Polaris 120 XC Rider's Safety Manual And Owner's Operation And Maintenance Manual
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Polaris 120 XC Rider's Safety Manual And Owner's Operation And Maintenance Manual

Polaris 120 XC Rider's Safety Manual And Owner's Operation And Maintenance Manual

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2001
120 XC
Snowmobile
Rider's Safety Manual
and Owner's Operation
and Maintenance Manual
Part No. 9916124
PRINTED IN THE U.S.A.

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  • Page 1 2001 120 XC Snowmobile Rider’s Safety Manual and Owner’s Operation and Maintenance Manual Part No. 9916124 PRINTED IN THE U.S.A.
  • Page 2 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust, which contain chemicals known to the State of California to cause cancer and birth defects or other reproductive harm, onto the snow on...
  • Page 3 Should any additional assistance be required, your dealer will work with our technical services department to resolve any problems. All of us at Polaris would like to extend our best wishes for plenty of fun-filled, safe snowmobiling pleasure with this new Polaris.
  • Page 4 (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two-year mem- bership in the Polaris PRO Family----the Preferred Registered Owners Family. This is an owners’ program for Polaris consumers like you, people who have chosen the finest recreational vehicle available, and who share an interest in Polaris and its products.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS RIDER’S SECTION ....... . R-1 - R-11 Understanding Warnings .

  • Page 6: Rider'ssection

    Never allow your child to operate this machine without adult supervision. CHILDREN: Before you ride your new Polaris snowmobile, there are some important things you should know. How to keep safe is the most important thing. You must also learn some things that will keep you and those around you safe while you are riding.

  • Page 7: Know Your Machine

    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”...
  • Page 8 KNOW YOUR MACHINE 6. Brake Lever - Squeeze this towards the handle to make your snowmobile slow down or stop. Always take your thumb off the throttle control when you pull the brake lever. 7. Ignition Switch - The key must be turned “on” before pulling on the recoil starter handle to start your snowmobile.
  • Page 9 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.
  • Page 10 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.
  • Page 11 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.

  • Page 12: Pre Operation Check

    If you have sticky brakes, do not start the engine. You could get hurt if you ride when you have sticky brakes. Have an adult or your Polaris Dealer fix the sticky brakes. If you have used the storage area under the seat, make sure the seat locking tabs are in place.
  • Page 13 PRE OPERATION CHECK 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.

  • Page 14: Riding Rules

    RIDING RULES 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. Remember that safety while you ride is the most important thing.
  • Page 15 RIDING RULES You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed. " Always wear the right kind of clothing when you are riding your snowmobile.
  • Page 16 RIDING RULES " Always drive your snowmobile while sitting down. Keep both hands on the handlebars and keep both feet on the running boards. Both Hands on Handlebars Sit Down Feet on Running Boards " When you are a beginner, always stay on level ground. "...
  • Page 17 RIDING RULES You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed. " Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away from them. Never ride on frozen water.
  • Page 18 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 R--13...

  • Page 19: Adult Section

    UNDERSTANDING WARNINGS ADULT SECTION SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey 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 know and understand the risk if these important warnings and cautions are not heeded.

  • Page 20: Safety Warning And Operation Decals

    There is a significant possibility of loss of control at higher speeds. Due to our concern for the safety of our customers and the general public, Polaris hereby requests that consumers do not install on a Polaris snowmobile any equip- ment which is intended to increase the speed or power of the machine, or make any other modifications to the machines for these purposes.
  • Page 21 SAFETY WARNING AND OPERATION DECALS The information contained in this decal is printed below. WARNING Read and understand warnings and the Owner’s Manual before operation. Severe injury or death can result from not heeding the warnings. This vehicle is intended for daylight use in restricted off-road areas clear of obstacles.

  • Page 22: Pre Operation Check

    PRE OPERATION CHECK WARNING Teach the operators to perform the following Pre-Operation Check before starting the engine each time before they ride. If they do not check their machine properly before riding, they could be seriously injured or killed. Check the throttle for proper operation. Check the throttle safety switch for proper operation.

  • Page 23: Operation Warnings

    OPERATION WARNINGS 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.
  • Page 24 OPERATION WARNINGS The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valve does not return to the normal closed position. Check for Proper Operation of Steering System Check for proper operation of the steering system by manually turning the skis completely to the right and to the left.
  • Page 25 OPERATION WARNINGS Do Not Operate Engine With Intake Silencer or Filter Removed CAUTION When operating engine with intake silencer or filter removed, damage to the engine may occur. Stay Clear of Track WARNING During warm-up and operation, stand clear of the rotating track. Entangle- ment and serious injury or death may result.
  • Page 26 OPERATION WARNINGS Disabled Operators WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in serious injury or death. Brake Lever Travel Distance A not to exceed 3/4″...
  • Page 27 OPERATION WARNINGS Lighting Check Check headlight and taillight for normal operation. Check Surroundings to Verify Clear Operating Area It is important to make certain there is a clear area all around the snowmobile, in- cluding an area clear of bystanders. Remember that the possibility always exists of some sideways vehicle movement or of debris being thrown by the track.
  • Page 28 This vehicle is intended for daylight use only. Check both the headlight and taillight of the machine to ensure proper operation. IMPORTANT: The headlight and tail- light are intended only to increase the visibility of the 120 XC SP during daylight operation.
  • Page 29 OPERATION WARNINGS Wire fences are a serious hazard. Teach your child to always be on the alert for fences. Single strands are especially dangerous, since there can be a great distance between posts. Guy wires on utility poles are also difficult to distinguish. Teach your child to reduce speed when traveling near poles, posts, or other obstacles.
  • Page 30 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 Actual Thermometer Reading (°F) Wind Speed in Wind Speed in Equivalent Temperature (°F) Calm --57 -112...
  • Page 31 OPERATION WARNINGS Cold Weather Drive-away Whenever the machine has been parked for some length of time, especially over- night, 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.
  • Page 32 OPERATION WARNINGS Hard Packed Snow WARNING Steering and braking control are substantially reduced when operating on on hard surfaces, hard-packed snow, or icy surfaces. Teach your child to reduce speed as required to maintain control in all driving condi- tions. If necessary, maximum speed may be regulated by using the procedure out- lined on page A--24.
  • Page 33 OPERATION WARNINGS Hilly Terrain WARNING Traveling on hilly terrain is not recommended. It takes some maneuvering of body weight that a child may not be capable of, which will leave the child at risk. If traveling on hilly terrain is unavoidable, teach your child to exercise ex- treme caution as well as the proper operating procedure as outlined below.

  • Page 34: Preservation Of The Environment

    Air Pollution As a part of Polaris’ plan for the snowmobile’s compatibility within the environment, our engineers are investigating ways to reduce emission levels of engines. We ex- pect our efforts to lead to the reduction of potential air pollution.

  • Page 35: Identification And Specifications

    IDENTIFICATION AND SPECIFICATIONS Vehicle Nomenclature Refer to the illustrations on the following pages. Hood Nosepan Headlight Trailing Arm Windshield Skis Handlebar Front Bumper Seat Vehicle I.D. Number (Right Side) Storage (under seat) Rear Bumper Taillight Snow Flap Track Rear Suspension A--17...
  • Page 36 IDENTIFICATION AND SPECIFICATIONS Controls and Instruments Stop Switch (Push/Pull). Operation found on page A--26. Throttle Control Recoil Starter Handle Choke Button Gas Cap Ignition Switch Brake Lever Tether Switch Hood Hold-Down 10. Console 11. Tether Strap A--18...

  • Page 37: Engine Break-In

    Per- form the following procedures carefully. CAUTION Use only Polaris Premium 4 All Season synthetic oil. Never substitute or mix oil brands. Serious engine damage and voiding of warranty can result. 1. Fill the fuel tank with either unleaded or leaded fuel that has a minimum pump oc- tane number of 87.
  • Page 38 D Never mix brands of oil. Serious chemical reactions can cause oil passage blockage, resulting in severe engine damage and voiding of engine war- ranty. The only oil recommended for this system is Polaris Premium 4 All Season Synthetic oil. This oil has been specially formulated for all temper- atures and has extreme cold flow characteristics.

  • Page 39: Operation

    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 fail- ure.
  • Page 40 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 fail- ure.
  • Page 41 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 oc- tane oxygenated pump gasoline.
  • Page 42 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.
  • Page 43 OPERATION Starting a Cold Engine Turn key to “On”. Pull engine stop switch (shut-off switch) up to “run” position. Pull the choke lever outward to “Full On” position. Grasp starter handle and pull slowly until recoil engages; then pull to start. CAUTION Do not pull the starter rope to its full extended position or allow it to snap back into the housing as damage can result.
  • Page 44 OPERATION Engine Stop Switch To stop the engine in an emer- gency, push down on the stop switch (A). This will ground out the ignition and bring the engine to a quick stop. To re-start the engine, the switch must be pulled up to the “On”...
  • Page 45 If the throttle lever does not work properly, do not start the engine. If the throttle lever operates properly, turn the ignition switch on and go through normal starting procedures. If the engine does not start, take the snowmobile to an authorized Polaris dealer for service. If excessive play develops in the...
  • Page 46 OPERATION Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emer- gency. SYSTEM WHAT IT DOES THROTTLE CONDITION Engine Stop Switch Interrupts ignition circuit Ignition Switch Interrupts ignition circuit Tether Switch Interrupts ignition circuit Choke Floods engine 1/2 throttle or less...
  • Page 47 OPERATION Pre-ride Warm-Up The following steps must be taken to ensure proper warm- up of the engine, drive train and track. With the snowmobile securely supported by the rear bumper, and with a minimum clearance of 4″ (10 cm) from the ground, use the following procedure.

  • Page 48: Maintenance

    MAINTENANCE Polaris Recommended Owner Maintenance Program This Polaris snowmobile has been engineered and manufactured by skilled Polar- is 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 given regular service and maintenance inspections.
  • Page 49 MAINTENANCE Weekly Maintenance Check For best machine performance and safe operation, check these points weekly and before any extended period of operation: Track alignment and adjustments Drive chain tension Brake operation, adjustment Headlight and taillight Emergency shut off switch operation and throttle safety switch function Suspension mounting bolts (tightness) Steering arm and tie rod ends (check for play or looseness) Ski saddle and spindle bolts (tighten)
  • Page 50 NOTE: The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer.
  • Page 51 MAINTENANCE ITEM WEEKLY OR BEFORE HOURS HOURS HOURS PAGE EXTENDED PERIOD OF OPERATION Check front & rear limiter strap A- -55 condition, tighten loose bolts Check hi-fax thickness, replace A- -51 when worn (Dealer) Tighten rear idler wheel bolts, if A- -48 loose Check spark plug condition...
  • Page 52 Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of mainte- nance and services performed on the unit. 50 Hour Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage...
  • Page 53 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 cause excessive fouling and malfunction.
  • Page 54 MAINTENANCE Wet Fouled The insulator tip is black. A damp oily film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Causes could be excessive oil, use of non-recommended injection oil, excessive idling, idle too low or too rich, or weak ignition output.
  • Page 55 The installed main jet is not necessarily correct for your elevation. It is the Polaris dealer’s responsibility to ensure that the correct main jets are installed in each machine for your area of operation.
  • Page 56 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 springs or damper/support grommets.
  • Page 57 MAINTENANCE Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable or cali- per should be adjusted using the following methods. WARNING Improper brake adjustment could result in brake failure which could result in severe injury or death. Cable Adjustment Make sure floating parts move freely and all parts are...
  • Page 58 MAINTENANCE Brake Adjustment Install brake band. Route Insert cable through housing cable through cable housing. Install spring on cable and thread cable through screw barrel. Hold opposite slotted side with flat tool Torque such feeler gauge. Insert 1/8″ allen wrench. Pull cable through barrel and tighten.
  • Page 59 MAINTENANCE Mechanical Brakes Brake Lever Travel Measure the clearance between the le- ver and brake block. Inspection should be made with the lever firmly de- pressed. Distance B should be no more than 3/4″ (1.9 cm) Excessive travel indicates a need to adjust the brake cable adjuster.
  • Page 60 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 every 10 hours of operation with aerosol chain lube or SAE 30 oil.
  • Page 61 MAINTENANCE Oil Level Safe Oil Level Maintain the oil level between the safe Between Marks marks 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 extend the life of various components.
  • Page 62 MAINTENANCE Front Suspension To minimize fatigue on the front shocks and springs during extended storage, it is recommended that the front end of the machine be safely blocked off the ground to remove tension from the shocks and springs. Engine Proper off-season preparation of the engine and fuel system is vital to the preven- tion of rust and corrosion formation on precision engine parts during storage.
  • Page 63 Fall Tune-Up To obtain maximum performance and use from your snowmobile, we encourage you to arrange for a fall service tune-up with your Polaris dealer. He has an experi- enced and trained service technician who is interested in keeping your machine in peak operating condition.
  • Page 64 MAINTENANCE WARNING Your snowmobile is propelled by a revolving track which must be partially ex- posed for proper operation. Serious injuries may be caused by operator care- lessness resulting in hands, feet, or clothing becoming entangled in the track. Be alert. Remember, being properly seated keeps you clear of the track. Track and Suspension Under normal conditions moderate track tension should be maintained...
  • Page 65 MAINTENANCE Track Tension (Cont.) If the track needs adjustment: Loosen rear idler shaft bolt (D). Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new.
  • Page 66 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. WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.
  • Page 67 MAINTENANCE Track Warm Up When storing your snowmobile outside overnight, it is recom- mended that the track be warmed up prior to driving the snowmo- bile. This reduces drive clutch wear. To warm up the track, safe- ly support the rear of the snowmo- bile off the ground, start the en- gine and abruptly engage the clutch.
  • Page 68 NOTE: The 120 XC SP track has molded in track clips. It is common for a thin layer of rubber to detach from clip area and peel off during initial use.
  • Page 69 MAINTENANCE Hi-Fax Replacement The 120 XC SP uses XTRA Lite style Hi-Fax. Hi Fax Wear Limit When any area of the Hi-Fax is worn to 7/16″ (1.1 cm), it should 7/16″ (1.1 cm) placed. This will save wear on other XTRA Lite vital components.
  • Page 70 WARNING Improper alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment. Contact your Polaris dealer. A--52...
  • Page 71 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 snowmo- bile and to prevent the wearing away of the ski caused by con- tact with roads and other bare terrain.
  • Page 72 Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension piv- ot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871066, several times during the season and again before summer storage each year.
  • Page 73 MAINTENANCE Suspension Components Front Limiter Strap Torsion Spring Sleeves Torsion Spring Carrier Wheel Rear Limiter Strap Spacer Adjuster Bolts Idler Wheel Toe Guard 10. Hi-fax 11. Rail 12. Torque Arm 13. Rail Bumper Suspension Lubrication points are indicated by a A--55...

  • Page 74: Troubleshooting

    Engine Troubleshooting The following information is provided to help you identify probable causes for ques- tions 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...

  • Page 75: Clutching Chart

    ACCESSORIES Accessories There are a wide range of accessories available for Polaris snowmobiles. Contact your dealer for a list of accessories available for your machine. Maintenance Items Gas Dock Recoil Starter Handle Tool Pouch Tool Kit Carbon Clean Grease, Premium All Season...

  • Page 76: Specifications

    SPECIFICATIONS Specifications - 120 XC SP Rider Seating Dry Weight (lbs.)±4 lbs Fuel Tank Capacity (Gal) Height, in. Length, in. Ski Center Distance, in. Width, in. Engine Fuji 4 Stroke 4 hp Alternator Output 12V 50 W Bore x Stroke (mm)

  • Page 77: Wiring Diagram

    WIRING DIAGRAM 2001 120 XC SP A--59...

  • Page 78: Service And Warranty

    B. Owners must provide their name, address, telephone number and model and serial number of stolen machines. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units, to further monitor thefts. Polaris warranty will aid in notification of recovered units to their proper owner.

  • Page 79: Warranty

    This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the snowmobile. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive op- tion, repair or replacement of any defective materials, or components or products.
  • Page 80 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 TRANSPORTATION TO AND FROM THE DEALER IS YOUR RE- SPONSIBILITY).
  • Page 81 D Backed by the strength of Polaris - no third party involvement. D Repairs use only genuine top quality Polaris parts. D Peace of mind. The Polaris Extended Service Contract is honored by all autho- rized Polaris snowmobile dealers in North America. However, where possible we urge you to contact the selling dealer.
  • Page 82 INDEX Accessories ....A- -57 Pre-Ride Warm Up ....A- -29 Auto Chain Tensioner .

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