2003 2003 120 XC SP 120 XC SP Owner's Manual Owner's Manual for Vehicle Maintenance for Vehicle Maintenance and Safety and Safety...
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...
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Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations. No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.
........Troubleshooting Specifications Polaris Recommended Products Service and Warranty Warranty .
Polaris dealer for assistance. This Owner’s Manual contains instructions for minor maintenance, but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified MSD (Master Service Dealer) Technician.
Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals. n A table of Polaris-recommended products for your snowmobile is provided on page 82. n You and your dealer must complete the registration form included with your snowmobile and forward it to us.
The maximum rider weight capacity is 140 lbs. (63.5 kg). CHILDREN: Before you ride your new Polaris snowmobile, there are some important things that you need to know. Your safety and the safety of others is the most important thing to think about at all times.
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 expect our efforts to lead to the reduction of potential air pollution.
INTRODUCTION Preservation of the Environment Environmental Protection As part of the continuing environmental education campaign, we are encouraging state and provincial governments across the snowbelt to adopt rigorous safety training programs which also encourage protection of our environment, wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment.
Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. If both keys are lost, the ignition switch must be replaced.
Equipment Modifications All Polaris snowmobiles have been designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modification;...
SAFETY Maintenance Program As with all snowmobiles, caution must be observed to ensure operator safety. Particular caution must be taken to make sure that the snowmobile is in excellent operating condition at all times. We strongly recommend that the operator, as well as an adult, check major and vital safety components before each use of the vehicle.
If any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing replacement will be provided by Polaris at no charge. The part number is printed on the decal.
The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.
YOUTH SECTION Know Your Snowmobile 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 down and the engine will stop.
Know Your Snowmobile 6. Brake Lever - Squeeze the brake lever toward the handlebar to make your snowmobile slow down or stop. Always take your thumb off the throttle lever when you squeeze the brake lever. 7. Ignition Switch - The ignition switch key must be turned ON before pulling on the recoil starter handle to start your snowmobile.
YOUTH SECTION Know Your Snowmobile Let’s learn more about the parts of your snowmobile before we talk about riding.
Know Your Snowmobile 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. It helps others see you when you’re riding during daylight, but it’s not supposed to be strong enough to help you see in the dark.
YOUTH SECTION Know Your Snowmobile Let’s review the three ways to stop your snowmobile: 1. Push the stop switch down. 2. Pull off the tether strap. 3. Turn the key off.
Never start the engine if you have a sticky throttle. You could get hurt if you ride with a sticky throttle. Have an adult or your Polaris dealer fix the throttle before you ride. n Make sure the brakes don’t stick. Squeeze the brake lever toward the handlebar and then let it go.
YOUTH SECTION Pre-Ride Check n Have an adult check the gas level to see if your snowmobile needs more. Children should never add their own gasoline. This must always be done by an adult. Before anyone adds gasoline to your snowmobile they must read the instructions and warnings on page 46 in this Owner’s Manual.
Riding Rules Now you’re ready to learn about driving your Polaris snowmobile. There are some things you can do and there are some things you must never do. Rules are very important when you’re driving a snowmobile. Adults have riding rules, too. The rules help keep us safe when we ride.
YOUTH SECTION Riding Rules Always wear the right kind of clothing when you’re riding your " snowmobile. You’ll need a good helmet with a face shield or goggles. Wear a warm jacket and snowpants. Make sure your cloth- ing fits properly. If it’s too small, it could keep you from moving easily.
Riding Rules Always drive your snowmobile while sitting down. Keep both " hands on the handlebars and keep both feet on the running boards. Never follow another snowmobile too closely. Always allow lots of " time and space to stop your snowmobile. Ride your snowmobile only "...
YOUTH SECTION 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...
Pre-Ride Check It’s up to you, the adult, 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.
ADULT SECTION Pre-Ride Check Before Starting The Engine n Read and Understand Your Owner’s Manual Read and make sure the operators understand the Owner’s Manual completely before allowing anyone to operate this snowmobile. It’s also a good idea to review it periodically to reinforce the information. It’s very important to familiarize the operator and guests with the cautions and warnings pertaining to the machine as well as safe operating procedures.
Do not continue to operate the machine with the throttle safety switch disconnected as serious injury or death could result. Return the machine to an authorized Polaris dealer for service before operating. ADULT SECTION WARNING...
ADULT SECTION Pre-Ride Check n Check engine stop switch Test the engine stop switch before each use of the snowmobile. To stop the engine in an emergency, push down on the stop switch (A). This will ground out the ignition and bring the engine to a quick stop.
Operation Warnings n Do not carry passengers This snowmobile is designed for a single operator. n Do not operate with intake silencer removed If the engine is operated with the intake silencer removed, damage to the engine may occur. Do not operate the engine with the intake silencer removed.
ADULT SECTION Operation Warnings n Do not touch the engine after it’s been running Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running. n Disabled operators Safe operation of this rider-active vehicle requires good judgement and physical skills.
ADULT SECTION Operation Warnings n Check brake lever travel Measure the clearance between the lever and brake block. Inspection should be made with the lever firmly depressed. Distance A should be no more than 3/4″ (1.9 cm). Excessive travel indicates a need to adjust the brake cable.
ADULT SECTION Operation Warnings n Check surroundings to verify clear operating area It’s important to make sure there’s a clear area all around the snowmobile, including an area clear of bystanders. Some sideways movement is possible when starting out, and debris may be thrown by the track.
Operation Warnings n Stop engine before attempting adjustments The snowmobile engine compartment contains moving parts. Shields and guards have been provided for safety, but it is still possible to carelessly get your hands or fingers into a moving chain or a rotating shaft. For this reason never attempt adjustments with the engine running.
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 taillight are intended only to increase the visibility of the 120 XC SP during daylight operation. Do not operate the snowmobile in the dark.
ADULT SECTION 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.
ADULT SECTION 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) Esti- mated mated Wind Speed in MPH in MPH Calm Wind Little Danger Speeds (For Properly Greater...
Operation Warnings WIND CHILL CHART (°C) Esti- mated mated Wind Speed Speed in KPH Wind Little Danger Speeds (For Properly Greater Clothed Person) Than 70 KPH 70 KPH Have Little Added Effect ADULT SECTION Actual Thermometer Reading (°C) Equivalent Temperature (°C) Increasing Danger Danger From Freezing of Exposed Flesh...
ADULT SECTION Operation Warnings Cold Weather Drive-Away Whenever the machine has been parked for some length of time, especially overnight, 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. Teach the operator not to be afraid of applying pressure to the throttle but at the same time, teach them not to be too forceful with the throttle which could cause the machine to lurch forward.
Operation Warnings Snow and Ice Build-Up Snow and ice buildup in the underhood area can interfere with the steering. Before allowing your child to drive the machine, be sure that ice and snow are not interfering with the steering. Manually turn the skis to the left and right.
ADULT SECTION Operation Warnings Driving on Ice It is dangerous to operate on ice or under slippery conditions. If ice or slippery conditions are unavoidable, use extreme caution and operate at speeds no faster than a walk. Never attempt an abrupt change of direction on a slippery surface.
Operation Warnings Driving Downhill When riding downhill, the operator must keep the speed at a minimum. It is important to apply just enough throttle to keep the clutch engaged while descending the hill. This will allow use of the engine’s compression to help slow the machine, and keep the snowmobile from rolling freely downhill.
ADULT SECTION Component Identification 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage (under seat) 7. Taillight 8. Track Rear Suspension Nosepan 10. Trailing Arm 11. Skis 12. Front Bumper 13. Rear Bumper 14. Snow Flap...
ADULT SECTION Component Identification 1. Stop Switch 2. Tether Strap 3. Throttle Control 4. Recoil Starter Handle 5. Hood Hold-Down 6. Choke Button 7. Gas Cap 8. Ignition Switch 9. Console 10. Brake Lever 11. Tether Switch...
The only oil recommended for this system is Polaris Premium 4 All Season Synthetic oil. This oil has been specially formulated for all temperatures and has extreme cold flow characteristics.
Break-In Period Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 All Season Synthetic oil. Never substitute or mix oil brands. Checking Engine Oil Before checking or refilling engine...
ADULT SECTION Operation Fuel When refueling, use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area.
Operation Speed/Performance Regulation Adults have the responsibility for teaching children the proper and safe way to ride a snowmobile. Please set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow a child to operate this machine without adult supervision. Under certain circumstances it may be necessary for an adult to regulate the speed and acceleration of the snowmobile by moving the governor lever spring.
ADULT SECTION Operation Starting the Engine Never start the snowmobile without checking all components to be sure of proper operation. Refer to the Pre-Ride Check beginning on page Starting a Cold Engine 1. Turn the key to ON. 2. Pull the engine stop switch (shut-off switch) up to the RUN position.
4″ (20 cm) from the ground. 2. Remove the key and cover the machine using the Polaris cover available for your model. See your dealer for more information. ADULT SECTION WHAT IT DOES...
ADULT SECTION Operation Pre-Ride Warm-Up Always warm up the engine, drive train and track before operating the snowmobile. With the snowmobile securely supported by the rear bumper with a minimum clearance of 4″ (10 cm) from the ground, use the following procedure to properly warm up the snowmobile. A loose track or flying debris could cause serious personal injury or death.
Polaris Recommended Maintenance Program Your Polaris snowmobile has been engineered and manufactured by skilled Polaris personnel to the highest degree of performance and reliability possible. In order to maintain this level of quality, your machine must have regular service and maintenance inspections.
NOTE: The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, we recommend the use of genuine Polaris parts, available from your Polaris dealer. ITEM...
Maintenance ITEM Check track alignment Check drive chain tension Check and tighten any loose suspension mounting bolts Tighten ski saddle and spindle bolts if loose Check front and rear limiter strap condition, tighten loose bolts Check hi-fax thickness, replace when worn (see dealer) Tighten rear idler wheel bolts if loose Check spark plug condition...
This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 50 Hour Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date 100 Hour Maintenance Inspection Authorized Polaris Servicing Dealer...
Avoid prolonged idle speeds, as plug fouling and carbonization will result. Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. S Use BR6ES spark plugs. S Proper electrode gap is .028″ (.70 mm).
ADULT SECTION Maintenance Spark Plugs Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. Torque to 12-14 ft.
Higher altitude operation may require different adjustment and settings. The number stamped in the end of the main jet indicates the jet size that was installed at the time of manufacture. For questions about optional jetting for conditions in your area, see your Polaris dealer. 1. Engine 2.
Throttle Cable Lubrication With the engine off, lubricate the throttle cable occasionally. Turn the handlebars to the left and lubricate liberally with Polaris All Season Grease. Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown. Operate the choke intermittently before turning the machine off.
Improper brake adjustment can result in brake failure, which could result in severe injury or death. Perform the adjustment procedures exactly as outlined or see your Polaris dealer for service. 1. Slide the two rubber protector covers (A) back to expose the cable adjuster.
ADULT SECTION Maintenance Chain Tensioner Inspect the chain. The chain should have 1″ of deflection as shown. If not, loosen the nut on the chain tensioner (A) and raise until 1″ (B) of deflection is attained. Tighten nut to 15-18 ft. lbs. When the chain comes within 1/8″...
To ensure long life of the snowmobile’s driveline, lubricate as follows: S Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease. S Lubricate Point B every 10 hours of operation with aerosol chain lube or SAE 30 oil.
Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement. If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the hood, console, nosepan, decals, and warning labels.
All bushings, spindle shafts, and tie rod ends should be coated with a light coat of oil or grease. Throttle and brake controls and cables should be lubricated with Polaris Premium All Season Grease. Force a small amount of lubricant down the cable.
ADULT SECTION Maintenance Engine Proper off-season preparation of the engine and fuel system is vital to the prevention of rust and corrosion formation on precision engine parts during storage. Without proper storage, jet restriction can cause lean conditions and very poor slow speed driving quality. When preparing your snowmobile for off-season storage, we recommend that you add fuel conditioner/stabilizer or Premium Carbon Clean (PN2871326) to the fuel tank.
ADULT SECTION Maintenance Carburetor Protection During Off-Season Storage When preparing your snowmobile for off-season storage we recommend that you add a fuel conditioner/stabilizer or Premium Carbon Clean (2871326) to the fuel tank. Follow the instructions on the can. Run the engine for five minutes to get additives through the entire fuel system.
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 experienced and trained service technician who is interested in keeping your machine in peak operating condition.
Maintenance Your snowmobile is propelled by a revolving track, which must be partially exposed for proper operation. Serious injuries may be caused by the operator’s hands, feet or clothing becoming entangled in the track. Be alert. Always sit properly on the seat. Track and Suspension Under normal conditions moderate track tension should...
ADULT SECTION Maintenance Track Adjustment If the track needs adjustment: 1. Loosen rear idler shaft bolt (D). 2. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 3. Repeat measurement on the other side of the track. NOTE: Check more frequently when the machine is new.
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. When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury.
ADULT SECTION Maintenance Track Warm Up When storing your snowmobile outside overnight, it is recommended that the track be warmed up prior to driving the snowmobile. This reduces drive clutch wear. To warm up the track, safely support the rear of the snowmobile off the ground, start the engine and abruptly engage the clutch.
Never operate the snowmobile or rotate under power a track that’s torn or damaged. 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.
ADULT SECTION Maintenance Hi-Fax Replacement The 120 XC SP uses XTRA Hi Fax Wear Limit Lite style Hi-Fax. When any area of the Hi-Fax is worn to 7/16″ (1.1 cm), it should be replaced. This will save wear 7/16″ (1.1 cm) on other vital components.
Do not attempt to change the ski alignment. Contact your Polaris dealer. The steering systems on Polaris snowmobiles can be adjusted with ski toe alignment. Improper toe alignment can cause erratic steering. Consult your dealer if a need for adjustment should become necessary.
ADULT SECTION Maintenance Steering Inspection and Adjustment The steering assembly of the machine should be checked periodically for loose nuts and bolts. See A,B,C,D,E, F, and G in illustration at right. With handlebars in straight ahead position and measuring from the straight edge of the skis, the measurement between the skis at point H should be 1/8 inches greater...
Maintenance Handlebar Adjustment 6. Slide the handlebar pad upward to access the adjuster bolts. If additional room is required, unzip one of the handlebar pad zippers and roll the pad to the side. 7. To adjust, remove the upper flange nut and carriage bolt. 8.
ADULT SECTION Maintenance Ski Skags The skag (A) is a replaceable bar attached to the underside of the ski. The purpose of the skag is to assist in turning the snowmobile and to prevent the wearing away of the ski caused by contact with roads and other bare terrain.
Suspension Lubrication To maintain rider comfort and to retard wear of the pivot shafts, the suspension pivot shafts should be lubricated with Polaris Premium All Season Grease 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.
ADULT SECTION Maintenance Suspension Components Suspension Lubrication points are indicated by a 1. Front Limiter Strap 2. Torsion Spring Sleeves 3. Torsion Spring 4. Carrier Wheel 5. Rear Limiter Strap 6. Spacer 7. Adjuster Bolts Rail Bumper Torque Arm 10. Rail 11.
Accessories Maintenance Items and Accessories The tools and maintenance items mentioned in this book, as well as a long line of other Polaris accessories, are available at your Polaris dealer. Paint Codes Color Description Indy Red Indy Black Paints can be ordered direct from Midwest Industrial Coatings (612) 942-1836.
SPECIFICATIONS Jetting Chart Altitude Ambient Below Temperature -30_F Below -34_C 0-600 (0-2000) 600-1200 (2000- -4000) Meters Meters (Feet) 1200- -1800 72.5 (4000-6000) 1800-2400 (6000-8000) 2400-3000 67.5 (8000-10000) 3000-3600 (10000-12000) Clutching Chart Altitude Weight Meters (Feet) 0-900 10-62 (0-3000) 900-1800 10-62 (3000-6000) 1800-2700 10-58...
Body Style Riders/Weight Engine Oil Dry Weight (est.) Fuel Tank Height Length Ski Center Distance Width Brake Type Clutch Type Track Length Track Width Drive Chain Length Front Type IFS Shock Type Rear Type Engine Model Number Alternator Output Bore x Stroke Displacement Carburetor Model Main Jet...
POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602 Premium Synthetic Gearcase Lubricant (qt.) 2871653 Premium Front Gearcase Lube (8 oz.) 2871654 Premium Drive Hub Fluid (8 oz.)
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. Obtaining Service and Warranty Assistance Read carefully and understand the service data and the Polaris Warranty contained in this manual.
SERVICE AND WARRANTY When writing about parts, service or warranty, always include the following information: 1. Serial number 2. Model number 3. Dealer name 4. Date of purchase Use the following space to record the model and serial numbers of your machine and engine.
REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement.
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 option, repair or replacement of any defective materials, or components or products.
TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person at Polaris.
S Additional engine protection beyond the original twelve month war- ranty. S Backed by the strength of Polaris - no third party involvement. S Repairs use only genuine top quality Polaris parts. S Peace of mind. The Polaris Extended Service Contract is honored by all authorized Polaris snowmobile dealers in North America.
Accessories ..... Auto Chain Tensioner ... . . Brake Adjustment .
Part No. 9917595 PRINTED IN THE USA...