Polaris 120 XC SP User Manual

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Summary of Contents

Page 2 - PROPOSITION 65

R--5KNOW YOUR MACHINELet’s learn more about your machine before we talk about riding.1. Hood - The hood covers the moving and hot parts of the engine

Page 3 - Check it out

R--6KNOW YOUR MACHINE6. 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

Page 4 - FOREWORD TO PARENTS

R--7KNOW YOUR MACHINELet’s review the three ways to stop yoursnowmobile.1. Pushing down on the engine stop switch on theright handlebar control will s

Page 5 - TABLE O F CONTENTS

R--8PRE OPERATION CHECKYou are almost ready to have an adult start your snowmobile. Beforethe snowmobile is started for the first time, you must do aP

Page 6

R--9PRE OPERATION CHECKn Make sure your track and skis are not frozen to the snow. Standbehind the machine and lift up on the back of the sled. This w

Page 7

R--10RIDING RULESAny operator of this machine must be at least 6 years old. Now you areready to learn about riding a snowmobile. You will learn what y

Page 8

R--11RIDING RULES" Always wear the right kind of clothing when you are riding yoursnowmobile. You will need a good helmet with a face shield orgo

Page 9

R--12RIDING RULES" Always drive your snowmobile while sitting down. Keep bothhands on the handlebars and keep both feet on the running boards.&qu

Page 10 - KNOW YOUR MACHINE

R--13RIDING RULES" Learn where there are lakes, rivers, ponds and ditches in yourdriving area. Stay away from them. Never ride on frozen water. Y

Page 11

R--14RIDING RULESLearn how to ride safely and correctly. Learn how to use your handsand arms as signals. Read and understand your Owner’s Manual.Left

Page 12

Read, understand, and follow all of the instructions andsafety precautions in this manual and on all product labels.Failure to follow the safety preca

Page 14

A-- 2UNDERSTANDING WARNINGSThe following precautionary signal words are used throughout thismanual to convey the following messages: It is very import

Page 15 - RIDING RULES

A-- 3UNDERSTANDING WARNINGSThe word “NOTE:” in this manual will alert you to keyinformation or instructions.Indicates a situation that can result in d

Page 16

A-- 4UNDERSTANDING WARNINGSAs with all snowmobiles, caution must be observed to ensure operatorsafety. Particular caution must be taken to make sure t

Page 17

A-- 5SAFETY DECALSNOTE: Warning decals have been placed on the vehicle for theoperator’s protection. Make certain the operator understands theinformat

Page 18

A-- 6SAFETY DECALSS Read and understand warnings and the Owner’ s Manual be-fore operation. Severe injury or death can result from notheeding the warn

Page 19

A-- 7PRE O PERATION CHECKTeach the operators to perform the following Pre-Operation Checkbefore starting the engine each time before they ride. If the

Page 20

A-- 8PRE O PERATION CHECKBefore Starting The EngineNOTE: It is up to you, the parent, to teach your child the proper and safeway to ride a snowmobile.

Page 21 - UNDERSTANDING WARNINGS

A-- 9PRE O PERATION CHECKn Check Throttle Safety SwitchTest the throttle safety switchsystem on a daily basis be-fore the machine is used.While seated

Page 22 - IMPORTANT

A-- 10OPERATION WARNINGSn Single Rider SnowmobilesThis snowmobile is designed for a single operator.n Do Not Operate Engine With Intake Silencer Remov

Page 23

1What’s the hottest thing on snow?Our new web site. It’s designed just for YOU!S Technical tipsS New product introductionsS Event schedulesS Parts and

Page 24 - SAFETY DECALS

A-- 11OPERATION WARNINGSn Do Not Touch the Engine After it Has Been RunningnDisabled OperatorsThe engine and exhaust become very hot when it is runnin

Page 25

A-- 12OPERATION WARNINGSn Brake Lever TravelMeasure the clearancebetween the lever andbrake block. Inspectionshould be made with thelever firmly depre

Page 26 - PRE O PERATION CHECK

A-- 13OPERATION WARNINGSn Be Seated and in Position to Control the VehicleImproper operator position on the snowmobile can be the source ofserious inj

Page 27

A-- 14OPERATION WARNINGSn Always Wear Clothing Designed for SnowmobilingClothing designed for snowmobiling is warm, comfortable and safe.n Know the Li

Page 28

A-- 15OPERATION WARNINGSWire fences are a serious hazard.Teach your child to always be on thealert for fences. Single strands areespecially dangerous,

Page 29 - OPERATION WARNINGS

A-- 16OPERATION WARNINGSWindchill/Temperature ChartsThe following information is provided as a guide to determine whattemperatures are dangerous when

Page 30

A-- 17OPERATION WARNINGSWIND CHILL CHART (°C)Esti-matedActual Thermometer Reading (°C)matedWindSpeed5 0 -5 -10 -15 -20 -25 -30 -35 -40Speedin KPHEquiv

Page 31

A-- 18OPERATION WARNINGSCold Weather Drive-awayWhenever the m achine has been parked for some length of time,especially overnight, always shake loose

Page 32

A-- 19OPERATION WARNINGSSnow and ice buildup in the underhood area can inter -fere with the steering.Hard Packed SnowTeach your child to reduce speed

Page 33

A-- 20OPERATION WARNINGSIceIt is dangerous to operate on ice or under slippery conditions. If ice orslippery conditions are unavoidable, use extreme c

Page 34

2FOREWORD TO PARENTSThank you for purchasing a Polaris snowmobile and welcome to ourworld wide family of Polaris enthusiasts. Polaris takes great prid

Page 35

A-- 21OPERATION WARNINGSRiding DownhillWhen riding downhill, the operator must keep the speed at a minimum.It is important to apply just enough thrott

Page 36

A-- 22PRESERVATION OF THE ENVIRONMENTTeach your child to drive their snowmobile with consideration for theprotection and preservation of the environme

Page 37

A-- 23PRESERVATION OF THE ENVIRONMENTEnvironmental ProtectionAs part of the continuing environmental education campaign, we areencouraging state and p

Page 38

A-- 24IDENTIFICATION AND SPECIFICATIONSVehicle NomenclatureRefer to the illustrations on the following pages.1. Hood 12. Nosepan2. Headlight 13. Trail

Page 39

A-- 25IDENTIFICATION AND SPECIFICATIONSControls and Instruments1. Stop Switch (Push/Pull).Operation found on pageA--33.2. Tether Strap3. Throttle Cont

Page 40

A-- 26ENGINE BREAK-INEngine Break -InThe break-in period for your new snowmobile is defined as the first tenhours of operation, or the time it takes t

Page 41 - Air Pollution

A-- 27ENGINE BREAK-INWith a basic understanding of how the snowmobile works, and withclose attention paid to maintenance tips, you will be ready to ri

Page 42 - Environmental Protection

A-- 28OPERATIONCarburetionProper carburetor adjustment is critical, since a mixture too lean (toomuch air, too little fuel) will result in overheating

Page 43 - Vehicle Nomenclature

A-- 29OPERATIONS Always stop the engine and refuel outdoors or in a well ventilated area.S Do not smoke or allow open flames or sparks in or near the

Page 44 - Controls and Instruments

A-- 30OPERATIONFuelThe fuel used in the Polaris engine is as important to engine life andperformance as the lubricant used.Most Polaris engines are de

Page 45 - ENGINE BREAK-IN

3TABLE O F CONTENTSRIDER’S SECTION R--1 - R--14Understanding Warnings R--1 - R--2Know Your Machine R--3 - R--7Pre Operation Check R--8 - R--9Riding Ru

Page 46

A-- 31OPERATIONNOTE: It is up to you, the parent, to teach your child the proper andsafe way to ride a snowmobile. You must set boundaries and adhere

Page 47 - OPERATION

A-- 32OPERATIONPre-StartingBefore starting the engine, always refer to all safety warningspertaining to snowmobile operation. Never start the snowmobi

Page 48

A-- 33OPERATIONStarting a Warm Engine1. Turn key to “On”.2. Pull engine stop switch (shut-off switch) up to “run” position.3. Grasp starter handle and

Page 49

A-- 34OPERATION4. If the throttle lever operates properly, turn the ignition switch onand go through normal starting procedures.5. If the engine does

Page 50

A-- 35OPERATIONDaily StorageWhenever the machine isplaced in overnight or dailystorage the following stepsmust be taken:S Park the snowmobile on aleve

Page 51

A-- 36OPERATIONPre-ride Warm-UpThe following steps must be taken to ensure proper warm-up of theengine, drive train and track.With the snowmobile secu

Page 52

A-- 37MAINTENANCEPolaris Recommended Maintenan ce ProgramThis Polaris snowmobile has been engineered and manufactured byskilled Polaris personnel to t

Page 53

A-- 38MAINTENANCECareful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and lubricatio

Page 54

A-- 39MAINTENANCEITEM WEEKLYORBEFOREEX-TENDEDPERIODOF OP-ERATION50HOURS100HOURS150HOURSSEEPAGECheck ski skags, replace whenworn to 1/2 original diamet

Page 55

A-- 40MAINTENANCEPresent this section of your manual to your dealer each time your snow-mobile is serviced. This will provide you and future owners wi

Page 56 - MAINTENANCE

R--1IMPORTANT NOTES FOR OWNERS ANDDRIVERSn After you read this manual store it in the vehicle for convenientreference. It should remain with the vehic

Page 57

A-- 41MAINTENANCESpark Plug SelectionOriginal equipment parts or their equivalent should always be used.However, the heat range of spark plugs is of u

Page 58

A-- 42MAINTENANCESpark Plug SelectionA new engine can cause temporary spark plug fouling even though theheat range is proper, due to the preservative

Page 59

A-- 43MAINTENANCEWet FouledThe insulator tip is black. Theremay be a carbon layer over theentire nose. Generally, theelectrodes are not worn. Causesco

Page 60

A-- 44MAINTENANCECarburetor AdjustmentsProper carburetor adjustments include the following:S Carburetor component changes for specific altitude and am

Page 61

A-- 45MAINTENANCEExhaust SystemAt approximately 50 hours it is a good idea to check the exhaust systemfor wear or damage. To inspect, allow engine and

Page 62

A-- 46MAINTENANCEThrottle Cable Pivot SlugLubricate the throttle cable pivotslug (A) every 50 hours or twicea year using and aerosollubricant.Brake Ad

Page 63

A-- 47MAINTENANCECable and Brake Adjustment1. Slide the two rubberprotector covers (A)back to expose thecable adjuster.2. Usingan8mmwrenchto hold the

Page 64

A-- 48MAINTENANCEBrake Lever TravelMeasure the clearance betweenthe lever and brake block.Inspection should be made withthe lever firmly depressed.Dis

Page 65

A-- 49MAINTENANCELubrication PointsNOTE: Driveline noise is normal and inherent in a chain drive systemsuch as this machine uses.To ensure long life o

Page 66

A-- 50MAINTENANCEOil LevelMaintain the oil level between thesafe marks (A) on the dipstick.Oil ChangeChange the oil after the initial 20hours of opera

Page 67

R--2IMPORTANT NOTES FOR OWNERS ANDDRIVERSPARENTS: Do not allow anyone under the age of 6 to operate thismachine. Review the information in this manual

Page 68

A-- 51MAINTENANCEControls and LinkageAll bushings, spindle shafts, and tie rod ends should be coated with alight coat of oil or grease. Throttle and b

Page 69

A-- 52MAINTENANCEEngineProper off-season preparation of the engine and fuel system i s vital tothe prevention of rust and corrosion formation on preci

Page 70

A-- 53MAINTENANCECarburetor Protection During Off-Season StorageWhen preparing your snowmobile for off-season storage werecommend that you add a fuel

Page 71

A-- 54MAINTENANCETransporting the SnowmobileWhenever the snowmobile is transported the following measuresshould be taken:1. Turn the fuel valve to “Of

Page 72

A-- 55MAINTENANCETrack and SuspensionUnder normal conditionsmoderate track tension shouldbe maintained during summerstorage. The rear of themachine sh

Page 73

A-- 56MAINTENANCENOTE: Measure at t he point where the weight is hanging.4. Check for specified slack between the wear surface of the track clipand th

Page 74

A-- 57MAINTENANCETrack AlignmentA periodic check should be made to see that the track is centered andrunning evenly on the slide rails. Misalignment w

Page 75

A-- 58MAINTENANCE1. Safely support the rearof the machine with thetrack off the groundusing a jackstand.2. Start the engine andapply a small amount of

Page 76

A-- 59MAINTENANCETrack Warm UpWhen storing yoursnowmobile outsideovernight, it i srecommended that thetrack be warmed up priorto driving thesnowmobile

Page 77

A-- 60MAINTENANCETrack InspectionUsing a hoist or jackstand,safely lift and support therear of the snowmobile offthe ground. R otate the trackby hand

Page 78

R--3KNOW YOUR MACHINEBefore you have an adult start the engine for you for the first time, l et’slearn about the controls on your new machine.1. Engin

Page 79

A-- 61MAINTENANCEHi-Fax ReplacementThe 120 XC SP usesXTRA Lite styleHi-Fax. When anyarea of the Hi-Fax isworn to 7/16″ (1.1cm), it should bereplaced.

Page 80

A-- 62MAINTENANCETrack LubricationTrack failure, loss of vehicle control and braking ability can result fromextended use of this vehicle on surfaces p

Page 81

A-- 63MAINTENANCESteering Inspectio n and AdjustmentThe steering assembly of themachine should be checkedperiodically for loose nuts andbolts. See A,B

Page 82

A-- 64MAINTENANCEHandlebar AdjustmentS Slide the handlebar padupward to access the ad-juster bolts. If additionalroom is required, unzipone of the han

Page 83

A-- 65MAINTENANCESki SkagsThe skag is a replaceablebar attached to theunderside of the ski. Thepurpose of t he skag is toassist in turning thesnowmobi

Page 84

A-- 66MAINTENANCENOTE:If rear idler wheel (1)assembly washers areremoved, be sure they arereinstalled with the domedside of the washer facingout (2) a

Page 85

A-- 67MAINTENANCESuspension ComponentsSuspension Lubrication points are indicated by a L.1. Front Limiter Strap 2. Rail Bumper3. Torsion Spring Sleeve

Page 86

A-- 68TROUBLESHOOTINGEngine TroubleshootingThe following information is provided to help you identify probablecauses for questions you may have about

Page 87 - TROUBLESHOOTING

A-- 69ACCESSORIESMaintenance Items and AccessoriesThe tools and maintenance items mentioned i n t his book are available atyour Polaris dealer as well

Page 88 - ACCESSORIES

A-- 70SPECIFICATIONSSpecifications - 120 XC SPRider Seating 1 Pilot Jet 50Dry Weight (lbs.)±4lbs140 Air Screw 1.5Fuel Tank Capacity(Gal).5 Ignition Ty

Page 89 - SPECIFICATIONS

R--4KNOW YOUR MACHINE6. Brake Lever - Squeeze this towards the handle to make yoursnowmobile slow down or stop.7. Ignition Switch - The key must be tu

Page 90 - WIRING DIAGRAM

A-- 71WIRING DIAGRAM2001 120 XC SP

Page 91 - SERVICE AND WARRANTY

A-- 72SERVICE AND WARRANTYPolaris Anti -Theft SystemThe Polaris anti-theft system monitoring program (PATS ) is designedto aid owners of registered sn

Page 92

A-- 73SERVICE AND WARRANTYWhen writing about parts, service or warranty, always include thefollowing information:1. Serial number 5. Details of troubl

Page 93 - WARRANTY

A-- 74WARRANTYLIMITED WARRANTYPolaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55430,gives a ONE YEAR LIMITED WARRANTY on all components of

Page 94

A-- 75WARRANTYThis warranty does not cover the use of unauthorized lubricants,chemicals, or fuels that are not compatible with the snowmobile.The excl

Page 95

A-- 76WARRANTYHOW TO OBTAIN WARRANTY SERVICEIf your snowmobile requires warranty service, you must take it to aPolaris dealer authorized to repair Pol

Page 96

A-- 77WARRANTYPolaris Extended Service ContractPolaris now is offering an extended engine service contract which pro-vides the following benefits:S Ad

Page 97

78INDEXAccessories A-69...Auto Chain Tensioner A-48...Brake Adjustment A-46...Brake Lever Travel A-48...

Related models: 2000 120 XCR | 2001 120 XCR |

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