Polaris 120 Pro X Owner's Manual
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Polaris 120 Pro X Owner's Manual

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  • 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 What’s the hottest thing on snow? A Polaris owner’s Web site, designed just for YOU! Technical tips New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.com/owner...
  • Page 4 Copyright 2003 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 5: Table Of Contents

    ......Polaris Products ......

  • Page 6: Welcome

    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.

  • Page 7: Introduction

    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.

  • Page 8: Important Notes For Owners And Drivers

    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.

  • Page 9: 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 expect our efforts to lead to the reduction of potential air pollution.
  • Page 10 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.

  • Page 11: Vehicle Identification Numbers

    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.

  • Page 12: Safety

    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;...
  • Page 13 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.
  • Page 14 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.
  • Page 15 SAFETY 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.

  • Page 16: Youth Section

    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.
  • Page 17 YOUTH SECTION Know Your Snowmobile Always take your thumb off the throttle lever when you squeeze the brake lever. 6. Brake Lever - Squeeze the brake lever toward the handlebar to make your snowmobile slow down or stop. 7. Ignition Switch - The ignition switch key must be turned ON before pulling on the recoil starter handle to start your snowmobile.
  • Page 18 YOUTH SECTION Know Your Snowmobile Let’s learn more about the parts of your snowmobile before we talk about riding.
  • Page 19 YOUTH SECTION 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.
  • Page 20 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.

  • Page 21: Pre-Ride Check

    Never start the engine if you have sticky brakes. You could get hurt if you ride with sticky brakes. Have an adult or your Polaris dealer fix the brakes before you ride. n Make sure the brakes don’t stick. Squeeze the brake lever toward the handlebar and then let it go.
  • Page 22 YOUTH SECTION Pre-Ride Check Always have an adult put gas in your snowmobile. Never try to do it yourself. 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.

  • Page 23: Riding Rules

    YOUTH SECTION 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.
  • Page 24 YOUTH SECTION Riding Rules Helmet Face Shield Jacket Gloves Pants Boots 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.
  • Page 25 YOUTH SECTION Riding Rules Both Hands on Handlebars Sit Down Feet on Running Boards 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 "...
  • Page 26 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...

  • Page 27: Adult Section

    ADULT SECTION 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.

  • Page 28: Pre-Ride Check

    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.
  • Page 29 WARNING 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.
  • Page 30 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.
  • Page 31 ADULT SECTION Operation Warnings n Do not carry passengers This snowmobile is designed for a single operator. n Do not operate with intake silencer removed CAUTION 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.

  • Page 32: Operation Warnings

    ADULT SECTION Operation Warnings n Do not touch the engine after it’s been running WARNING Hot components can cause serious burns to skin. Do not touch engine and exhaust parts after the engine has been running. n Disabled operators WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.
  • Page 33 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.
  • Page 34 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.
  • Page 35 ADULT SECTION Operation Warnings n Stop engine before attempting adjustments WARNING 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.
  • Page 36 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 PRO X during daylight operation. Do not operate the snowmobile in the dark.
  • Page 37 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.
  • Page 38 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- Actual Thermometer Reading (°F) mated mated Wind Speed in MPH in MPH Equivalent Temperature (°F) Calm Wind...
  • Page 39 ADULT SECTION Operation Warnings WIND CHILL CHART (°C) Esti- Actual Thermometer Reading (°C) mated mated Wind Speed Speed Equivalent Temperature (°C) in KPH Wind Little Danger Increasing Great Speeds (For Properly Danger Danger Greater Clothed Person) Than 70 KPH 70 KPH Have Danger From Freezing of Exposed Flesh Little...
  • Page 40 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.
  • Page 41 ADULT SECTION Operation Warnings Snow and Ice Build-Up Snow and ice buildup in the underhood area can interfere with the steering. WARNING 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.
  • Page 42 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.
  • Page 43 ADULT SECTION 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.

  • Page 44: Component Identification

    ADULT SECTION Component Identification 1. Hood Rear Suspension 2. Headlight Nosepan 3. Windshield 10. Trailing Arm 4. Handlebar 11. Skis 5. Seat 12. Front Bumper 6. Storage (under seat) 13. Rear Bumper 7. Taillight 14. Snow Flap 8. Track...
  • Page 45 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...

  • Page 46: Break-In Period

    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.
  • Page 47 (C). NOTE: Always use Polaris Premium 4 All Season Synthetic Oil or any class SE, SF (API classification) or higher grade oil. If multi-grade oil is used, oil consumption will increase when the...

  • Page 48: Operation

    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 WARNING Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated area.
  • Page 49 ADULT SECTION 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.
  • Page 50 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.
  • Page 51 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.
  • Page 52 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. WARNING A loose track or flying debris could cause serious personal injury or death.

  • Page 53: Maintenance

    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.
  • Page 54 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...
  • Page 55 ADULT SECTION Maintenance ITEM DAILY WEEKLY OR BEFORE PAGE EXTENDED PERIOD OF OPERATION 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...
  • Page 56 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 maintenance and services performed on the snowmobile. 50 Hour Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 100 Hour Maintenance Inspection...
  • Page 57 CAUTION 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). S Spark plug torque is 12-14 ft. lbs. (16-19 Nm).
  • Page 58 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.
  • Page 59 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.
  • Page 60 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.
  • Page 61 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.
  • Page 62 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. (20-24 Nm). When the chain comes within 1/8″...
  • Page 63 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.
  • Page 64 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.
  • Page 65 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.
  • Page 66 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.
  • Page 67 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.
  • Page 68 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.
  • Page 69 ADULT SECTION Maintenance WARNING 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...
  • Page 70 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 (E) 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.
  • Page 71 ADULT SECTION 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 72 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.
  • Page 73 Never operate the snowmobile or rotate under power a track that’s torn or damaged. NOTE: The 120 PRO X track has molded in track clips. It is common for a thin layer of rubber to detach from clip area and peel off...
  • Page 74 ADULT SECTION Maintenance Hi-Fax Replacement The 120 PRO X uses XTRA 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.
  • Page 75 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.
  • Page 76 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...
  • Page 77 ADULT SECTION 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.
  • Page 78 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.
  • Page 79 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.
  • Page 80 ADULT SECTION Maintenance Suspension Components Suspension Lubrication points are indicated by a 1. Front Limiter Strap Rail Bumper 2. Torsion Spring Sleeves Torque Arm 3. Torsion Spring 10. Rail 4. Carrier Wheel 11. Hi-fax 5. Rear Limiter Strap 12. Toe Guard 6.

  • Page 81: Accessories

    ADULT SECTION 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 Polaris “P” No. Raw Material No.

  • Page 82: Specifications

    SPECIFICATIONS Jetting Chart Ambient Below -30_ to -10_ to +10_ to +30_ to Above Temperature -30_F -10_F +10_F +30_F +50_ F +50_F (-34_C) (-34_ to -23_ to -12_ to -1_ to Above -23_C) -12_C -1_C +10_C +10_C 0-600 72.5 72.5 72.5 Altitude (0-2000)
  • Page 83 SPECIFICATIONS Capacities and Dimensions Body Style Mini Indy Riders/Weight 1/150 lbs. (68 kg) maximum Engine Oil .6 qts. (.57 l) Dry Weight (est.) 147.5 lbs. (67 kg) Fuel Tank .5 gal. (1.9 l) Height 31 in. (78.7 cm) Length 75 in. (190.5 cm) Ski Center Distance 30 in.

  • Page 84: Polaris Products

    POLARIS 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.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.)

  • Page 85: Warranty

    2. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. Polaris warranty will aid in notifying the proper owner when a unit is recovered.
  • Page 86 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.
  • Page 87 How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized 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 responsibility).
  • Page 88 In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre- - Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty.
  • Page 89 S Failures caused due to improper adjustments. Failure due to unauthorized service. S Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. S Failure due to use of unauthorized parts or modifications.
  • Page 90 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.

  • Page 91: Index

    INDEX Accessories ..... Paint Codes ..... Auto Chain Tensioner .

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