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Polaris 2000 120 XCR Service Manual

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  • Page 2 2000-2007 120 Youth Snomobile Service Manual PN 9920517 © Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 3 Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron M-10, Registerd Trademark of FAST, Inc Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer.

  • Page 4: Table Of Contents

    2000 120 XCR ........

  • Page 5: Specifications

    MODEL SPECIFICATIONS SPECIFICATIONS ETTING Ambient Temperature 2007 DRAGON 120 NGINE Altitude Engine type Fuji meters (feet) Engine displacement 2.36/60 Bore in/mm 1.69/43 Stroke in/mm 0-600 72.5 72.5 67.5 67.5 67.5 .0006-.0029/.015-.074 Piston to cylinder clearance in/mm (0-2000) .008-.016/.2-.4 Piston ring end gap in/mm 600-1200 67.5 67.5...
  • Page 6 MODEL SPECIFICATIONS RONT USPENSION Suspension type Arvin IFS shocks IFS spring rate 80/1.43 lbs-in/kg-mm 6.75/17.1 IFS Spring installed length in/mm 3.0/7.62 Front vertical travel in/cm 30/76.2 Ski Center Distance Camber in/mm .125/.3175 Toe in/mm USPENSION Mini Indy Suspension type Front track shock (FTS) FTS Spring Rate lbs-in/kg-mm FTS pre-load...

  • Page 7: 2006 120 Pro X

    MODEL SPECIFICATIONS 2006 120 PRO X S# 0600001 ETTING FOR NGINE AND ABOVE Ambient Temperature NGINE Engine type Fuji Engine displacement Altitude meters (feet) 2.36/60 Bore in/mm 1.69/43 Stroke in/mm .0006-.0029/.015-.074 Piston to cylinder clearance in/mm .008-.016/.2-.4 Piston ring end gap in/mm 0-600 72.5 72.5...
  • Page 8 MODEL SPECIFICATIONS APACITIES LECTRICAL .5/1.9 23°@3600 Fuel gal/l Ignition timing .6/.6 .028/.70 Oil qts/l Spark plug gap in/mm Mechanical NGK BR6ES Brake fluid type Spark plug 50w@3600 Voltage regulator/output RACK IMENSIONS 10/25 Width in/cm 69/175 Length in/cm .79/2.1 Lug height in/cm Track tension sag in/cm with 10 lbs/4.54kg placed 8 in/ .75/1.9...

  • Page 9: 2005 Pro X 120

    MODEL SPECIFICATIONS 2005 PRO X 120 ETTING Ambient Temperature NGINE Engine Model Number EH122PM015 Altitude Engine type Fuji meters (feet) Engine displacement 2.36/60 Bore in/mm 1.69/43 Stroke in/mm .0006-.0029/.015-.074 Piston to cylinder clearance in/mm 0-600 72.5 72.5 72.5 (0-2000) .008-.016/.2-.4 Piston ring end gap in/mm 600-1200 72.5...
  • Page 10 MODEL SPECIFICATIONS RONT USPENSION Suspension type Arvin IFS shocks USPENSION Mini Indy Suspension type 6.9/17.5 Rear travel in/cm * notes that shock is rebuildable 7041844-067 LH Torsion spring PNs (LH/RH) 7041845-067 RH Torsion spring diameter in/ .406 IMENSIONS 34/86 Width in/cm 75/191 Length in/cm 31/79...

  • Page 11: 2004 120 Pro X - 2003 120Xc Sp

    MODEL SPECIFICATIONS 2004 120 PRO X - 2003 120XC SP ETTING Ambient Temperature NGINE 2004-EH122PM014 Engine Model Number 2003-EH122PM013 Altitude Fuji meters (feet) Engine type Engine displacement cc’s 2.36(60) Bore in/mm 1.57(43) Stroke in/mm 0-600 72.5 72.5 72.5 .0006-.0029/.015-.074 Piston to cylinder clearance in/mm (0-2000) 600-1200 72.5...
  • Page 12 MODEL SPECIFICATIONS RONT USPENSION Suspension type Arvin IFS shocks USPENSION Mini Indy Suspension type 6.9/17.5 Rear travel in/cm * notes that shock is rebuildable 7041844-067 LH Torsion spring PNs (LH/RH) 7041845-067 RH Torsion spring diameter in/ .406 IMENSIONS 34/86 Width in/cm 75/191 Length in/cm 31/79...

  • Page 13: 2002 120 Xc Sp -2001 120 Xcr

    MODEL SPECIFICATIONS 2002 120 XC SP -2001 120 XCR ETTING Ambient Temperature NGINE 2001-EH122PM012 Engine Model Number 2001-EH122PM011 Altitude Fuji meters (feet) Engine type Engine displacement cc’s 2.36(60) Bore in/mm 1.57(43) Stroke in/mm 0-600 72.5 72.5 72.5 .0006-.0029/.015-.074 Piston to cylinder clearance in/mm (0-2000) 600-1200 72.5...
  • Page 14 MODEL SPECIFICATIONS RONT USPENSION Suspension type Arvin IFS shocks USPENSION Mini Indy Suspension type 6.9/17.5 Rear travel in/cm * notes that shock is rebuildable 7041844-067 LH Torsion spring PNs (LH/RH) 7041845-067 RH Torsion spring diameter in/ .406 IMENSIONS 34/86 Width in/cm 75/191 Length in/cm 31/79...

  • Page 15: 2000 120 Xcr

    MODEL SPECIFICATIONS 2000 120 XCR USPENSION Front Track Shock/Rear Shock NGINE RIVETRAIN Track (WxLxLug)(in/cm) 10x69x.79 (25.4x175.3x2) Engine Model Number 2000-EH122PM010 Bore/Stroke (in/mm) 2.36x1.57 (60x43) ETTING Ambient Temperature Cylinder Liner Iron Displacement (cc)/Cylinders/ 121cc/1/Fan Type Altitude Ignition Solid State meters (feet)
  • Page 16 GENERAL CHAPTER 2 GENERAL HOW TO USE THIS MANUAL..........2.2 MODELS LISTED .

  • Page 17: How To Use This Manual

    The following chart explains the abbreviations that are used throughout this section. ABBREVIATION MEANING Power Take Off Magneto Rear Torque Arm Front Torque Arm cubic centimeters Revolutions Per Minuet Polaris Electric Reverse PERC Control ft-lb foot pounds newton meters Capacitor Discharge Ignition kg-mm kilograms per millimeter lb.-in...

  • Page 18: Snowmobile Number Designations

    GENERAL SNOWMOBILE NUMBER DESIGNATIONS MODEL NUMBER DESIGNATION EXAMPLE S06MC6FS (2006 600 HO DRAGON FUSION) ODEL PTION DENTIFIER ODEL ODEL NGINE ODIFIER DENTIFIER DENTIFIER 1st digit 2/3rd digit 4th digit 5th digit 6th digit* 7th digit* 8th digit 9th digit** C=Dragon 121 1A=121 F/C OHV 4 Cycle Fuji D=Classic 3A=340 F/C Piston Port...

  • Page 19: Vin Number Designation

    GENERAL VIN NUMBER DESIGNATION Vehicle Descriptors Vehicle Identifiers World Mfg. ID PUBLICATION PART NUMBERS Misc. Publications UBLICATION UMBER 2007 2007 Specification/Quick Reference Manual 9920653 2007 2007 Wiring Diagrams 9920688 Track Diagnosis Poster 9918459 2006 2006 Specification/Quick Reference Manual 9920147 2006 2006 Wiring Diagrams 9920672 Monotube Shock Rebuilding Video...
  • Page 20 GENERAL OWNER'S MODEL OWNER'S PARTS ASSEMBLY SERVICE 2007 MODEL MANUAL PARTS BOOK NUMBER MANUAL MICROFISCHE INSTRUCTIONS MANUAL SUPPLEMENT 600 HO IQ Stock B S07PP6FSB 9920459 9920460 9920461 9920462 9919882 9920463 600 SDI IQ S07PP6HS 9920464 9920487 9920466 9920467 9919882 9920463 600 SDI IQ Stock A S07PP6HSA 9920464...

  • Page 21: General Reference

    GENERAL GENERAL REFERENCE GASOLINE VOLATILITY STANDARD BOLT TORQUE SPECIFICATION MBIENT AXIMUM APOR ANGE CLASS PRESSURE HIGH 60° F 110° F+ 7.0 psi (0.5 bar) (16° C) (43° C+) 50° F 110° F Grade 2 Grade 8 Grade 5 9.0 psi (0.6 bar) (10°...

  • Page 22: Sae Tap Drill Sizes

    GENERAL SAE TAP DRILL SIZES 1/64 ....0156 1/32 ....0312 .

  • Page 23: Glossary Of Terms

    = liters Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 liters x 1.057 = US quarts cm). Polaris measures chain length in number of pitches. CI: Cubic inches. US gallon x 3.785 = liter Clutch Buttons: Plastic bushings which aid rotation of the movable liter x.264...

  • Page 24: Special Tools

    GENERAL SPECIAL TOOLS Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. SPECIAL TOOLS Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
  • Page 25 GENERAL 2.10...
  • Page 26 GENERAL 2.11...
  • Page 27 GENERAL 2.12...
  • Page 28 POLARIS RECOMMENDED PROGRAM........3.3...
  • Page 29 MAINTENANCE TRANSPORTING & TOWING ..........3.12 TRANSPORTING .

  • Page 30: Maintenance Program

    The following chart is a guide based on average riding Brake System conditions. You may need to increase frequency based on riding Brake Fluid conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your FUEL MANAGEMENT Polaris dealer. Pilot Air Screws Carburetor...

  • Page 31: Lubrication

    MAINTENANCE LUBRICATION REQUENCY ILES EASO Lubricate the following fittings with Polaris Premium All 1000 2000 (240) (240) (1600) (3200) Season grease annually or approximately every 50 hours (except where noted on maintenance chart) Tether Switch and Strap CHASSIS • Spindles (left and right) (1).

  • Page 32: Chain Maintenance

    SUSPENSION To maintain rider comfort and to retard wear of the pivot shafts (6), the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease, PN 2871423, several times during the season and again before summer storage each year. The riding characteristics of the snowmobile will be affected by lack of lubrication of these shafts.

  • Page 33: Fluid Change

    When oil has been drained, make sure that the drain plug has the o-ring installed and install the drain plug. Using a long funnel, add 20 oz. (.6L) of Polaris 0W-40 to the crankcase through the opening where you removed the dipstick.

  • Page 34: Cable Inspection/Adjustment

    MAINTENANCE CABLE INSPECTION/ADJUSTMENT THROTTLE LEVER FREE PLAY Throttle lever free play must always provide a specified BRAKE CABLE INSPECTION clearance between throttle lever and throttle block. This clearance is controlled by the throttle cable at the carburetor. If excessive brake lever to brake block clearance is evident, the brake cable or caliper should be adjusted using the following methods.

  • Page 35: Track Maintenance

    MAINTENANCE After adjustments are complete, be sure to torque locknuts TRACK MAINTENANCE and idler shaft bolts. TRACK MAINTENANCE WARNINGS WARNING 35-40 ft.lb (48-55Nm) When performing the following checks and TRACK TENSION adjustments, stay clear of all moving parts to avoid serious personal injury Track adjustment is critical for proper handling.

  • Page 36: Rear Idler Wheels

    MAINTENANCE Start machine and slowly rotate the track at least five revolutions, let the track stop rotating by itself (do not apply brakes). WARNING 10. Turn engine off. 11. Check track alignment (side to side) by comparing the The snowmobile is propelled by a revolving track distance from the guide clip to Hi-fax on both sides.

  • Page 37: Steering System

    The spark plug and its condition is STEERING SYSTEM indicative of engine operation. The spark plug firing The steering systems on Polaris snowmobiles can be adjusted end condition should be examined after the engine with ski toe alignment. Improper toe alignment can cause erratic is warmed up and the vehicle is driven at higher steering.

  • Page 38: Fuel Valve & Fuel Lines

    WARNING NOSEPAN CARE If your nosepan becomes dirty with soot, you can use Polaris Carburetor adjustments should be performed only Carbon Clean (PN 2872890) to remove the soot. by a knowledgeable service technician at a Polaris servicing dealer using the proper tools, procedures and specifications.

  • Page 39: Storage

    Be certain the fuel cap is installed correctly. CARBURETOR/THROTTLE BODY Always tie the snowmobile to the transporting unit securely using suitable straps. Fog engine with Polaris Fogging Oil (aerosol type) according to directions on can. TOWING FUEL SYSTEM Do not use this snowmobile to tow.
  • Page 40 ENGINE / CARBURETOR / CLUTCH CHAPTER 4 ENGINE / CARBURETOR / CLUTCH WARNINGS ............4.3 WARNINGS .
  • Page 41 ENGINE / CARBURETOR / CLUTCH RECOIL STARTER ........... . . 4.30 DISSASSEMBLY .

  • Page 42: Warnings

    Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands are substituted.

  • Page 43: Torque Specifications

    ENGINE / CARBURETOR / CLUTCH reconnect it last. Battery electrolyte contains sulfuric acid and is poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External - Flush with water. Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

  • Page 44: Clearance Data & Limits

    ENGINE / CARBURETOR / CLUTCH CLEARANCE DATA & LIMITS CYLINDER HEAD...

  • Page 45: Cylinder / Piston

    ENGINE / CARBURETOR / CLUTCH CYLINDER / PISTON Out-of-Round Cylinder Taper...
  • Page 46 ENGINE / CARBURETOR / CLUTCH...

  • Page 47: Connecting Rod

    ENGINE / CARBURETOR / CLUTCH CONNECTING ROD...

  • Page 48: Cam Shaft / Valves

    ENGINE / CARBURETOR / CLUTCH CAM SHAFT / VALVES...
  • Page 49 ENGINE / CARBURETOR / CLUTCH (45 seat) 4.10...

  • Page 50: Engine Maintenance

    ENGINE / CARBURETOR / CLUTCH ENGINE MAINTENANCE DAILY MAINTENANCE Maintenance Remarks Clean away dust and debris from engine Governor linkage is especially sensitive to dust Check fuel leakage from fuel system. If any, re-tighten fasteners or replace necessary parts Loose bolts and nuts may come off and result in breakage of Inspect for loose hardware and re-tighten if necessary other parts Check oil level and add to full mark...

  • Page 51: Engine Removal

    ENGINE / CARBURETOR / CLUTCH Remove nut (F) retaining brake band (G). Pull cable (H) out ENGINE REMOVAL from housing. Remove band (G). REMOVAL Shut off fuel. Disconnect throttle cable at holder (H) using a screw driver to loosen set screw, and remove cable bracket bolt. Slide cable out and set aside Remove the clutch guard bolts and remove the clutch guard.
  • Page 52 ENGINE / CARBURETOR / CLUTCH Remove cables from harness guide clips (J). 11. Remove the steering post. 12. Find master link on drive chain. Remove keeper and slide master link out. Do not re-use master link. Always replace with new. Remove the chain. Disconnect the stop switch (K).

  • Page 53: Engine Installation

    ENGINE / CARBURETOR / CLUTCH Insert the recoil handle and tie a secure knot in recoil handle ENGINE INSTALLATION (B). Engine Installation Torques Item ft.lb. (in.lb) Mounting fastener 17ft.lb 23.5Nm Steering post fastener (50 in.lbs) 5.8 Nm Steering tie rod fastener 18 ft.lb 25Nm Clutch fastener...
  • Page 54 = In. / mm. Brake Lever Freeplay .125" - .375" (6-10mm) Steering rod ends 18 ft.lb. (25Nm) 17. Grease PTO shaft with Polaris Premium All Season Grease. NOTE: Inspect key on clutch before installation and replace clutch if needed. 4.15...

  • Page 55: Engine Components

    ENGINE / CARBURETOR / CLUTCH ENGINE COMPONENTS 23. Torque band nut (E) to 6 ft.lbs (8.3Nm). CYLINDER & CRANKCASE The cylinder and crankcase assembly is a single piece of aluminum diecasting. The cylinder liner, made of special cast iron, is molded into the aluminum casting. The crankcase has a mounting surface on the output shaft side, where the main bearing cover is attached.

  • Page 56: Piston Rings

    ENGINE / CARBURETOR / CLUTCH VALVE ARRANGEMENT aluminum alloy casting, and carries two compression rings and one oil control ring. The intake valve is located on flywheel side of the cylinder head. The hard alloy valve seats are molded in the cylinder head and stellite is fused to the exhaust valve face.

  • Page 57: Lubrication

    ENGINE / CARBURETOR / CLUTCH LUBRICATION AIR FILTER All rotating and sliding parts are splash lubricated by the oil There is no air filter element in the 120. scraper on the connecting rod. NOTE: An air filter is not required for operation in winter conditions.

  • Page 58: Engine Component Locations

    ENGINE / CARBURETOR / CLUTCH ENGINE COMPONENT LOCATIONS 4.19...

  • Page 59: Engine Disassembly

    ENGINE / CARBURETOR / CLUTCH Remove cleaner case. ENGINE DISASSEMBLY Unhook governor spring (A) from speed control lever (B). PREPERATIONS & SUGGESTIONS Remove governor lever from governor shaft. Detach governor lever, governor rod and rod spring from When disassembling the engine, memorize the locations of carburetor.
  • Page 60 ENGINE / CARBURETOR / CLUTCH 13. Remove starter pulley (6) from flywheel. Place 19 mm 16. Remove rocker cover (8) and gasket (9) from cylinder head socket wrench on flywheel nut and strike tip of lever with (10). a soft face hammer to loosen nut. 17.

  • Page 61: Engine Assembly

    ENGINE / CARBURETOR / CLUTCH 27. Remove clips (18) and piston pin (19). ENGINE ASSEMBLY 28. Remove piston from connecting rod. 29. Remove piston rings (20) from piston. Engine Assembly Torques Item ft.lb Connecting Rod Cab Bolt 6.5-8.3 8.8-11.2 Crankcase Bolt Torque 8-9.5 Cylinder Head (Step 1) Cylinder Head (Step 2)
  • Page 62 ENGINE / CARBURETOR / CLUTCH Lubricate bearing surfaces of camshaft. Align the timing • Measure the height B1 (From mating surface to the crank gear). mark on the crankshaft gear with the timing mark on the camshaft (3) and install the camshaft in the crankcase as shown in the illustration.
  • Page 63 ENGINE / CARBURETOR / CLUTCH Install the oil ring first (4), then second ring (5), then top Install connecting rod cap. ring (6). Spread the ring only far enough to slip over the Torque Connecting Rod to specification. piston and into the correct groove (7). Use care not to distort the ring.
  • Page 64 ENGINE / CARBURETOR / CLUTCH 15. Install cylinder head to cylinder with new head gasket. Tighten four flange bolts evenly in three steps by the following tightening torque: = In. / mm. Valve Clearance (Intake & Exhaust): Cylinder Head .0031"-.0047" (.08-.12mm) 1st step 3.6 ft.lb (5Nm) NOTE: Check and adjust valve clearance while 2nd Step 7.2 ft.lb (10Nm)

  • Page 65: Engine Break In

    ENGINE / CARBURETOR / CLUTCH 23. Install ignition coil to crankcase. Adjust air gap between the number 2 hole on the speed control lever. ignition coil and flywheel using a feeler gauge and tighten bolts to specification. 28. Turn speed control lever all the way toward high speed position and make sure the throttle valve in carburetor is at wide open position.

  • Page 66: Decompression System

    ENGINE / CARBURETOR / CLUTCH DECOMPRESSION SYSTEM EH12-2 engines are employing an automatic decompression system as a standard feature. This enables easy and light starting of the engine. The automatic decompression system releases the compression of the engine by opening the exhaust valve slightly at cranking.

  • Page 67: Fuel Delivery

    ENGINE / CARBURETOR / CLUTCH FUEL DELIVERY The float chamber is located below the carburetor body, and, with a float and a needle valve, maintains a constant fuel level during engine operation. Fuel flows from the fuel tank into the float chamber through the needle valve.

  • Page 68: Pilot System

    21 Packing clip (20) and needle valve (19). If needle valve needs to be Choke Valve 22 Bolt replaced, replace it with genuine Polaris parts. Ring 23 Body Float 12. When removing needle valve and float, gently tap one side...

  • Page 69: Recoil Starter

    ENGINE / CARBURETOR / CLUTCH 10. If spring in reel is close to popping up, re-perform previous RECOIL STARTER steps. Equipment needed: Screwdriver, pliers, and protective glasses. WARNING Do not drop or shake the reel. Hold the spring in the WARNING reel when removing.
  • Page 70 16. If spring escapes from reel when disassembling recoil, hook outer end of spring onto notch of reel and rewind spring into housing. 17. Lubricate rotating parts, sliding parts, and spring with Polaris Premium All Season Grease when reassembling recoil and prior to long term storage. l. 5 WARNING Spring tension is highest when reel is being wound.

  • Page 71: Clutch

    Install grease seal fiber washer (3). Install drum (7) and snap ring (1) When clutch is installed and torqued to specification, pump two (2) pumps initially of Polaris Premium All Season grease in fitting. After initial greasing, pump 1/2 to 1 pump every 10 hours 10.

  • Page 72: Fuel Tank

    ENGINE / CARBURETOR / CLUTCH FUEL TANK TROUBLE SHOOTING FUEL TANK REMOVAL FUEL SYSTEM Drain fuel from tank. Carburetor not choked sufficiently when engine is cold. With engine removed, loosen the two Torx™ screws (A) Water, dust, or gum in gasoline interfering with fuel flow securing fuel tank to chassis.

  • Page 73: Engine Misfires

    ENGINE / CARBURETOR / CLUTCH ENGINE MISFIRES ENGINE BACKFIRES THROUGH CARBURETOR Incorrect or worn spark plug electrode gap. Adjust to Water or dirt in gasoline, or low grade gasoline. .025” (0.635 mm). Intake valve stuck. Valves overheated, or hot carbon particles in combustion = In.
  • Page 74 BODY/STEERING CHAPTER 5 BODY/STEERING TORQUE APPLICATIONS ..........5.2 STEERING .

  • Page 75: Torque Applications

    BODY/STEERING TORQUE APPLICATIONS Due to the special grade bolts and nuts required for specific applications, observe the following torque values in the areas specified. Refer to exploded views for torque values and orientation of components and fasteners. Illustration depicts proper orientation of rod ends and bolts on steering components. 16ft.lb (21.7Nm) 16ft.lb (21.7Nm) 7 ft.lb (9.5Nm)

  • Page 76: Steering

    ROD END PROCEDURE Some of the fasteners used in the IFS are special and cannot be purchased at a hardware store. Always use genuine Polaris parts Rod ends must be parallel to their respective mounting surface and hardware when replacing front end components.

  • Page 77: Toe Adjustment

    BODY/STEERING If skis do not measure equally, loosen tie rod end jam nuts TOE ADJUSTMENT (inner and outer) and turn tie rod until equal measurements With tape measure, measure from handlebar to a common are achieved. point on both sides of machine to center handlebars. Once you have skis in straight ahead position, measure from the straight edge of the skis.

  • Page 78: Ski Spindle/Bushing Removal

    Slide the spindle (1) out from top of the trailing arm (6) and keep track of the top (4) and bottom (5) bushings. SKI SPINDLE/BUSHING INSTALLATION Grease spindle and bushings liberally with Polaris Premium All Season grease. Install spindle (1), through the top bushing (4) and then into the trailing arm (6).

  • Page 79: Skag Replacement

    BODY/STEERING Install the ski assembly (11-14, 16-19 and 21-22). RADIUS ROD REPLACEMENT Install the ski bolt (15) and Nylock Nut (20). Insert the tie rod bolt (8) through the tie rod end and the spindle. 10. Place the washer (2) on the bottom along with the Nylock nut (3) and torque to 16 ft.lb (22 Nm).

  • Page 80: Body

    BODY/STEERING BODY TRAILING ARM REPLACEMENT IFS SHOCK REPLACEMENT Lift and support front end of machine. Be sure the machine is stable and solidly supported before proceeding. Serious injury may result if machine tips or falls. Using 1/2” wrench and 3/16” allen wrench, loosen and remove shock bolts.

  • Page 81: Decals

    BODY/STEERING To flame treat the decal area: DECALS Pass the flame of a propane torch back and forth quickly Plastic polyethylene material must be “flame treated” prior to installing a decal to ensure good adhesion. The flame treating over the area where the decal is to be applied until the procedure can often be used to reduce or eliminate the whitish surface appears slightly glossy.
  • Page 82 SUSPENSION CHAPTER 6 SUSPENSION TORQUE APPLICATIONS ..........5.2 STEERING .
  • Page 83 SUSPENSION RAIL SLIDES REAR SUSPENSION REAR SUSPENSION GREASE POINTS RAILSLIDE REPLACEMENT 7/16” (1.1cm) The 120 uses XTRA Lite style rail slide. When any area of the rail slide is worn to 7/16”(1.1 cm), it should be replaced. This will save wear on other vital components. The rail slide is designed to operate in conditions with adequate snow cover to provide sufficient lubrication.
  • Page 84 SUSPENSION REAR SUSPENSION EXPLODED VIEW SUSPENSION ITEMS ESCRIPTION ESCRIPTION ESCRIPTION Torsion Spring Toe Block Track Adjuster Front Limiter Strap Idler Wheel Torque Arm Rail Rear Idler Shaft Carrier Wheel TORQUE TABLE ORQUE 15-17 FT.LB (20-23Nm) 100 in.lb (11Nm) 40 ft.lb (54Nm) 6 ft.lb (8Nm) Apply Premium All Season grease (PN 2871322) to all grease fittings.
  • Page 85 SUSPENSION When all suspension bolts have been removed, slide skid SUSPENSION REMOVAL Shut off fuel. out and remove upper carrier wheels and shaft. Remove one Loosen idler wheel bolts and loosen track adjusting bolts. wheel and spacer and slide shaft out of limiter strap. Lift complete suspension skid out from track.
  • Page 86 SUSPENSION Drive pin out of left side (brake side) drive sprocket. Slide DRIVE SPROCKET & DRIVESHAFT driver down shaft. REMOVAL To ease rivet removal, punch out center f the rivet with a center punch prior to removal. Drill five (5) rivets from rear sprocket guard. Remove sprocket guard by pulling back toward rear of sled.
  • Page 87 SUSPENSION Slide bearing out from right side of sled (clutch side) and DRIVE SPROCKET & DRIVESHAFT slide drive shaft through. Now there is enough clearance to INSTALLATION remove drive chain sprocket. Insert track and drive shaft. Make sure track is installed so it will turn in proper direction.
  • Page 88 SUSPENSION With both bearings and flangettes in place, install pin in Install suspension mounting screws and torque to drive chain sprocket. The shoulder on the sprocket will specification. align the bearings to the proper position on drive shaft. Tip machine upright. Install drive chain outlined in Chapter Slide drive shaft driver into position and install pin and insert the rear suspension.
  • Page 89 SUSPENSION NOTES...
  • Page 90 ELECTRICAL CHAPTER 7 ELECTRICAL IGNITION SYSTEM ............7.2 OVERVIEW.
  • Page 91 ELECTRICAL L3 flow through the base terminal of the power transistor. This IGNITION SYSTEM generates the collector current I4, which will bypass the current I1 and abruptly shut off the current I2 because the power OVERVIEW transistor is turned off. This sudden current change generates a high voltage on the secondary side of the ignition coil and which sparks the spark plug.
  • Page 92 ELECTRICAL ENGINE ELECTRICAL DIAGRAM Ignition Coil Sparkplug Cap Charge Coil Sparkplug Flywheel...
  • Page 93 ELECTRICAL THROTTLE ELECTRICAL TESTING SPEED CONTROL ASSURANCE SWITCH REV LIMITER / REGULATOR TESTING ADJUSTMENT With the engine running at idle, open hood and locate governor arm (See Engine chapter). Push governor arm toward Throttle lever free play must always provide a specified carburetor.
  • Page 94 ELECTRICAL 120 WIRING DIAGRAM...
  • Page 95 ELECTRICAL NOTES...
  • Page 96 Engine Assembly ......4.22–4.26 2000 120 XCR Specifications ....1.12 Precautions 4.22...
  • Page 97 Piston Wash Reading ......2.8 Clutch 3.12 Polaris Recommended Program ....3.3 Controls & Linkage 3.12 Publication Part Numbers .
  • Page 98 Track Tension ........3.8 Track Warm Up ....... . 3.9 Trailing Arm Replacement .
  • Page 99 IX.4...

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