Polaris 120 XC SP - User Manual

3 TABLE OF CONTENTS RIDER’S SECTION R-- 1 - R-- 14 Understanding Warnings R--1 - R--2 Know Your Machine R--3 - R--7 Pre Operation Check R--8 - R--9 Riding Rules R--10 - R--14 ADULT SECTION A-- 1 - A-- 77 Understanding Warnings A--2 - A--3 Safety Decals Pre Operation Check A--7 - A--9 Operation Warni...

R--1 IMPORTANT NOTES FOR OWNERS AND DRIVERS n After you read this manual store it in the vehicle for convenient reference. It should remain with the vehicle when sold. n This manual contains the latest information at the time of printing. We reserve the right to make product changes and improvements...

R--3 KNOW YOUR MACHINE 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 and the engine will stop. The stop switch must be in the “up” position to star...

R--4 KNOW YOUR MACHINE 6. Brake Lever - Squeeze this towards the handle to make your snowmobile slow down or stop. 7. Ignition Switch - The key must be turned “on” before pulling on the recoil starter handle to start your snowmobile. You can also use this key to turn off the engine.8. Tether Strap/S...

R--5 KNOW YOUR MACHINE Let’s learn more about your machine before we talk about riding. 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 ...

R--6 KNOW YOUR MACHINE 6. Seat / Storage - You sit on the seat. When the engine isn’t running, you can take the cushion off and put things under the seat in the special compartment. 7. Taillight - The taillight is always on when the engine is running. It will help others see you when you are riding....

R--7 KNOW YOUR MACHINE Let’s review the three ways to stop your snowmobile. 1. Pushing down on the engine stop switch on the right handlebar control will shut off the engine. 2. Disconnecting the tether strap will shut off the engine. 3. Turning the key to off will shut off the engine. 1 2 3

R--8 PRE OPERATION CHECK You are almost ready to have an adult start your snowmobile. Before the snowmobile is started for the first time, you must do a PRE-OPERATION CHECK . In fact, every time you ride your snowmobile you must have an adult help you check these things before starting it. Let’s lea...

R--9 PRE OPERATION CHECK n Make sure your track and skis are not frozen to the snow. Stand behind the machine and lift up on the back of the sled. This will free the track if it is frozen to the ground. Turn the handlebars to move the skis back and forth to make sure they aren’t frozen. If any of th...

R--10 RIDING RULES Any operator of this machine must be at least 6 years old. Now you are ready to learn about riding a snowmobile. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won’t be safe when you ride. Remembe...

R--12 RIDING RULES " Always drive your snowmobile while sitting down. Keep both hands on the handlebars and keep both feet on the running boards. " When you are a beginner, always stay on level ground. " Don’t ride your snowmobile on roads or over railroad tracks. Your snowmobile makes n...

R--14 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

A--2 UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: It is very important this owner’s manual is read and thoroughly explained to each operator(s) of this machine.The operator(s) should be at least 6 years old and be a...

A--3 UNDERSTANDING WARNINGS The word “NOTE:” in this manual will alert you to key information or instructions. Indicates a situation that can result in damage to the machine. NOTE IMPORTANT “IMPORTANT:” will alert you to important information or instructions. CAUTION This is the safety alert symbol....

A--5 SAFETY DECALS NOTE: Warning decals have been placed on the vehicle for the operator’s protection. Make certain the operator understands the information on all the decals. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needi...

A--8 PRE OPERATION CHECK Before Starting The Engine NOTE: It is up to you, the parent, 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 witho...

A--9 PRE OPERATION CHECK n Check Throttle Safety Switch Test the throttle safety switch system on a daily basis be- fore the machine is used.While seated in a normal rid- ing position, and with the en- gine idling, hold the throttle lever pin stationary by exert- ing pressure on the pivot pin in the...

A--10 OPERATION WARNINGS n Single Rider Snowmobiles This snowmobile is designed for a single operator. n Do Not Operate Engine With Intake Silencer Removed n Stay Clear of Track n Do Not Operate Engine With Drive Chain Guard Removed When operating engine with intake silencer removed, damage to the e...

A--11 OPERATION WARNINGS n Do Not Touch the Engine After it Has Been Running n Disabled Operators The engine and exhaust become very hot when it is running. Touching the hot engine could cause a severe burn. WARNING Safe operation of this rider-active vehicle requires good judgement and physical ski...

A--12 OPERATION WARNINGS n 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 the mechanical bra...

A--13 OPERATION WARNINGS n Be Seated and in Position to Control the Vehicle Improper operator position on the snowmobile can be the source of serious injury. Operating a snowmobile does require skill and balance for proper control, and an improper position can seriously reduce the child’s ability to...

A--14 OPERATION WARNINGS n Always Wear Clothing Designed for Snowmobiling Clothing designed for snowmobiling is warm, comfortable and safe. n Know the Limitations of the Machine and the Skills of the Driver The operator should be aware that there are state and local laws governing snowmobile operati...

A--16 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) Estimated Wind Actual Thermometer Reading ( ° F) Wind Speed in MPH 50 40 30 20 10 0 -10 -20 -30 -40 ...

A--18 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 machine. T...

A--19 OPERATION WARNINGS Snow and ice buildup in the underhood area can inter- fere with the steering. Hard Packed Snow Teach your child to reduce speed as required to maintain control in all driving conditions. If necessary, maximum speed may be regulated by using the procedure outlined on page A--...

A--20 OPERATION WARNINGS 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 chance of “spin-out” inc...

A--21 OPERATION WARNINGS Riding 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 keep the sno...

A--22 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 is the sta...

A--23 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, wildlife a...

A--24 IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature Refer to the illustrations on the following pages. 1. Hood 12. Nosepan 2. Headlight 13. Trailing Arm 3. Windshield 14. Skis 4. Handlebar 15. Front Bumper 5. Seat 16. Vehicle I.D. Number (Right Side) 6. Storage (under seat) 17. Rear Bumper ...

A--25 IDENTIFICATION AND SPECIFICATIONS Controls and Instruments 1. Stop Switch (Push/Pull). Operation found on page A--33. 2. Tether Strap3. Throttle Control4. Recoil Starter Handle5. Hood Hold-Down6. Choke Button7. Gas Cap8. Ignition Switch9. Console10. Brake Lever11. Tether Switch 10 8 11 6 3 1 4...

A--27 ENGINE BREAK-IN With a basic understanding of how the snowmobile works, and with close attention paid to maintenance tips, you will be ready to ride. Keep in mind these recommendations as well as those covered throughout this manual. Checking Engine Oil Before checking or refilling engine oil,...

A--28 OPERATION Carburetion 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 failure. A lean mi...

A--30 OPERATION Fuel The fuel used in the Polaris engine is as important to engine life and performance as the lubricant used.Most Polaris engines are designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There is a great deal of variability in the quality of the 87 octa...

A--31 OPERATION NOTE: It is up to you, the parent, 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. Speed/Performa...

A--32 OPERATION Pre-Starting Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the snowmobile without checking all components to be sure of proper operation. See Operation Warnings beginning on page A--31.Important safety items include, b...

A--33 OPERATION Starting a Warm Engine 1. Turn key to “On”.2. Pull engine stop switch (shut-off switch) up to “run” position.3. Grasp starter handle and pull slowly until recoil engages; then pull to start. Engine Stop Switch To stop the engine in an emergency, push down on the stop switch (A). This...

A--34 OPERATION 4. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. 5. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service. If excessive play develops in the throttle cable, the safety switch may...

A--35 OPERATION Daily Storage Whenever the machine is placed in overnight or daily storage the following steps must be taken: S Park the snowmobile on a level surface and support it at the rear so the track is suspended approximately 4 ″ (20 cm) from the ground. S Remove the key and cover the machin...

A--37 MAINTENANCE Polaris Recommended Maintenance Program This 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 high degree of performance and reliability this machine must be...

A--38 MAINTENANCE Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained on the following chart and maintenance pages of this manual.For continued maximum machine performance and co...

A--40 MAINTENANCE Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accu- rate log of maintenance and services performed on the unit. 50 Hour Initial Maintenance Inspection Authorized Polaris Servicing DealerSe...

A--41 MAINTENANCE Spark Plug Selection Original equipment parts or their equivalent should always be used. However, the heat range of spark plugs is of utmost importance. A spark plug with a heat range which is too high will cause engine damage. A spark plug with a heat range which is too low will c...

A--43 MAINTENANCE Wet Fouled The insulator tip is black. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Causes could be excessive idling, idle too low or too rich, or weak ignition output. Fuel Valve/Fuel Lines The fuel valve and the fuel lines should be in...

A--44 MAINTENANCE Carburetor Adjustments Proper carburetor adjustments include the following: S Carburetor component changes for specific altitude and ambient tem- peratures; S Choke adjustment; S Air screw settings, if applicable; S Idle RPM adjustments; S Throttle safety switch checks and servicin...

A--45 MAINTENANCE Exhaust System At approximately 50 hours it is a good idea to check the exhaust system for wear or damage. To inspect, allow engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining sprin...

A--46 MAINTENANCE Throttle Cable Pivot Slug Lubricate the throttle cable pivot slug (A) every 50 hours or twice a year using and aerosol lubricant. Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable should be adjusted. If proper adjustment cannot be achiev...

A--47 MAINTENANCE Cable and Brake Adjustment 1. Slide the two rubber protector covers (A) back to expose the cable adjuster. 2. Using an 8mm wrench to hold the barrel nut (B), loosen the jam nut (C) with a 10mm wrench. 3. With your left hand, grasp the cables (D) as close to the adjuster as possible...

A--48 MAINTENANCE Brake Lever Travel Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance B should be no more than 3/4 ″ (1.9 cm) Excessive travel indicates a need to adjust the brake cable adjuster. Refer to the mechanical brak...

A--49 MAINTENANCE Lubrication Points 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:A Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Seaso...

A--50 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. Cleaning Your Snowmobile Keeping your snowmobile clean will not only improve its appearance but it can also ...

A--51 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 LBS1, WD-40, etc. Force a small amount of lubricant down the cable. Bearings To prevent corrosio...

A--52 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 quality.When pre...

A--53 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 minutes to g...

A--54 MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported the following measures should be taken:1. Turn the fuel valve to “Off”.2. Be certain the fuel cap and oil cap are installed correctly.3. Always tie the snowmobile to the transporting unit securely using suitable str...

A--55 MAINTENANCE Track and Suspension Under normal conditions moderate track tension should be maintained during summer storage. The rear of the machine should be supported off the ground to allow free hanging of the track. Track Tension Track adjustment is critical for proper handling. Always main...

A--57 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. When performing the following checks and adjustments, stay clear of all moving parts to avoid...

A--58 MAINTENANCE 1. Safely support the rear of the machine with the track off the ground using a jackstand. 2. Start the engine and apply a small amount of throttle until the track turns slowly at least five complete revolutions. Stop the engine. 3. Inspect track alignment by looking through the tr...

A--59 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 and abruptly...

A--60 MAINTENANCE Track Inspection Using a hoist or jackstand, safely lift and support the rear of the snowmobile off the ground. Rotate the track by hand to check for any possible damage.To inspect track rods, carefully examine the track along the entire length of each rod, bending the track and in...

A--61 MAINTENANCE Hi-Fax Replacement The 120 XC SP 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 provide suffici...

A--62 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 cover, icy tr...

A--63 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, the measure...

A--64 MAINTENANCE Handlebar Adjustment S Slide the handlebar pad upward to access the ad- juster bolts. If additional room is required, unzip one of the handlebar pad zippers and roll the pad to the side. S To adjust, remove the up- per flange nut and car- riage bolt. S Loosen the lower flange nut o...

A--65 MAINTENANCE Ski Skags The skag 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 checked once a wee...

A--66 MAINTENANCE NOTE: If rear idler wheel (1) assembly washers are removed, be sure they are reinstalled with the domed side of the washer facing out (2) as shown. Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubrica...

A--67 MAINTENANCE Suspension Components Suspension Lubrication points are indicated by a L . 1. Front Limiter Strap 2. Rail Bumper 3. Torsion Spring Sleeves 4. Torque Arm 5. Torsion Spring 6. Rail 7. Carrier Wheel 8. Hi-fax 9. Rear Limiter Strap 10. Toe Guard 11. Spacer 12. Idler Wheel 13. Adjuster ...

A--68 TROUBLESHOOTING Engine Troubleshooting The following information is provided to help you identify probable causes for questions you may have about the operation of your snowmobile. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START No Fuel Wate...

A--69 ACCESSORIES Maintenance Items and Accessories The tools and maintenance items mentioned in this book are available at your Polaris dealer as well as a long line of other Polaris accessories. Paint Codes Color Description Polaris “P” No. Raw Material No. Indy Red P293 8520297 Indy Black P067 85...

A--70 SPECIFICATIONS Specifications - 120 XC SP Rider Seating 1 Pilot Jet 50 Dry Weight (lbs.) ± 4 lbs 140 Air Screw 1.5 Fuel Tank Capacity (Gal) .5 Ignition Type Transistor Height, in. 31 Spark Plug Type BR6ES Length, in. 74 Brake Type Mechanical Band Ski Center Distance, in. 30 Clutch Center Dista...

A--72 SERVICE AND WARRANTY Polaris Anti-Theft System The Polaris anti-theft system monitoring program (PATS) is designed to aid owners of registered snowmobiles in recovery of their machines, if stolen. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper ...

A--74 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55430, gives a ONE YEAR LIMITED 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 d...

A--76 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your snowmobile requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPO...

A--77 WARRANTY Polaris Extended Service Contract Polaris now is offering an extended engine service contract which pro- vides the following benefits: S Additional engine protection beyond the original twelve month warran- ty. S Backed by the strength of Polaris - no third party involvement. S Repair...

78 INDEX Accessories A-69 . . . . . . . . . . . . . . . . . . . . . Auto Chain Tensioner A-48 . . . . . . . . . . . . . Brake Adjustment A-46 . . . . . . . . . . . . . . . . Brake Lever Travel A-48 . . . . . . . . . . . . . . . Carburetor Adjustments A-44 . . . . . . . . . . . Carburetor Protection ...