Polaris 120 Pro X - Manuals

5 INTRODUCTION After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n This manual contains the latest information at the time of printing. We reserve the right to make product changes and improvements without notice. n The il...

6 INTRODUCTION Important Notes for Owners and Drivers PARENTS: Do not allow anyone under the age of six (6) to operate this machine. Review the information in this manual with any child who may be operating the snowmobile. It is up to you to teach any operator the proper and safe way to ride a snowm...

7 INTRODUCTION Preservation of the Environment Teach your child to drive their snowmobile with consideration for the protection and preservation of the environment. Noise Level One of the most publicized subjects with regard to snowmobiles is noise. The Society of Automotive Engineers (SAE), which i...

8 INTRODUCTION Preservation of the Environment Environmental Protection As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety training programs which also encourage protection of our environment, w...

9 INTRODUCTION Vehicle Identification Numbers The frame vehicle identification number (VIN) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers...

10 SAFETY WARNING Failure to follow the warnings in this manual can result in severe injury or death. Read and understand the owner’s manual and all warnings before operating a Polaris snowmobile. Adults must thoroughly explain this information to all operators of the snowmobile.All operators must b...

11 SAFETY Maintenance Program As with all snowmobiles, caution must be observed to ensure operator safety. Particular caution must be taken to make sure that the snowmobile is in excellent operating condition at all times. We strongly recommend that the operator, as well as an adult, check major and...

12 SAFETY Safety Decals Safety and warning decals have been placed on the vehicle for the operator’s protection. Make sure the operator understands the information on all decals. If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing repl...

13 SAFETY The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, alerts you to...

14 YOUTH SECTION Know Your Snowmobile Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine. 1. Engine Stop Switch - When the engine is running, you can push this button down and the engine will stop. The stop switch must be in the U...

15 YOUTH SECTION Know Your Snowmobile Always take your thumb off the throttle lever when you squeeze the brake lever. 6. Brake Lever - Squeeze the brake lever toward the handlebar to make your snowmobile slow down or stop. 7. Ignition Switch - The ignition switch key must be turned ON before pulling...

16 YOUTH SECTION Know Your Snowmobile Let’s learn more about the parts of your snowmobile before we talk about riding. 1 2 3 4 5 6 9 8 10 7

17 YOUTH SECTION Know Your Snowmobile 1. Hood - The hood covers the moving and hot parts of the engine and must be securely latched before you ride the snowmobile. 2. Headlight - The headlight is always on when the engine is running. It helps others see you when you’re riding during daylight, but it...

18 YOUTH SECTION Know Your Snowmobile Let’s review the three ways to stop your snowmobile: 1. Push the stop switch down.2. Pull off the tether strap.3. Turn the key off. 1 2 3

21 YOUTH SECTION Riding Rules Now you’re ready to learn about driving your Polaris snowmobile. There are some things you can do and there are some things you must never do. Rules are very important when you’re driving a snowmobile. Adults have riding rules, too. The rules help keep us safe when we r...

24 YOUTH SECTION Riding Rules Learn how to ride safely and correctly. Learn how to use your hands and arms as signals. Read and understand your Owner’s Manual. Left Turn Right Turn Stop

25 ADULT SECTION Pre-Ride Check It’s up to you, the adult, to teach your child the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision. WARNIN...

26 ADULT SECTION Pre-Ride Check Before Starting The Engine n Read and Understand Your Owner’s Manual Read and make sure the operators understand the Owner’s Manual completely before allowing anyone to operate this snowmobile. It’s also a good idea to review it periodically to reinforce the informati...

27 ADULT SECTION Pre-Ride Check n Check throttle safety switch Test the throttle safety switch system on a daily basis before the machine is used.While seated in a normal riding position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the ...

28 ADULT SECTION Pre-Ride Check n Check engine stop switch Test the engine stop switch before each use of the snowmobile. To stop the engine in an emergency, push down on the stop switch (A). This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch mu...

29 ADULT SECTION Operation Warnings n Do not carry passengers This snowmobile is designed for a single operator. n Do not operate with intake silencer removed CAUTION If the engine is operated with the intake silencer removed, damage to the engine may occur. Do not operate the engine with the intake...

30 ADULT SECTION Operation Warnings n Do not touch the engine after it’s been running WARNING Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running. n Disabled operators WARNING Safe operation of this rider-active vehicle requires goo...

31 ADULT SECTION Operation Warnings n Check brake lever travel Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance A should be no more than 3/4 ″ (1.9 cm). Excessive travel indicates a need to adjust the brake cable. Refer to t...

32 ADULT SECTION Operation Warnings n Check surroundings to verify clear operating area It’s important to make sure there’s a clear area all around the snowmobile, including an area clear of bystanders. Some sideways movement is possible when starting out, and debris may be thrown by the track. Teac...

33 ADULT SECTION Operation Warnings n Stop engine before attempting adjustments WARNING The snowmobile engine compartment contains moving parts. Shields and guards have been provided for safety, but it is still possible to carelessly get your hands or fingers into a moving chain or a rotating shaft....

34 ADULT SECTION Operation Warnings n Know limitations of machine and skills of driver The operator should be aware that there are state and local laws governing snowmobile operation and that these laws should be followed. They have been established for the protection of all snowmobile riders. Most ...

36 ADULT SECTION Operation Warnings Windchill/Temperature Charts The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile.WIND CHILL CHART ( ° F) Esti- mated Actual Thermometer Reading ( ° F) mated Wind Speed in MPH 50 40 30 20 10 0 -1...

38 ADULT SECTION Operation Warnings Cold Weather Drive-Away Whenever the machine has been parked for some length of time, especially overnight, always shake loose the skis and track for the operator before attempting to put the machine into motion. The throttle will require some pressure to move the...

39 ADULT SECTION Operation Warnings Snow and Ice Build-Up Snow and ice buildup in the underhood area can interfere with the steering. WARNING Before allowing your child to drive the machine, be sure that ice and snow are not interfering with the steering. Manually turn the skis to the left and right...

40 ADULT SECTION Operation Warnings Driving on Ice It is dangerous to operate on ice or under slippery conditions. If ice or slippery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction on a slippery surface. The ch...

41 ADULT SECTION Operation Warnings Driving Downhill When riding downhill, the operator must keep the speed at a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow use of the engine’s compression to help slow the machine, and ...

42 ADULT SECTION Component Identification 1. Hood 8. Rear Suspension 2. Headlight 9. Nosepan 3. Windshield 10. Trailing Arm 4. Handlebar 11. Skis 5. Seat 12. Front Bumper 6. Storage (under seat) 13. Rear Bumper 7. Taillight 14. Snow Flap15. Track 2 1 3 4 5,6 7 15 9 10 11 12 14 13 8

44 ADULT SECTION Break-In Period Engine Break-In The break-in period for your new snowmobile is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment ...

45 ADULT SECTION Break-In Period CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season Synthetic oil. Never substitute or mix oil brands. Checking Engine Oil Before checking or refilling engine oil, be sure the engi...

46 ADULT SECTION Operation Fuel When refueling, use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.Always r...

47 ADULT SECTION Operation Speed/Performance Regulation Adults have the responsibility for teaching children the proper and safe way to ride a snowmobile. Please set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow a child to operate this machine without ...

48 ADULT SECTION Operation Starting the Engine Never start the snowmobile without checking all components to be sure of proper operation. Refer to the Pre-Ride Check beginning on page 25. Starting a Cold Engine 1. Turn the key to ON.2. Pull the engine stop switch (shut-off switch) up to the RUN posi...

49 ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emergency. SYSTEM WHAT IT DOES THROTTLE CONDITION Engine Stop Switch Interrupts ignition circuit All Ignition Switch Interrupts ignition circuit All Tether Switch Int...

50 ADULT SECTION Operation Pre-Ride Warm-Up Always warm up the engine, drive train and track before operating the snowmobile. With the snowmobile securely supported by the rear bumper with a minimum clearance of 4 ″ (10 cm) from the ground, use the following procedure to properly warm up the snowmob...

51 ADULT SECTION Maintenance Polaris Recommended Maintenance Program Your Polaris snowmobile has been engineered and manufactured by skilled Polaris personnel to the highest degree of performance and reliability possible. In order to maintain this level of quality, your machine must have regular ser...

52 ADULT SECTION Maintenance Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the following chart and in the maintenance section of this manual.Service and adjustments are ...

54 ADULT SECTION Maintenance Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 50 Hour Initial Maintenance Inspection Authorized Polaris Servi...

55 ADULT SECTION Maintenance Spark Plugs A new engine can cause temporary spark plug fouling even though the heat range is proper, due to the preservative which has been added during assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization w...

56 ADULT SECTION Maintenance Spark Plugs Spark Plug Removal and Replacement 1. Remove the spark plug cap.2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. Torque to 12-14 ft. lbs. (16-19 Nm)...

57 ADULT SECTION Maintenance Carburetor Proper carburetor adjustment is critical, since a mixture too lean (too much air, too little fuel) will result in overheating of the combustion chamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine failur...

58 ADULT SECTION Maintenance Throttle Cable Lubrication With the engine off, lubricate the throttle cable occasionally. Turn the handlebars to the left and lubricate liberally with Polaris All Season Grease. Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown. Operate ...

59 ADULT SECTION Maintenance Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable should be adjusted. If proper adjustment cannot be achieved by using the following methods, check the brake band for excessive wear. Your snowmobile dealer can install a new br...

60 ADULT SECTION Maintenance Chain Tensioner Inspect the chain. The chain should have 1 ″ of deflection as shown. If not, loosen the nut on the chain tensioner (A) and raise until 1 ″ (B) of deflection is attained. Tighten nut to 15-18 ft. lbs. (20-24 Nm).When the chain comes within 1/8 ″ (C) of the...

61 ADULT SECTION Maintenance Lubrication NOTE: Driveline noise is normal and inherent in a chain drive system such as this machine uses. To ensure long life of the snowmobile’s driveline, lubricate as follows: S Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All...

62 ADULT SECTION Maintenance Oil Level Maintain the oil level between the safe marks (A) on the dipstick. Oil Change Change the oil after the initial 20 hours of operation and again after each 50 hours. Washing Your Snowmobile Keeping your snowmobile clean will not only improve its appearance but it...

63 ADULT SECTION Maintenance Controls and Linkage All bushings, spindle shafts, and tie rod ends should be coated with a light coat of oil or grease. Throttle and brake controls and cables should be lubricated with Polaris Premium All Season Grease. Force a small amount of lubricant down the cable. ...

64 ADULT SECTION Maintenance Engine Proper off-season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage.Without proper storage, jet restriction can cause lean conditions and very poor slow speed driving quali...

65 ADULT SECTION Maintenance Carburetor Protection During Off-Season Storage When preparing your snowmobile for off-season storage we recommend that you add a fuel conditioner/stabilizer or Premium Carbon Clean (2871326) to the fuel tank. Follow the instructions on the can. Run the engine for five m...

66 ADULT SECTION Maintenance Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken:1. Turn the fuel valve off.2. Be sure the fuel cap is installed correctly.3. Always tie the snowmobile to the transporting unit securely using suitable straps. NOTE:...

67 ADULT SECTION Maintenance WARNING Your snowmobile is propelled by a revolving track, which must be partially exposed for proper operation. Serious injuries may be caused by the operator’s hands, feet or clothing becoming entangled in the track. Be alert. Always sit properly on the seat. Track and...

68 ADULT SECTION Maintenance Track Adjustment If the track needs adjustment:1. Loosen rear idler shaft bolt (D).2. Tighten or loosen the track adjusting screws (E) as necessary to provide equal adjustment on both sides of the track. 3. Repeat measurement on the other side of the track. NOTE: Check m...

69 ADULT SECTION Maintenance Track Alignment A periodic check should be made to see that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. WARNING When performing the following checks and adjustments, stay clear of all mo...

70 ADULT SECTION Maintenance Track Warm Up When storing your snowmobile outside overnight, it is recommended that the track be warmed up prior to driving the snowmobile. This reduces drive clutch wear. To warm up the track, safely support the rear of the snowmobile off the ground, start the engine a...

71 ADULT SECTION Maintenance Track Inspection WARNING Inspecting the track while the engine is running can result in serious personal injury if the track should being to move. Never inspect the track with the engine running Using a hoist or jackstand, safely lift and support the rear of the snowmobi...

72 ADULT SECTION Maintenance Hi-Fax Replacement The 120 PRO X uses XTRA Lite style Hi-Fax. When any area of the Hi-Fax is worn to 7/16 ″ (1.1 cm), it should be replaced. This will save wear on other vital components.The slide rail is designed to operate in conditions with adequate snow cover to prov...

73 ADULT SECTION Maintenance Track Lubrication Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between hi-fax and track guide clips. Examples of marginal lubrication would include lakes without snow co...

74 ADULT SECTION Maintenance Steering Inspection and Adjustment The steering assembly of the machine should be checked periodically for loose nuts and bolts. See A,B,C,D,E, F, and G in illustration at right.With handlebars in straight ahead position and measuring from the straight edge of the skis, ...

75 ADULT SECTION Maintenance Handlebar Adjustment 6. Slide the handlebar pad upward to access the adjuster bolts. If additional room is required, unzip one of the handlebar pad zippers and roll the pad to the side. 7. To adjust, remove the upper flange nut and carriage bolt. 8. Loosen the lower flan...

76 ADULT SECTION Maintenance Ski Skags The skag (A) is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads and other bare terrain. We recommend that skags be che...

77 ADULT SECTION Maintenance Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease several times during the season and again before summer storage each year. The riding characte...

78 ADULT SECTION Maintenance Suspension Components Suspension Lubrication points are indicated by a L . 1. Front Limiter Strap 8. Rail Bumper 2. Torsion Spring Sleeves 9. Torque Arm 3. Torsion Spring 10. Rail 4. Carrier Wheel 11. Hi-fax 5. Rear Limiter Strap 12. Toe Guard 6. Spacer 13. Idler Wheel 7...

79 ADULT SECTION Accessories Maintenance Items and Accessories The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer. Paint Codes Color Description Polaris “P” No. Raw Material No. Indy Red P293 8520297 Indy ...

80 SPECIFICATIONS Jetting Chart Ambient Temperature Below -30 _ F (-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 Altitude in Meters (F t) 0-600 (0-2000) 75 72.5 72.5 72.5 7...

82 POLARIS PRODUCTS Part No. Description Engine Lubricant 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.) 2871653 Premium Front Gearcase Lube (8 oz.) 2871654 Premium Drive Hub Fluid (8 oz.) Grease / Spe...

83 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on ...

84 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective p...

86 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-- Delivery Inspection, perform all applicable service bulletins and have the co...

87 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is ...

88 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for ex...

89 INDEX A-B Accessories 79 . . . . . . . . . . . . . . . . . . . . . Auto Chain Tensioner 60 . . . . . . . . . . . . . Brake Adjustment 59 . . . . . . . . . . . . . . . . Brake Lever Travel 58 . . . . . . . . . . . . . . . Break-In Period 44-45 . . . . . . . . . . . . . . C Carburetor 57 . . . . . ...

5 INTRODUCTION After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n This manual contains the latest information at the time of printing. We reserve the right to make product changes and improvements without notice. n The il...

6 INTRODUCTION Important Notes for Owners and Drivers PARENTS: Do not allow anyone under the age of six (6) to operate this machine. Review the information in this manual with any child who may be operating the snowmobile. It is up to you to teach any operator the proper and safe way to ride a snowm...

7 INTRODUCTION Preservation of the Environment Teach your child to drive their snowmobile with consideration for the protection and preservation of the environment. Noise Level One of the most publicized subjects with regard to snowmobiles is noise. The Society of Automotive Engineers (SAE), which i...

8 INTRODUCTION Preservation of the Environment Environmental Protection As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety training programs which also encourage protection of our environment, w...

9 INTRODUCTION Vehicle Identification Numbers The frame vehicle identification number (VIN) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers...

10 SAFETY WARNING Failure to follow the warnings in this manual can result in severe injury or death. Read and understand the owner’s manual and all warnings before operating a Polaris snowmobile. Adults must thoroughly explain this information to all operators of the snowmobile.All operators must b...

11 SAFETY Maintenance Program As with all snowmobiles, caution must be observed to ensure operator safety. Particular caution must be taken to make sure that the snowmobile is in excellent operating condition at all times. We strongly recommend that the operator, as well as an adult, check major and...

12 SAFETY Safety Decals Safety and warning decals have been placed on the vehicle for the operator’s protection. Make sure the operator understands the information on all decals. If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing repl...

13 SAFETY The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, alerts you to...

14 YOUTH SECTION Know Your Snowmobile Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine. 1. Engine Stop Switch - When the engine is running, you can push this button down and the engine will stop. The stop switch must be in the U...

15 YOUTH SECTION Know Your Snowmobile Always take your thumb off the throttle lever when you squeeze the brake lever. 6. Brake Lever - Squeeze the brake lever toward the handlebar to make your snowmobile slow down or stop. 7. Ignition Switch - The ignition switch key must be turned ON before pulling...

16 YOUTH SECTION Know Your Snowmobile Let’s learn more about the parts of your snowmobile before we talk about riding. 1 2 3 4 5 6 9 8 10 7

17 YOUTH SECTION Know Your Snowmobile 1. Hood - The hood covers the moving and hot parts of the engine and must be securely latched before you ride the snowmobile. 2. Headlight - The headlight is always on when the engine is running. It helps others see you when you’re riding during daylight, but it...

18 YOUTH SECTION Know Your Snowmobile Let’s review the three ways to stop your snowmobile: 1. Push the stop switch down.2. Pull off the tether strap.3. Turn the key off. 1 2 3

21 YOUTH SECTION Riding Rules Now you’re ready to learn about driving your Polaris snowmobile. There are some things you can do and there are some things you must never do. Rules are very important when you’re driving a snowmobile. Adults have riding rules, too. The rules help keep us safe when we r...

24 YOUTH SECTION Riding Rules Learn how to ride safely and correctly. Learn how to use your hands and arms as signals. Read and understand your Owner’s Manual. Left Turn Right Turn Stop

25 ADULT SECTION Pre-Ride Check It’s up to you, the adult, to teach your child the proper and safe way to ride a snowmobile. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision. WARNIN...

26 ADULT SECTION Pre-Ride Check Before Starting The Engine n Read and Understand Your Owner’s Manual Read and make sure the operators understand the Owner’s Manual completely before allowing anyone to operate this snowmobile. It’s also a good idea to review it periodically to reinforce the informati...

27 ADULT SECTION Pre-Ride Check n Check throttle safety switch Test the throttle safety switch system on a daily basis before the machine is used.While seated in a normal riding position, and with the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the ...

28 ADULT SECTION Pre-Ride Check n Check engine stop switch Test the engine stop switch before each use of the snowmobile. To stop the engine in an emergency, push down on the stop switch (A). This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch mu...

29 ADULT SECTION Operation Warnings n Do not carry passengers This snowmobile is designed for a single operator. n Do not operate with intake silencer removed CAUTION If the engine is operated with the intake silencer removed, damage to the engine may occur. Do not operate the engine with the intake...

30 ADULT SECTION Operation Warnings n Do not touch the engine after it’s been running WARNING Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running. n Disabled operators WARNING Safe operation of this rider-active vehicle requires goo...

31 ADULT SECTION Operation Warnings n Check brake lever travel Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance A should be no more than 3/4 ″ (1.9 cm). Excessive travel indicates a need to adjust the brake cable. Refer to t...

32 ADULT SECTION Operation Warnings n Check surroundings to verify clear operating area It’s important to make sure there’s a clear area all around the snowmobile, including an area clear of bystanders. Some sideways movement is possible when starting out, and debris may be thrown by the track. Teac...

33 ADULT SECTION Operation Warnings n Stop engine before attempting adjustments WARNING The snowmobile engine compartment contains moving parts. Shields and guards have been provided for safety, but it is still possible to carelessly get your hands or fingers into a moving chain or a rotating shaft....

34 ADULT SECTION Operation Warnings n Know limitations of machine and skills of driver The operator should be aware that there are state and local laws governing snowmobile operation and that these laws should be followed. They have been established for the protection of all snowmobile riders. Most ...

36 ADULT SECTION Operation Warnings Windchill/Temperature Charts The following information is provided as a guide to determine what temperatures are dangerous when riding your snowmobile.WIND CHILL CHART ( ° F) Esti- mated Actual Thermometer Reading ( ° F) mated Wind Speed in MPH 50 40 30 20 10 0 -1...

38 ADULT SECTION Operation Warnings Cold Weather Drive-Away Whenever the machine has been parked for some length of time, especially overnight, always shake loose the skis and track for the operator before attempting to put the machine into motion. The throttle will require some pressure to move the...

39 ADULT SECTION Operation Warnings Snow and Ice Build-Up Snow and ice buildup in the underhood area can interfere with the steering. WARNING Before allowing your child to drive the machine, be sure that ice and snow are not interfering with the steering. Manually turn the skis to the left and right...

40 ADULT SECTION Operation Warnings Driving on Ice It is dangerous to operate on ice or under slippery conditions. If ice or slippery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction on a slippery surface. The ch...

41 ADULT SECTION Operation Warnings Driving Downhill When riding downhill, the operator must keep the speed at a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow use of the engine’s compression to help slow the machine, and ...

42 ADULT SECTION Component Identification 1. Hood 8. Rear Suspension 2. Headlight 9. Nosepan 3. Windshield 10. Trailing Arm 4. Handlebar 11. Skis 5. Seat 12. Front Bumper 6. Storage (under seat) 13. Rear Bumper 7. Taillight 14. Snow Flap15. Track 2 1 3 4 5,6 7 15 9 10 11 12 14 13 8

44 ADULT SECTION Break-In Period Engine Break-In The break-in period for your new snowmobile is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment ...

45 ADULT SECTION Break-In Period CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season Synthetic oil. Never substitute or mix oil brands. Checking Engine Oil Before checking or refilling engine oil, be sure the engi...

46 ADULT SECTION Operation Fuel When refueling, use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline.Always r...

47 ADULT SECTION Operation Speed/Performance Regulation Adults have the responsibility for teaching children the proper and safe way to ride a snowmobile. Please set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow a child to operate this machine without ...

48 ADULT SECTION Operation Starting the Engine Never start the snowmobile without checking all components to be sure of proper operation. Refer to the Pre-Ride Check beginning on page 25. Starting a Cold Engine 1. Turn the key to ON.2. Pull the engine stop switch (shut-off switch) up to the RUN posi...

49 ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emergency. SYSTEM WHAT IT DOES THROTTLE CONDITION Engine Stop Switch Interrupts ignition circuit All Ignition Switch Interrupts ignition circuit All Tether Switch Int...

50 ADULT SECTION Operation Pre-Ride Warm-Up Always warm up the engine, drive train and track before operating the snowmobile. With the snowmobile securely supported by the rear bumper with a minimum clearance of 4 ″ (10 cm) from the ground, use the following procedure to properly warm up the snowmob...

51 ADULT SECTION Maintenance Polaris Recommended Maintenance Program Your Polaris snowmobile has been engineered and manufactured by skilled Polaris personnel to the highest degree of performance and reliability possible. In order to maintain this level of quality, your machine must have regular ser...

52 ADULT SECTION Maintenance Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the following chart and in the maintenance section of this manual.Service and adjustments are ...

54 ADULT SECTION Maintenance Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 50 Hour Initial Maintenance Inspection Authorized Polaris Servi...

55 ADULT SECTION Maintenance Spark Plugs A new engine can cause temporary spark plug fouling even though the heat range is proper, due to the preservative which has been added during assembly of the engine to combat rust and corrosion. Avoid prolonged idle speeds, as plug fouling and carbonization w...

56 ADULT SECTION Maintenance Spark Plugs Spark Plug Removal and Replacement 1. Remove the spark plug cap.2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. Torque to 12-14 ft. lbs. (16-19 Nm)...

57 ADULT SECTION Maintenance Carburetor Proper carburetor adjustment is critical, since a mixture too lean (too much air, too little fuel) will result in overheating of the combustion chamber causing pre-ignition of the fuel. This results in piston burning, bearing failure, or complete engine failur...

58 ADULT SECTION Maintenance Throttle Cable Lubrication With the engine off, lubricate the throttle cable occasionally. Turn the handlebars to the left and lubricate liberally with Polaris All Season Grease. Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown. Operate ...

59 ADULT SECTION Maintenance Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable should be adjusted. If proper adjustment cannot be achieved by using the following methods, check the brake band for excessive wear. Your snowmobile dealer can install a new br...

60 ADULT SECTION Maintenance Chain Tensioner Inspect the chain. The chain should have 1 ″ of deflection as shown. If not, loosen the nut on the chain tensioner (A) and raise until 1 ″ (B) of deflection is attained. Tighten nut to 15-18 ft. lbs. (20-24 Nm).When the chain comes within 1/8 ″ (C) of the...

61 ADULT SECTION Maintenance Lubrication NOTE: Driveline noise is normal and inherent in a chain drive system such as this machine uses. To ensure long life of the snowmobile’s driveline, lubricate as follows: S Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All...

62 ADULT SECTION Maintenance Oil Level Maintain the oil level between the safe marks (A) on the dipstick. Oil Change Change the oil after the initial 20 hours of operation and again after each 50 hours. Washing Your Snowmobile Keeping your snowmobile clean will not only improve its appearance but it...

63 ADULT SECTION Maintenance Controls and Linkage All bushings, spindle shafts, and tie rod ends should be coated with a light coat of oil or grease. Throttle and brake controls and cables should be lubricated with Polaris Premium All Season Grease. Force a small amount of lubricant down the cable. ...

64 ADULT SECTION Maintenance Engine Proper off-season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage.Without proper storage, jet restriction can cause lean conditions and very poor slow speed driving quali...

65 ADULT SECTION Maintenance Carburetor Protection During Off-Season Storage When preparing your snowmobile for off-season storage we recommend that you add a fuel conditioner/stabilizer or Premium Carbon Clean (2871326) to the fuel tank. Follow the instructions on the can. Run the engine for five m...

66 ADULT SECTION Maintenance Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken:1. Turn the fuel valve off.2. Be sure the fuel cap is installed correctly.3. Always tie the snowmobile to the transporting unit securely using suitable straps. NOTE:...

67 ADULT SECTION Maintenance WARNING Your snowmobile is propelled by a revolving track, which must be partially exposed for proper operation. Serious injuries may be caused by the operator’s hands, feet or clothing becoming entangled in the track. Be alert. Always sit properly on the seat. Track and...

68 ADULT SECTION Maintenance Track Adjustment If the track needs adjustment:1. Loosen rear idler shaft bolt (D).2. Tighten or loosen the track adjusting screws (E) as necessary to provide equal adjustment on both sides of the track. 3. Repeat measurement on the other side of the track. NOTE: Check m...

69 ADULT SECTION Maintenance Track Alignment A periodic check should be made to see that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. WARNING When performing the following checks and adjustments, stay clear of all mo...

70 ADULT SECTION Maintenance Track Warm Up When storing your snowmobile outside overnight, it is recommended that the track be warmed up prior to driving the snowmobile. This reduces drive clutch wear. To warm up the track, safely support the rear of the snowmobile off the ground, start the engine a...

71 ADULT SECTION Maintenance Track Inspection WARNING Inspecting the track while the engine is running can result in serious personal injury if the track should being to move. Never inspect the track with the engine running Using a hoist or jackstand, safely lift and support the rear of the snowmobi...

72 ADULT SECTION Maintenance Hi-Fax Replacement The 120 PRO X uses XTRA Lite style Hi-Fax. When any area of the Hi-Fax is worn to 7/16 ″ (1.1 cm), it should be replaced. This will save wear on other vital components.The slide rail is designed to operate in conditions with adequate snow cover to prov...

73 ADULT SECTION Maintenance Track Lubrication Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between hi-fax and track guide clips. Examples of marginal lubrication would include lakes without snow co...

74 ADULT SECTION Maintenance Steering Inspection and Adjustment The steering assembly of the machine should be checked periodically for loose nuts and bolts. See A,B,C,D,E, F, and G in illustration at right.With handlebars in straight ahead position and measuring from the straight edge of the skis, ...

75 ADULT SECTION Maintenance Handlebar Adjustment 6. Slide the handlebar pad upward to access the adjuster bolts. If additional room is required, unzip one of the handlebar pad zippers and roll the pad to the side. 7. To adjust, remove the upper flange nut and carriage bolt. 8. Loosen the lower flan...

76 ADULT SECTION Maintenance Ski Skags The skag (A) is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads and other bare terrain. We recommend that skags be che...

77 ADULT SECTION Maintenance Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease several times during the season and again before summer storage each year. The riding characte...

78 ADULT SECTION Maintenance Suspension Components Suspension Lubrication points are indicated by a L . 1. Front Limiter Strap 8. Rail Bumper 2. Torsion Spring Sleeves 9. Torque Arm 3. Torsion Spring 10. Rail 4. Carrier Wheel 11. Hi-fax 5. Rear Limiter Strap 12. Toe Guard 6. Spacer 13. Idler Wheel 7...

79 ADULT SECTION Accessories Maintenance Items and Accessories The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer. Paint Codes Color Description Polaris “P” No. Raw Material No. Indy Red P293 8520297 Indy ...

80 SPECIFICATIONS Jetting Chart Ambient Temperature Below -30 _ F (-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 Altitude in Meters (F t) 0-600 (0-2000) 75 72.5 72.5 72.5 7...

82 POLARIS PRODUCTS Part No. Description Engine Lubricant 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.) 2871653 Premium Front Gearcase Lube (8 oz.) 2871654 Premium Drive Hub Fluid (8 oz.) Grease / Spe...

83 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on ...

84 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective p...

86 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-- Delivery Inspection, perform all applicable service bulletins and have the co...

87 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is ...

88 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for ex...

89 INDEX A-B Accessories 79 . . . . . . . . . . . . . . . . . . . . . Auto Chain Tensioner 60 . . . . . . . . . . . . . Brake Adjustment 59 . . . . . . . . . . . . . . . . Brake Lever Travel 58 . . . . . . . . . . . . . . . Break-In Period 44-45 . . . . . . . . . . . . . . C Carburetor 57 . . . . . ...