7INTRODUCTIONPreservation of the EnvironmentTeach your child to drive their snowmobile with consideration for theprotection and preservation of the en
8INTRODUCTIONPreservation of the EnvironmentEnvironmental ProtectionAs part of the continuing environmental education campaign, we areencouraging stat
9INTRODUCTIONVehicle Identification NumbersThe frame vehicle identification number (VIN) and engine serialnumber are important for model identificatio
10SAFETYWARNINGFailure to follow the warnings in this manual can result in severeinjury or death. Read and understand the owner’s manual and allwarnin
11SAFETYMaintenance ProgramAs with all snowmobiles, caution must be observed to ensure operatorsafety. Particular caution m ust be taken to make sure
12SAFETYSafety DecalsSafety and warning decals have been placed on the vehicle for theoperator’s protection. Make sure the operator understands theinf
13SAFETYThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these wordsand symbols a
14YOUTH SECTIONKnow Your SnowmobileBefore you have an adult start the engine for you for the first time, let’slearn about the controls on your new mac
15YOUTH SECTIONKnow Your SnowmobileAlways take your thumb off the throttle lever when you squeezethe brake lever.6. Brake Lever - Squeeze the brake le
16YOUTH SECTIONKnow Your SnowmobileLet’s learn m ore about the parts of your snowmobile before we talkabout riding.12345698107
17YOUTH SECTIONKnow Your Snowmobile1. Hood - The hood covers the moving and hot parts of the engineand must be securely latched before you ride the sn
18YOUTH SECTIONKnow Your SnowmobileLet’s review the three ways to stop your snowmobile:1. Push the stop switch down.2. Pull off the tether strap.3. Tu
19YOUTH SECTIONPre-Ride CheckYou’re almost ready to have an adult start your snowmobile. Beforethe snowmobile is started for the first time, you must
20YOUTH SECTIONPre-Ride CheckAlways have an adult put gas in your snowmobile. Never try to doit yourself.n Have an adult check the gas level to see if
21YOUTH SECTIONRiding RulesNow you’re ready t o learn about driving your Polaris snowmobile.There are some things you can do and there are some things
22YOUTH SECTIONRiding Rules" Always wear the right kind of clothing when you’re riding yoursnowmobile. You’ll need a good helmet with a face shie
23YOUTH SECTIONRiding Rules" Always drive your snowmobile while sitting down. Keep bothhands on the handlebars and keep both feet on the running
24YOUTH SECTIONRiding RulesLearn how to ride safely and correctly. Learn how to use your handsand arms as signals. Read and understand your Owner’s Ma
25ADULT SECTIONPre-Ride CheckIt’s up to you, the adult, to teach your child the proper and safe way toride a snowmobile. You must set boundaries and a
26ADULT SECTIONPre-Ride CheckBefore Starting The Enginen Read and Understand Your Owner’s ManualRead and make sure the operators understand the Owner’
WARNINGWARNINGRead, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the
27ADULT SECTIONPre-Ride Checkn Check throttle safety switchTest the throttle safety switch systemon a daily basis before the machineis used.While seat
28ADULT SECTIONPre-Ride Checkn Check engine stop switchTest the engine stop switch beforeeach use of the snowmobile. Tostop the engine in an emergency
29ADULT SECTIONOperation W arningsn Do not carry passengersThis snowmobile is designed for a single operator.n Do not operate with intake silencer rem
30ADULT SECTIONOperation W arningsn Do not touch the engine after it’s been runningWARNINGHot components can cause serious burns to skin. Do not touch
31ADULT SECTIONOperation W arningsn Check brake lever travelMeasure the clearancebetween the lever and brakeblock. Inspection should bemade with the l
32ADULT SECTIONOperation W arningsn Check surroundings to verify clear operating areaIt’s important to make sure there’s a clear area all around thesn
33ADULT SECTIONOperation W arningsn Stop engine before attempting adjustmentsWARNINGThe snowmobile engine compartment contains moving parts.Shields an
34ADULT SECTIONOperation W arningsn Know limitations of machine and skills of driverThe operator should be aware that there are state and local lawsgo
35ADULT SECTIONOperation W arningsWire fences are a serious hazard. Teachyour child to always be on the alert forfences. Single strands are especially
36ADULT SECTIONOperation W arningsWindchill/Temperature ChartsThe following information is provided as a guide to determine whattemperatures are dange
37ADULT SECTIONOperation W arningsWIND CHILL CHART (°C)Esti-matedActual Thermometer Reading (°C)matedWindSpeed5 0 -5 -10 -15 -20 -25 -30 -35 -40Speedi
38ADULT SECTIONOperation W arningsCold Weather Drive-AwayWhenever the m achine has been parked for some length of time,especi ally overnight, always s
39ADULT SECTIONOperation W arningsSnow and Ice Build-UpSnow and ice buildup in the underhood area can interfere with thesteering.WARNINGBefore allowin
40ADULT SECTIONOperation W arningsDriving on IceIt is dangerous to operate on ice or under slippery conditions. If ice orslippery conditions are unavo
41ADULT SECTIONOperation W arningsDriving DownhillWhen riding downhill, the operator must keep the speed at a minimum.It is important to apply j ust e
42ADULT SECTIONComponent Identification1. Hood 8. Rear Suspension2. Headlight 9. Nosepan3. Windshield 10. Trailing Arm4. Handlebar 11. Skis5. Seat 12.
43ADULT SECTIONComponent Identification1. Stop Switch2. Tether Strap3. Throttle Control4. Recoil Starter Handle5. Hood Hold-Down6. Choke Button7. Gas
44ADULT SECTIONBreak-In PeriodEngine Break-InThe break-in period for your new snowmobile is defined as the first tenhours of operation, or the time it
45ADULT SECTIONBreak-In PeriodCAUTIONMixing brands or using a non-recommended oil may causeserious engine damage. We recommend the use of PolarisPremi
46ADULT SECTIONOperationFuelWhen refueling, use either leaded or unleaded gasoline with aminimum pump octane number of 87=(R+ M/2) octane.Fuel SafetyW
2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat
47ADULT SECTIONOperationSpeed/Performance RegulationAdults have the responsibility for teaching children the proper and safeway to ride a snowmobile.
48ADULT SECTIONOperationStarting the EngineNever start the snowmobile without checking all components to be sureof proper operation. Refer to the Pre-
49ADULT SECTIONOperationEmergency Stopping ProceduresThe following chart lists methods for stopping the engine in the eventof an emergency.SYSTEM WHAT
50ADULT SECTIONOperationPre-Ride Warm-UpAlways warm up the engine, drive train and track before operating t hesnowmobile. With the snowmobile securely
51ADULT SECTIONMaintenancePolaris Recommended Maint en an ce ProgramYour Polaris snowmobile has been engineered and manufactured byskilled Polaris per
52ADULT SECTIONMaintenanceCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and l
53ADULT SECTIONMaintenanceITEM DAILY WEEKLY ORBEFOREEXTENDEDPERIOD OFOPERATION50HRS100HRS150HRSSEEPAG ECheck track alignment X 69Check drive chain ten
54ADULT SECTIONMaintenancePresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future ow
55ADULT SECTIONMaintenanceSpark PlugsA new engine can cause temporary spark plug fouling even though theheat range is proper, due to the preservative
56ADULT SECTIONMaintenanceSpark PlugsSpark Plug Removal and Replacement1. Remove the spark plug cap.2. Using the special wrench provided in the tool p
3TABLE OF CONTENTSWelcome 4...Introduction 5...Important Notes for Owners and Drivers 6...
57ADULT SECTIONMaintenanceCarburetorProper carburetor adjustment is critical, since a mixture too l ean (toomuch air, too little fuel) will result in
58ADULT SECTIONMaintenanceThrottle Cable LubricationWith the engine off, lubricate the throttlecable occasionally. Turn the handlebarsto the left and
59ADULT SECTIONMaintenanceBrake AdjustmentIf excessive brake lever to brake block clearance is evident, the brakecable should be adjusted. If proper a
60ADULT SECTIONMaintenanceChain Ten sionerInspect the chain. The chain should have 1″ of deflection as shown. Ifnot, loosen the nut on the chain tensi
61ADULT SECTIONMaintenanceLubricationNOTE: Driveline noise is normal and inherent in a chain drivesystem such as this machine uses.To ensure long life
62ADULT SECTIONMaintenanceOil LevelMaintain the oil level between thesafe marks (A) on the dipstick.Oil ChangeChange the oil after the initial 20hours
63ADULT SECTIONMaintenanceControls and Lin kag eAll bushings, spindle shafts, and tie rod ends should be coated with alight coat of oil or grease. Thr
64ADULT SECTIONMaintenanceEngineProper off-season preparation of the engine and fuel system is vital tothe prevention of rust and corrosion formation
65ADULT SECTIONMaintenanceCarburetor Pro tectio n During Off-Seaso n StorageWhen preparing your snowmobile for off-season storage werecommend that you
66ADULT SECTIONMaintenanceTransporting the SnowmobileWhenever the snowmobile is transported the following measuresshould be taken:1. Turn the fuel val
4WELCOMEDear Parents:We believe your children should have the opportunity to enjoy TheWay Out experience along with you. We’ve provided this owner’sma
67ADULT SECTIONMaintenanceWARNINGYour snowmobile is propelled by a revolving track, which must bepartially exposed for proper operation. Serious injur
68ADULT SECTIONMaintenanceTrack AdjustmentIf the track needs adjustment:1. Loosen rear idler shaft bolt (D).2. Tighten or loosen the track adjusting s
69ADULT SECTIONMaintenanceTrack AlignmentA periodic check should be made to see that the track is centered andrunning evenly on the slide rails. Misal
70ADULT SECTIONMaintenanceTrack Warm UpWhen storing your snowmobileoutside overnight, it isrecommended that the track bewarmed up prior to driving the
71ADULT SECTIONMaintenanceTrack InspectionWARNINGInspecting the track while the engine is running can result inserious personal injury if the track sh
72ADULT SECTIONMaintenanceHi-F ax ReplacementThe 120 PRO X uses XTRALite style Hi-Fax. When anyarea of the Hi-Fax is worn to7/16″ (1.1 cm), it should
73ADULT SECTIONMaintenanceTrack LubricationTrack failure, loss of vehicle control and braking ability can result fromextended use of this vehicle on s
74ADULT SECTIONMaintenanceSteering Inspection and AdjustmentThe steering assembly of themachine should be checkedperiodically for loose nuts andbolts.
75ADULT SECTIONMaintenanceHandlebar Adjustment6. Slide the handlebar padupward to access the adjusterbolts. If additional room isrequired, unzip one o
76ADULT SECTIONMaintenanceSki SkagsThe skag (A) is a replaceable barattached to the underside ofthe ski. The purpose of theskag is to assist in turnin
5INTRODUCTIONAfter reading this manual, store it in the snowmobile for convenientreference. It should remain with the snowmobile when sold.n This manu
77ADULT SECTIONMaintenanceSuspension LubricationTo maintain rider comfort and to retard wear of the pivot shafts, thesuspension pivot shafts should be
78ADULT SECTIONMaintenanceSuspension ComponentsSuspension Lubrication points are indicated by a L.1. Front Limiter Strap 8. Rail Bumper2. Torsion Spri
79ADULT SECTIONAccessoriesMaintenance Items and AccessoriesThe tools and maintenance items mentioned in this book, as well as along line of other Pola
80SPECIFICATIONSJetting ChartAmbientTemperatureBelow-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+30_ to+50_ F
81SPECIFICATIONSCapacities and DimensionsBody Style Mini IndyRiders/Weight 1/150 lbs. (68 kg) maximumEngine Oil .6 qts. (.57 l)Dry Weight (est.) 147.5
82POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.)Gearcase / Transmission Lubricants287
83WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warrantyinform
84WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polari
85WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND FI
86WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if appl
6INTRODUCTIONImportant Notes for Owners and DriversPARENTS: Do not allow anyone under the age of six (6) to operatethis machine. Review the informatio
87WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that we
88WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
89INDEXA-BAccessories 79......Auto Chain Tensioner 60....Brake Adjustment 59.....Brake Lever Travel 58....
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