Polaris 120 Pro X User Manual

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Summary of Contents

Page 2

7INTRODUCTIONPreservation of the EnvironmentTeach your child to drive their snowmobile with consideration for theprotection and preservation of the en

Page 3 - PROPOSITION 65

8INTRODUCTIONPreservation of the EnvironmentEnvironmental ProtectionAs part of the continuing environmental education campaign, we areencouraging stat

Page 4

9INTRODUCTIONVehicle Identification NumbersThe frame vehicle identification number (VIN) and engine serialnumber are important for model identificatio

Page 5

10SAFETYWARNINGFailure to follow the warnings in this manual can result in severeinjury or death. Read and understand the owner’s manual and allwarnin

Page 6 - TABLE OF CONTENTS

11SAFETYMaintenance ProgramAs with all snowmobiles, caution must be observed to ensure operatorsafety. Particular caution m ust be taken to make sure

Page 7

12SAFETYSafety DecalsSafety and warning decals have been placed on the vehicle for theoperator’s protection. Make sure the operator understands theinf

Page 8

13SAFETYThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these wordsand symbols a

Page 9

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

Page 10 - INTRODUCTION

15YOUTH SECTIONKnow Your SnowmobileAlways take your thumb off the throttle lever when you squeezethe brake lever.6. Brake Lever - Squeeze the brake le

Page 11

16YOUTH SECTIONKnow Your SnowmobileLet’s learn m ore about the parts of your snowmobile before we talkabout riding.12345698107

Page 13 - Equipment Modifications

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

Page 14 - Maintenance Program

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

Page 15 - Safety Decals

19YOUTH SECTIONPre-Ride CheckYou’re almost ready to have an adult start your snowmobile. Beforethe snowmobile is started for the first time, you must

Page 16 - IMPORTANT

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

Page 17 - YOUTH SECTION

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

Page 18

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

Page 19

23YOUTH SECTIONRiding Rules" Always drive your snowmobile while sitting down. Keep bothhands on the handlebars and keep both feet on the running

Page 20

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

Page 21

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

Page 22

26ADULT SECTIONPre-Ride CheckBefore Starting The Enginen Read and Understand Your Owner’s ManualRead and make sure the operators understand the Owner’

Page 23

WARNINGWARNINGRead, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the

Page 24

27ADULT SECTIONPre-Ride Checkn Check throttle safety switchTest the throttle safety switch systemon a daily basis before the machineis used.While seat

Page 25

28ADULT SECTIONPre-Ride Checkn Check engine stop switchTest the engine stop switch beforeeach use of the snowmobile. Tostop the engine in an emergency

Page 26

29ADULT SECTIONOperation W arningsn Do not carry passengersThis snowmobile is designed for a single operator.n Do not operate with intake silencer rem

Page 27

30ADULT SECTIONOperation W arningsn Do not touch the engine after it’s been runningWARNINGHot components can cause serious burns to skin. Do not touch

Page 28 - ADULT SECTION

31ADULT SECTIONOperation W arningsn Check brake lever travelMeasure the clearancebetween the lever and brakeblock. Inspection should bemade with the l

Page 29

32ADULT SECTIONOperation W arningsn Check surroundings to verify clear operating areaIt’s important to make sure there’s a clear area all around thesn

Page 30

33ADULT SECTIONOperation W arningsn Stop engine before attempting adjustmentsWARNINGThe snowmobile engine compartment contains moving parts.Shields an

Page 31

34ADULT SECTIONOperation W arningsn Know limitations of machine and skills of driverThe operator should be aware that there are state and local lawsgo

Page 32

35ADULT SECTIONOperation W arningsWire fences are a serious hazard. Teachyour child to always be on the alert forfences. Single strands are especially

Page 33

36ADULT SECTIONOperation W arningsWindchill/Temperature ChartsThe following information is provided as a guide to determine whattemperatures are dange

Page 35

37ADULT SECTIONOperation W arningsWIND CHILL CHART (°C)Esti-matedActual Thermometer Reading (°C)matedWindSpeed5 0 -5 -10 -15 -20 -25 -30 -35 -40Speedi

Page 36

38ADULT SECTIONOperation W arningsCold Weather Drive-AwayWhenever the m achine has been parked for some length of time,especi ally overnight, always s

Page 37

39ADULT SECTIONOperation W arningsSnow and Ice Build-UpSnow and ice buildup in the underhood area can interfere with thesteering.WARNINGBefore allowin

Page 38

40ADULT SECTIONOperation W arningsDriving on IceIt is dangerous to operate on ice or under slippery conditions. If ice orslippery conditions are unavo

Page 39

41ADULT SECTIONOperation W arningsDriving DownhillWhen riding downhill, the operator must keep the speed at a minimum.It is important to apply j ust e

Page 40

42ADULT SECTIONComponent Identification1. Hood 8. Rear Suspension2. Headlight 9. Nosepan3. Windshield 10. Trailing Arm4. Handlebar 11. Skis5. Seat 12.

Page 41

43ADULT SECTIONComponent Identification1. Stop Switch2. Tether Strap3. Throttle Control4. Recoil Starter Handle5. Hood Hold-Down6. Choke Button7. Gas

Page 42

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

Page 43

45ADULT SECTIONBreak-In PeriodCAUTIONMixing brands or using a non-recommended oil may causeserious engine damage. We recommend the use of PolarisPremi

Page 44

46ADULT SECTIONOperationFuelWhen refueling, use either leaded or unleaded gasoline with aminimum pump octane number of 87=(R+ M/2) octane.Fuel SafetyW

Page 45

2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

Page 46

47ADULT SECTIONOperationSpeed/Performance RegulationAdults have the responsibility for teaching children the proper and safeway to ride a snowmobile.

Page 47

48ADULT SECTIONOperationStarting the EngineNever start the snowmobile without checking all components to be sureof proper operation. Refer to the Pre-

Page 48

49ADULT SECTIONOperationEmergency Stopping ProceduresThe following chart lists methods for stopping the engine in the eventof an emergency.SYSTEM WHAT

Page 49

50ADULT SECTIONOperationPre-Ride Warm-UpAlways warm up the engine, drive train and track before operating t hesnowmobile. With the snowmobile securely

Page 50

51ADULT SECTIONMaintenancePolaris Recommended Maint en an ce ProgramYour Polaris snowmobile has been engineered and manufactured byskilled Polaris per

Page 51

52ADULT SECTIONMaintenanceCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and l

Page 52

53ADULT SECTIONMaintenanceITEM DAILY WEEKLY ORBEFOREEXTENDEDPERIOD OFOPERATION50HRS100HRS150HRSSEEPAG ECheck track alignment X 69Check drive chain ten

Page 53

54ADULT SECTIONMaintenancePresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future ow

Page 54

55ADULT SECTIONMaintenanceSpark PlugsA new engine can cause temporary spark plug fouling even though theheat range is proper, due to the preservative

Page 55

56ADULT SECTIONMaintenanceSpark PlugsSpark Plug Removal and Replacement1. Remove the spark plug cap.2. Using the special wrench provided in the tool p

Page 56

3TABLE OF CONTENTSWelcome 4...Introduction 5...Important Notes for Owners and Drivers 6...

Page 57 - Maintenance

57ADULT SECTIONMaintenanceCarburetorProper carburetor adjustment is critical, since a mixture too l ean (toomuch air, too little fuel) will result in

Page 58

58ADULT SECTIONMaintenanceThrottle Cable LubricationWith the engine off, lubricate the throttlecable occasionally. Turn the handlebarsto the left and

Page 59

59ADULT SECTIONMaintenanceBrake AdjustmentIf excessive brake lever to brake block clearance is evident, the brakecable should be adjusted. If proper a

Page 60

60ADULT SECTIONMaintenanceChain Ten sionerInspect the chain. The chain should have 1″ of deflection as shown. Ifnot, loosen the nut on the chain tensi

Page 61

61ADULT SECTIONMaintenanceLubricationNOTE: Driveline noise is normal and inherent in a chain drivesystem such as this machine uses.To ensure long life

Page 62

62ADULT SECTIONMaintenanceOil LevelMaintain the oil level between thesafe marks (A) on the dipstick.Oil ChangeChange the oil after the initial 20hours

Page 63

63ADULT SECTIONMaintenanceControls and Lin kag eAll bushings, spindle shafts, and tie rod ends should be coated with alight coat of oil or grease. Thr

Page 64

64ADULT SECTIONMaintenanceEngineProper off-season preparation of the engine and fuel system is vital tothe prevention of rust and corrosion formation

Page 65

65ADULT SECTIONMaintenanceCarburetor Pro tectio n During Off-Seaso n StorageWhen preparing your snowmobile for off-season storage werecommend that you

Page 66

66ADULT SECTIONMaintenanceTransporting the SnowmobileWhenever the snowmobile is transported the following measuresshould be taken:1. Turn the fuel val

Page 67

4WELCOMEDear Parents:We believe your children should have the opportunity to enjoy TheWay Out experience along with you. We’ve provided this owner’sma

Page 68

67ADULT SECTIONMaintenanceWARNINGYour snowmobile is propelled by a revolving track, which must bepartially exposed for proper operation. Serious injur

Page 69

68ADULT SECTIONMaintenanceTrack AdjustmentIf the track needs adjustment:1. Loosen rear idler shaft bolt (D).2. Tighten or loosen the track adjusting s

Page 70

69ADULT SECTIONMaintenanceTrack AlignmentA periodic check should be made to see that the track is centered andrunning evenly on the slide rails. Misal

Page 71

70ADULT SECTIONMaintenanceTrack Warm UpWhen storing your snowmobileoutside overnight, it isrecommended that the track bewarmed up prior to driving the

Page 72

71ADULT SECTIONMaintenanceTrack InspectionWARNINGInspecting the track while the engine is running can result inserious personal injury if the track sh

Page 73

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

Page 74

73ADULT SECTIONMaintenanceTrack LubricationTrack failure, loss of vehicle control and braking ability can result fromextended use of this vehicle on s

Page 75

74ADULT SECTIONMaintenanceSteering Inspection and AdjustmentThe steering assembly of themachine should be checkedperiodically for loose nuts andbolts.

Page 76

75ADULT SECTIONMaintenanceHandlebar Adjustment6. Slide the handlebar padupward to access the adjusterbolts. If additional room isrequired, unzip one o

Page 77

76ADULT SECTIONMaintenanceSki SkagsThe skag (A) is a replaceable barattached to the underside ofthe ski. The purpose of theskag is to assist in turnin

Page 78

5INTRODUCTIONAfter reading this manual, store it in the snowmobile for convenientreference. It should remain with the snowmobile when sold.n This manu

Page 79

77ADULT SECTIONMaintenanceSuspension LubricationTo maintain rider comfort and to retard wear of the pivot shafts, thesuspension pivot shafts should be

Page 80

78ADULT SECTIONMaintenanceSuspension ComponentsSuspension Lubrication points are indicated by a L.1. Front Limiter Strap 8. Rail Bumper2. Torsion Spri

Page 81

79ADULT SECTIONAccessoriesMaintenance Items and AccessoriesThe tools and maintenance items mentioned in this book, as well as along line of other Pola

Page 82

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

Page 83 - SPECIFICATIONS

81SPECIFICATIONSCapacities and DimensionsBody Style Mini IndyRiders/Weight 1/150 lbs. (68 kg) maximumEngine Oil .6 qts. (.57 l)Dry Weight (est.) 147.5

Page 84

82POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.)Gearcase / Transmission Lubricants287

Page 85 - POLARIS PRODUCTS

83WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warrantyinform

Page 86 - WARRANTY

84WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polari

Page 87

85WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND FI

Page 88

86WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if appl

Page 89

6INTRODUCTIONImportant Notes for Owners and DriversPARENTS: Do not allow anyone under the age of six (6) to operatethis machine. Review the informatio

Page 90

87WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that we

Page 91

88WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

Page 92

89INDEXA-BAccessories 79......Auto Chain Tensioner 60....Brake Adjustment 59.....Brake Lever Travel 58....

Related models: 2003 120 XC SP | 2004 120 Pro X |

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