Polaris 120 Youth - User Manual

5 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Important Notes for Owners and Drivers . . . . . . . . . . . . 6 Preservation of the Environment . . . . . . . . . . . . . . . . . . 7 Vehicle Identification Numbers . . . . . . . . . . . . . . . . . . . 9 Saf...

6 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold.You and your dealer must complete the registration form included with your snowmobile and forward i...

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

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 protec- tion of our environment,...

9 INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers in the spaces pro- vided. Vehicle Model Number: ____________________________________________________ Tunnel VIN: _____________________________________________________________(lower right side of the tunnel)...

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

11 SAFETY Equipment Modifications All Polaris snowmobiles have been designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modification; especially those that increase speed or power. There is a significant possi...

12 SAFETY Maintenance Program This snowmobile is not a toy. The information in this manual is pro- vided to aid you in its safe operation. For the safety of the operator, always make sure that the snowmobile is in excellent operating condition at all times. We strongly recommend that the operator, a...

13 SAFETY Safety Decals Safety and warning decals have been placed on the vehicle for the oper- ator'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. Replacement safety decals a...

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 snowmobile. Engine Stop Switch When the engine is running, push this button down to stop the engine. Pull the stop switch up before trying to start t...

15 YOUTH SECTION Know Your Snowmobile Gas Cap An adult will take the gas cap off to put gas in your snowmobile. Never take the gas cap off. Always make sure it's tightly closed. Recoil Starter Handle Pull the recoil starter handle to start your snowmobile. An adult will help you start it the first t...

16 YOUTH SECTION Know Your Snowmobile Let's learn more about the parts of your snowmobile before we learn about riding. Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Track Taillight

18 YOUTH SECTION Know Your Snowmobile Let's review the 2 ways to stop your snowmobile: STOP Push the stop switch down Pull the strap off the tether switch

20 YOUTH SECTION Pre-Ride Check n Gas Leve l Have an adult check the gas level to see if your snowmobile needs more gas. Children should never open the gas cap or add gas. Always have an adult do this. Before anyone adds gas to your snowmobile they must read the instructions and warnings on page 43 ...

21 YOUTH SECTION Riding Rules Now you're ready to learn about driving your Polaris snowmobile. This snowmobile is not a toy. 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 rul...

24 YOUTH SECTION Riding Rules Learn how to use your hands and arms as signals. Use these signals to let others know when you are getting ready to turn or stop your snow- mobile. Read and understand your Owner's Manual. Left Turn Right Turn Stop

25 ADULT SECTION Pre-Ride Check As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehi- cle without adult supervision. n Check the throttle fo...

26 ADULT SECTION Pre-Ride Check n Read and Understand Your Owner's Manual Read and make sure the operators understand the Owner's Manual com- pletely before allowing anyone to operate this snowmobile. It's also a good idea to review it periodically to reinforce the information. It's very important t...

27 ADULT SECTION Pre-Ride Check n Check the throttle safety switch Test the throttle safety switch system on a daily basis before the vehicle is used.With the engine idling, hold the throttle lever pin stationary by exerting pressure on the pivot pin in the direction shown in the illustration. Apply...

28 ADULT SECTION Pre-Ride Check n Inspect the track Driving for extended periods of time with marginal lubrication could severely damage the track. Driving on icy trails or driving when there is little or no snow are two examples of situations that would provide mar- ginal lubrication and are not re...

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 n Stay clear of track n Do not operate with drive chain guard removed CAUTION If the engine is operated with the intake silencer removed, dam...

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

31 ADULT SECTION Operation Warnings n Check brake lever travel Depress the brake lever fully. Measure the clearance between the lever and brake block. Clear- ance should be no more than 3/4" (1.9 cm).Excessive travel indicates a need to adjust the brake cable. Refer to the mechanical brake adjus...

32 ADULT SECTION Operation Warnings n Check surroundings Make sure the operation area is clear of obstacles and bystanders. Some sideways movement is possible when the snowmobile first begins to move, and debris may be thrown by the track. Teach the operator to check the operating area before riding...

33 ADULT SECTION Operation Warnings n Always wear clothing designed for snowmobiling Always make sure the operator is wearing an approved helmet and eye protection. Do not allow the child to wear loose clothing or long scarves because they can easily become entangled in moving parts. If your child h...

34 ADULT SECTION Operation Warnings n Stop engine before attempting adjustments n Know limitations of machine and skills of driver The operator should be aware that most areas have laws governing snowmobile operation and that these laws should be followed. They have been established for the protecti...

35 ADULT SECTION Operation Warnings n Instruct all operators Teach all young drivers to always be alert and to pay attention to the driving area ahead. When teaching inexperienced operators to ride, set up a predetermined course. Establish boundaries and make sure all oper- ators know and understand...

36 ADULT SECTION Operation Warnings Driving Responsibly As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehi- cle without adult supervision....

37 ADULT SECTION Operation Warnings Snow Conditions This snowmobile is designed to operate best on snow. Maneuverability is attained by the steering, skis, and the shifting of the driver's body weight. Maximum control will be attained by shifting body weight. Maneuverability will change for lighter ...

38 ADULT SECTION Operation Warnings Driving on Hills Traveling on hills is not recommended. A child may not be capable of maneuvering body weight as needed for operating on hills. If traveling on hills is unavoidable, teach your child to use extreme caution and obey the following proper operating pr...

39 ADULT SECTION Operation Warnings Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART ( _ F) WINDCHILL CHART ( _ C) Wind Speed in MPH Actual Thermometer Reading ( _ F) 40 35 30 25 20 15 10 5 0 -5 ...

40 ADULT SECTION Component Identification Snow Flap Ski Handlebar Seat and Storage Hood Headlight Windshield Track Taillight Rear Suspension Nosepan Trailing Arm Front Bumper Rear Bumper

42 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...

43 ADULT SECTION Operation Fuel When refueling, use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M)/2 octane. Do not use E-85 fuel. WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasol...

44 ADULT SECTION Operation Speed/Performance Regulation As the adult, you must teach the child the proper and safe way to ride a snowmobile. Set boundaries and adhere to them, keeping the child's safety foremost in your mind. Never allow the child to operate this vehi- cle without adult supervision....

45 ADULT SECTION Operation Starting the Engine Never start the engine before performing the Pre-Ride Check. See pages 19 and 25.1. Pull the engine stop switch up to the RUN position.2. Do not use the choke when starting a warm engine. If the engine is cold, pull the choke lever completely out to the...

46 ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the snowmobile in the event of an emergency. See pages 14 and 27 for more information about the engine stop switch and throttle safety switch. Daily Storage At the end of each ride, park the snow-...

47 ADULT SECTION Operation Pre-Ride Warm-Up Always warm up the engine, drive train and track before operating the snowmobile. Support the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) off the ground. 1. Start the engine. Allow it to idle for two to thr...

48 ADULT SECTION Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI)...

49 ADULT SECTION Maintenance Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page ...

50 ADULT SECTION Maintenance Periodic Maintenance Chart The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Pola...

52 ADULT SECTION Maintenance Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.Refer to the specifications section beginning on page 80 for recom- mended...

53 ADULT SECTION Maintenance Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi- cates the proper type and heat range for the engine and the service. NOTE: The tip should not be white...

54 ADULT SECTION Maintenance Fuel Valve/Fuel Lines Inspect the fuel valve and the fuel lines regularly. Carefully check the system's fuel line condition after periods of storage. Normal deteriora- tion from weather and fuel compounds can occur. Replace any worn or damaged components. Exhaust System ...

55 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...

56 ADULT SECTION Maintenance Brake Lever Travel Firmly depress the brake lever. Measure the clearance between the lever and brake block.If clearance is more than 3/4" (19 mm), adjust the brake cable as outlined below. Brake Cable Adjustment If proper adjustment cannot be achieved using the follo...

57 ADULT SECTION Maintenance Brake Cable Adjustment 4. Check the actuator linkage to ensure there is adequate freedom of movement for positive brake operation and that all floating parts move freely and that all parts are mounted securely. Tighten hardware as required. 5. Tighten the adjuster jam nu...

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 Chain Tensioner Inspect the chain. Proper deflection is one inch (25 mm). Adjust the chain if deflection is incorrect.1. Loosen the nut on the chain tensioner.2. Raise the tensioner until the correct deflection is attained.3. Tighten the nut to 15-18 ft. lbs. (20-24 Nm)....

60 ADULT SECTION Maintenance Driveline Lubrication NOTE: Driveline noise is normal for this vehicle. To ensure long life of the snowmobile's driveline, lubricate as follows:• Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease. • Lubricate Point B e...

61 ADULT SECTION Maintenance Engine Oil Oil Recommendations Polaris recommends the use of Performance Synthetic 4-Stroke oil (PS- 4 or PS-4 Plus) for this engine. PS-4 has been specially formulated for use in Polaris 4-cycle snowmobile engines. It's a fully synthetic, high performance, multi-viscosi...

62 ADULT SECTION Maintenance Engine Oil Oil Change 1. Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. 2. Place a drain pan under the drain plug. NOTE: The drain plug is located under the bulkhead and in front of the engine. 3. Remove the drain plug....

63 ADULT SECTION Maintenance Track Tension Track adjustment is critical for proper handling. Always maintain cor- rect tension and alignment.1. Operate the snow- mobile to warm up the track. 2. Stop the engine.3. Support the rear of the snowmobile slightly off the ground with an appropriate snow- mo...

64 ADULT SECTION Maintenance Track Tension Adjustment 1. Loosen the rear idler shaft bolt.2. Tighten or loosen the track adjusting screws to provide equal adjust- ment on both sides of the track. 3. Repeat the measurement on the other side of the track. NOTE: Check tension more frequently when the m...

65 ADULT SECTION Maintenance Track Alignment Check track alignment at the intervals outlined in the periodic mainte- nance chart beginning on page 50. Make sure the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Support...

66 ADULT SECTION Maintenance Track Warm Up After storing your snowmobile outside overnight, warm up the track before driving the snow- mobile. This reduces drive clutch wear.1. Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. 2. Start the engine.3. A...

67 ADULT SECTION Maintenance Track Inspection Check track condition at the intervals outlined in the periodic mainte- nance chart beginning on page 50. 1. Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. 2. Rotate the track by hand to check for wear ...

68 ADULT SECTION Maintenance Slider Replacement Polaris rail slides have a wear limit indicator groove to indicate the minimum permissible slide thick- ness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Fail- ure to do so may result in perma- nen...

69 ADULT SECTION Maintenance Steering Inspection Each week, or before a long ride, check all steering system fasteners. Tighten any loose fasteners. The stars in the illustration below indicate fastener locations. Steering Adjustment With the handlebars in a straight ahead position, and with vehicle...

70 ADULT SECTION Maintenance Handlebar Adjustment 1. 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. 2. Remove the upper flange nut and carriage bolt. 3. Loosen the lower flange nut only...

71 ADULT SECTION 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.Check skags weekly to maintain posi...

72 ADULT SECTION Maintenance Lubrication Recommendations Suspension To maintain rider comfort and to retard wear of the pivot shafts, lubri- cate the suspension pivot shafts with Polaris Premium All Season Grease several times during the season and again before summer storage each year. Lack of lubr...

73 ADULT SECTION Maintenance Lubrication Recommendations Inspect and lubricate all greaseable components at the intervals outlined in the Periodic Maintenance Chart beginning on page 50. Controls and Linkage Lubricate all bushings and tie rod ends with a light coat of oil or grease. Remove the spind...

74 ADULT SECTION Maintenance Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a prof...

75 ADULT SECTION Maintenance Storage Off season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean. See page 76.2. Support the front end ...

76 ADULT SECTION Maintenance Storage Stabilize the Fuel 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. See page 82 for the part numbers of Polaris products.1. Fill the fuel tank with fre...

77 ADULT SECTION Maintenance Storage Track and Suspension Support the rear of the snowmobile slightly off the ground with an appropriate snowmobile support. This will allow the track to hang freely.Elevate the front end of the machine and place blocks securely under it to remove tension from the sho...

78 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. Fall ...

79 TROUBLESHOOTING Engine Turns Over, Fails to Start Contact your Polaris dealer for service if you're unable to identify solu- tions using the following chart. Possible Cause Solution Tether switch not engaged Install tether switch/strap Engine stop switch not on Pull stop switch up to RUN position...

80 SPECIFICATIONS Capacities and Dimensions Body Style Mini Indy Rider/Weight Capacity 1/140 lbs. (63.5 kg) maximum Dry Weight 147.5 lbs. (67 kg) Fuel Tank Capacity .5 gal. (1.9 l) Engine Oil Capacity 20 oz. (.6 l) Height 31 in. (78.7 cm) Length 75 in. (190.5 cm) Width 34 in. (86.4 cm) Track Length ...

81 SPECIFICATIONS Carburetor Jetting AMBIENT TEMPERATURE ALTITUDE Meters (Feet) Below -25 ° F (-31 ° C) -30 ° to -10 ° F (-34 ° to -23 ° C) -15 ° to +5 ° F (-26 ° C to -15 ° C) 0 ° to +20 ° F (-18 ° to -7 ° C) +15 ° to +35 ° F (-9 ° to +2 ° C) +30 ° to +50 ° F (-1 ° to +10 ° C) +45 ° to +65 ° F (+7 ...

82 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2874865 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2874866 Performance Synthetic 4-Stroke (PS-4) Oil (gal.) 2876244 Performance Synthetic 4-Stroke (PS-4 Plus) Oil (qt.) 2876245 Performance Synthetic ...

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

84 WARRANTY Service and Warranty Information Polaris Anti-Theft System The Polaris anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft. A. In addition to notifying the...

85 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...

87 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 cons...

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

89 WARRANTY Polaris Second Year Engine Service Contract Coverage Coverage for second year engine failures due to defects in materials and workmanship will be determined by Polaris in its sole discretion. Coverage is automatic with no addi- tional paperwork required. The free Second Year Engine Servi...

90 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 exp...

91 WARRANTY Exported Vehicles How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs ...

92 WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris stan- dard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified snowmobile engine me...

94 MAINTENANCE LOG 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 accurate log of maintenance and services performed on the snowmobile. DATE HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 50 100 150

96 INDEX A Air Pollution . . . . . . . . . . . . . . . . . . . 7 B Bearings . . . . . . . . . . . . . . . . . . . . . . 73 Brake Cable Adjustment . . . . . . . 56-57 Brake Lever . . . . . . . . . . . . . . . . . . . 14 Brake Lever Travel . . . . . . . . . . . . . 56 Break-In Period . . . . . . . . ....