Lubric ation points ar e indic ated by a L . 1. Front Limite r Str ap 8. Rail Bumpe r 2. T orsion Spring Sleeve s 9. T orque Ar m 3. T orsion Spring 10. R ail 4. C arrier Wh eel 1 1. Hi-fax 5. Rea r Limiter Stra p 12. T oe Guard 6. S pacer 13. Idler Wheel 7. Adjuste r Bolts 4 6 2 1 5 ...
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Polaris 120 XC SP - page 81
79 ADULT SECTION Accessor ies Maintenance Items and Accessories The tools and ma intena nce items mentione d in this book, as well a s a long l ine o f other P ol aris acces sori es , are avail able at your P olaris deal er . Pa int Code s Colo r Descri pti on Polaris “P” No. Raw Mater ial No. Indy Red P293 8520297 Indy Black P067 8520246 Paint ...
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Polaris 120 XC SP - page 82
80 SPECIFICA TIO NS Jetting Chart Altitude A mbient T emperature Below -30 _ F Below -34 _ C -30 _ to -10 _ F -34 _ to -23 _ C -10 _ to +10 _ F -23 _ to -12 _ C +10 _ to +30 _ F -12 _ to -1 _ C +3 0 _ to +50 _ F -1 _ to +10 _ C Above +50 _ F Above +10 _ C 0-600 (0-2000) 75 72.5 72.5 72.5 70 70 M e t e r s 600-1200 (2000- - 4000) 75 72.5 72.5 72.5 7 ...
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Polaris 120 XC SP - page 83
81 SPECIFICA TIO NS Ca pa cities a nd Dim ensio ns Body St yle Mi ni Indy Ri ders/ W eight 1/150 l bs. /68 kg maxi mum Eng ine Oil .6 qt s. /. 57 l Dry W eight (est .) 147. 5 l bs. /67 kg Fue l T an k .5 ga l./1.9 l Hei ght 31 in. /78. 7 cm Lengt h 75 in. /190. 5 cm Ski Ce nte r Dista nc e 30 in. / 76.2 cm Wid th 34 in./ 86. 4 cm Brake T ype Mechan ...
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Polaris 120 XC SP - page 84
82 POLARIS RECOMMENDED PRODUCTS Part No. Descri pti on Engine Lubr icant 2871281 Premi um 4 Synt heti c 0W - 40 Engine Oi l (4- Cycle) (qt . ) Gearcase / T ransmi ssion Lubri cant s 2873602 Premi um Synthet ic Gear case Lubricant ( qt. ) 2871653 Premi um Fr ont Gearcase Lube ( 8 oz.) 2871654 Pre mium D rive H ub F luid (8 o z.) Grease / Speci ali z ...
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Polaris 120 XC SP - page 85
83 SERV ICE AND WARRANTY Pola ri s Anti - Theft System The Polar is anti- theft syste m monitoring progr am ( P A TS) is designed to ai d owners o f regis tered sn owm obi les i n recovery o f thei r machi nes, if stolen. Ad min is tra t io n 1 Polaris snowmobile owner r eports the ft. A. I n addition to notifying the proper law e nfor ce ment of f ...
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Polaris 120 XC SP - page 86
84 SERV ICE AND WARRANTY Whe n writing about parts, service or w arr anty , always include the following inf ormation: 1. Serial number 5. Details of trouble exper ience d 2. Model number 6. Length of time and conditions of opera tion 3. Deale r na me 7. I ndicate previous c orr espondenc e 4. Date of purchase Use the following space to re cord the ...
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Polaris 120 XC SP - page 87
85 WARRANTY LIM ITED W ARRANTY Polaris I ndustries Inc., 2100 Highway 55, Medina, Minnesota 55340, gives a ONE YEAR LIMITED W AR RANTY on all components of the Po lari s sno wmo bil e again st defect s in m ateri al or work mans hi p. This warranty covers the p arts an d l abor charges fo r repair o r replacem ent of defe ctive parts whic h are cov ...
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Polaris 120 XC SP - page 88
86 WARRANTY This warr anty does not c over the us e of unauthorize d lubrica nts, che mica ls, or fuels that are not compa tible with the snowmobile. The excl usi ve remedy fo r breach of thi s warrant y shal l be, at P olari s’ exclu si ve op ti on, repai r or rep lacemen t o f any d efecti ve mat erial s, or components or products. THE REMEDIES ...
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Polaris 120 XC SP - page 89
87 WARRANTY HOW TO OBT AIN W ARRANTY SERVICE If your snowmobile re quires w arr anty se rvice , you must take it to a Polaris de ale r author ized to re pair Pola ris snowmobile s. When reque sting war ranty se rvice you must present your copy of the W arrant y Regi st rati on form to t he dealer . (THE C OST OF TRANS POR T A TION TO AND FROM THE D ...
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Polaris 120 XC SP - page 90
88 WARRANTY Pol ari s Exten ded Servi ce Con tract Polaris now is of f ering a n exte nded engine ser vice contrac t which pro- vides the following benef its: S Additional engine prote ction beyond the original twelve month war- ranty . S Backe d by the str ength of Pola ris - no third pa rty involveme nt. S Repa irs use only ge nuine top qua lity ...
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Polaris 120 XC SP - page 91
89 INDEX A Accessories 79 ..................... Auto C hain T ensioner 60 ............. B Brake A djustm ent 59 ................ Brake L ever T ravel 58 ............... Break-In P eriod 44-45 .............. C Carburetor 57 ..................... Carburetor P rot ection 65 ............. Checki ng Engine O il 45 ............. Choke and C able L ubrica ...
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Polaris 120 XC SP - page 92
P art No. 9917595 PRINTED IN THE USA ...
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