Polaris 2004 120 PRO X Manuals

Manuals and User Guides for Polaris 2004 120 PRO X. We have 1 Polaris 2004 120 PRO X manual available for free PDF download: Service Manual

Polaris 2004 120 PRO X Service Manual

Polaris 2004 120 PRO X Service Manual (99 pages)

Brand: Polaris | Category: Snowmobiles | Size: 7.78 MB

Table of Contents

Table of Contents

4
- 2007 Dragon 120
  5
- Chapter 1
  5
- Specifications
  5
- 2006 120 Pro X
  7
- 2005 Pro X 120
  9
- 2004 120 Pro X - 2003 120Xc Sp
  11
- 2002 120 XC Sp -2001 120 Xcr
  13
- 2000 120 Xcr
  15
Chapter 2 General 2

16
- Abbreveations
  17
- Gearing
  17
- How to Use this Manual
  17
- Jetting
  17
- Models Listed
  17
- Snowmobile Number Designations
  18
  - Model Number Designation Example
    18
- Vehicle Identification Number (Vin)
  18
  - Tunnel Decal
    18
  - Vin Number Designation
    19
- Publication Part Numbers
  19
  - Misc. Publications
    19
  - 2007 Service Publications
    19
- General Reference
  21
  - Standard Bolt Torque Specification
    21
  - Stroke Gasoline / Oil Pre MIX
    21
  - Gasoline Volatility
    21
  - Sae Tap Drill Sizes
    22
  - Metric Tap Drill Sizes
    22
  - Decimal Equivalents
    22
  - Glossary of Terms
    23
- Special Tools
  24
Chapter 3 Maintenance

28
- Maintenance Program
  30
- Lubrication
  31
  - Clutch Greasing
    31
  - Chain Maintenance
    32
  - Oil Level
    32
  - Suspension
    32
  - Throttle Cable Lubrication
    32
  - Choke Cable Lubrication
    32
- Chain Tensioner
  33
  - Chain Tensioner Inspection
    33
- Fluid Change
  33
  - Oil Change
    33
- Cable Inspection/Adjustment
  34
  - Brake Cable Inspection
    34
  - Brake Cable Adjustment
    34
  - Throttle Lever Free Play
    34
- Track Maintenance
  35
  - Track Maintenance Warnings
    35
  - Track Alignment
    35
  - Track Tension
    35
  - Rear Idler Wheels
    36
  - Track Warm up
    36
- Spark Plug
  36
  - Spark Plug Selection
    36
- Steering System
  37
  - Steering Inspection
    37
  - Steering Adjustment
    37
- Carburetor
  38
  - General Carburetor Information
    38
  - Carburetor Adjustments
    38
- Cleaning
  38
  - Air Filter
    38
- Electrical
  38
  - Electrical Connections
    38
- Exhaust
  38
  - Exhaust Inspection
    38
- Fuel Valve & Fuel Lines
  38
- Storage
  39
  - Chassis and Hood
    39
  - Front Suspension
    39
  - Clutch and Drive System
    39
  - Controls and Linkage
    39
  - Electrical Connections
    39
  - Carburetor/Throttle Body
    39
  - Fuel System
    39
  - Corrosion
    39
  - Shocks
    39
Chapter 4 Engine / Carburetor / Clutch

40
- General Information
  42
- Warnings
  42
- Torque Specifications
  43
- Clearance Data & Limits
  44
  - Cylinder Head
    44
  - Cylinder / Piston
    45
  - Connecting Rod
    47
  - Cam Shaft / Valves
    48
- Engine Maintenance
  50
- Engine Removal
  51
  - Removal
    51
- Engine Installation
  53
  - Installing the Engine
    53
- Engine Components
  55
  - Cylinder & Crankcase
    55
  - Main Bearing Cover
    55
  - Crankshaft
    55
  - Connecting Rod and Piston
    55
  - Piston Rings
    56
  - Camshaft
    56
  - Valve Arrangement
    56
  - Cylinder Head
    56
  - Governor System
    56
  - Cooling System
    56
  - Lubrication
    57
  - Ignition System
    57
  - Decompression System
    57
  - Carburetor
    57
  - Air Filter
    57
- Engine Component Locations
  58
- Engine Disassembly
  59
  - Preperations & Suggestions
    59
  - Engine Desassembly
    59
- Engine Assembly
  61
  - Precautions for Reassembly
    61
  - Engine Reassembly
    61
  - Engine Break in
    65
  - Decompression System
    66
- Fuel Delivery
  67
  - Pilot System
    68
  - Main System
    68
  - Choke System
    68
  - Disassembly and Reassembly
    68
- Recoil Starter
  69
  - Dissassembly
    69
  - Assembly
    69
- Clutch
  71
  - Clutch Service
    71
- Fuel Tank
  72
  - Fuel Tank Removal
    72
  - Fuel Tank Installation
    72
- Trouble Shooting
  72
  - Fuel System
    72
  - Ignition System
    72
  - Compression System
    72
  - Engine Misfires
    73
  - Engine Stops
    73
  - Engine over Heats
    73
  - Engine Knocks
    73
  - Engine Backfires through Carburetor
    73
Chapter 5 Body/Steering

74
- Torque Applications
  75
- Handlebar Adjustment
  76
- Inspection
  76
- Rod End Engagement
  76
- Rod End Procedure
  76
- Steering
  76
- Toe Adjustment
  77
- Ski Spindle/Bushing Installation
  78
- Ski Spindle/Bushing Removal
  78
- Radius Rod Replacement
  79
- Skag Replacement
  79
- Tie Rod Replacement
  79
- Body
  80
  - Ifs Shock Replacement
    80
  - Trailing Arm Replacement
    80
  - Decals
    81
- Troubleshooting
  81

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