Polaris 120 v5 Owner's Manual PDF

Pages 99
Year 2006
Language(s)
English en
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1 of 99

Summary of Content for Polaris 120 v5 Owner's Manual PDF

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cause cancer and birth defects or other reproductive harm, onto the snow on which they operate... Keep this engine properly tuned and avoid unnecessary

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For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician...

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WELCOME Dear Parents: We believe your children should have the opportunity to enjoy The Way Out experience along with you... Weve provided this owners manual to assist you and your children in learning about the safe operation and care of your new Polaris snowmobile... Please review the information in this manual with any child who may operate the snowmobile... Help your children learn to operate the snowmobile with safety as a top priority... Help them also learn to show respect for our environment and for the rights of others while operating the snowmobile... Since the operator will be a newcomer to the exciting winter sport of snowmobiling, please be sure he/she understands this information before riding the snowmobile... Never allow a child to operate the snowmobile without adult supervision... The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your childs snowmobile are thoroughly inspected at various intervals... For safe and enjoyable operation of the vehicle, be sure to follow all of the instructions and recommendations in this manual... A table of Polaris-recommended products is provided on page 84... If you have any questions about the snowmobile, contact a Polaris dealer for assistance...

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WELCOME Dear Children: Before you ride your new Polaris snowmobile, there are some important things that you need to know... Your parents and Polaris want you to enjoy riding your new snowmobile, and thats why you need to read and understand the information in your owners manual... Ask your parents to explain anything you dont understand, and pay close attention to the warnings and instructions you read... Your safety and the safety of others is the most important thing to think about at all times... As the driver of the snowmobile, you must learn how to keep yourself and those around you safe while youre riding... So read your manual, and then enjoy riding your new Polaris snowmobile!

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Copyright 2005 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... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited...

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ADULT SECTION 27... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Pre-Ride Check 27... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Operation Warnings 31... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Component Identification 44... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Break-In Period 46... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Operation 48... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Emission Control Information 53... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Maintenance 54... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Accessories 81... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Troubleshooting 81... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

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IMPORTANT Parents should sit down with their children and read the Youth Section with them before allowing them to use this snowmobile... Parents must also read the Adult Section before allowing their children to ride this snowmobile...

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INTRODUCTION Important Notes for Owners and Drivers PARENTS: Do not allow anyone under the age of six (6) to operate this machine... Review the information in this manual with any child who may be operating the snowmobile... It is up to you to teach any operator the proper and safe way to ride a snowmobile... You must set boundaries and adhere to them, keeping the operators safety foremost in your mind... Never allow a child to operate this machine without adult supervision... These units are not designed for adult use... Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded... The maximum rider weight capacity is 140 lbs... (63... 5 kg)...

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In order to be meaningful, all regulations require the cooperation of the snowmobile owner... Muffling systems, designed to reduce noise levels, should not be altered or removed... Snowmobile drivers must be aware that they have a public responsibility to operate their snowmobiles with concern for others... As a snowmobile operator you may not realize the sound of your snowmobile may annoy non-snowmobilers... We are attempting to do our part through the manufacture of quieter machines, and we also ask your help in the effort to further reduce the impact of noise...

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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... It is very important that we encourage them as well as become actively involved ourselves... Teach your child the following:

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INTRODUCTION Vehicle Identification Numbers The frame vehicle identification number (VIN) and engine serial number are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts... In the event your vehicle is stolen, these numbers are essential to the recovery and identification of your vehicle...

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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; especially those that increase speed or power... Theres a significant possibility of loss of control at higher speeds... We are concerned for the safety of our customers and for the general public... Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury... Therefore, we strongly recommend that consumers do not install on a Polaris snowmobile any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes... The warranty on your Polaris snowmobile is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power...

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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...

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CAUTION Improper use of this snowmobile or failure to maintain it in good operating condition can result in injury... To reduce this possibility, read the important safety information on the following decal and make sure all operators and guests are familiar with all warnings, cautions and safe operating procedures... They must also understand the consequences and risks if they choose to ignore or neglect this information...

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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...

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2... Throttle Control - The throttle control makes your snowmobile go forward when you press it with your thumb... You must always make sure the throttle control does not stick before you operate your snowmobile... Read more about it on page 21...

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8... Tether Strap/Switch - The tether strap must always be attached snugly to your right wrist and to your snowmobile every time you drive... If you fall off your snowmobile, the tether strap will pull away from the switch and the engine will stop...

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YOUTH SECTION Know Your Snowmobile Lets learn more about the parts of your snowmobile before we talk about riding...

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running... It helps others see you when youre riding during daylight, but its not supposed to be strong enough to help you see in the dark... Drive your snowmobile only in the daylight...

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1... Push the stop switch down... 2... Pull off the tether strap... 3... Turn the key off...

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n Make sure the throttle doesnt stick... Push the throttle lever toward the handlebar and then let it go... The lever should come right back to where it was before you pushed it... If it comes back slowly or stays close to the handlebar, you have a sticky throttle... This means that something is wrong or broken... Dont start the snowmobile until an adult fixes the sticky throttle...

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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 48 in this Owners Manual...

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YOUTH SECTION Riding Rules Now youre 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 youre driving a snowmobile... Adults have riding rules, too... The rules help keep us safe when we ride... You must be at least six (6) years old before you can ride this snowmobile... The adult with you is your teacher... Always pay attention to what your teacher says so you can learn how to always drive safely... Lets learn how to ride!

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" Always wear the right kind of clothing when youre riding your snowmobile... Youll need a good helmet with a face shield or goggles... Wear a warm jacket and snowpants... Make sure your cloth- ing fits properly... If its too small, it could keep you from moving easily... If its too big, it could hang down and get caught in the track or another moving part... Never, ever wear a long scarf... Wear warm snowmobile boots and gloves, and make sure your boot laces are tied... If you have long hair, be sure to tie it up...

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" Ride your snowmobile only where you know its safe to drive and where you have per- mission to drive... Be careful of the things around you...

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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 Owners Manual...

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ADULT SECTION Pre-Ride Check Its 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 childs safety foremost in your mind... Never allow your child to operate this machine without adult supervision...

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Read and make sure the operators understand the Owners Manual completely before allowing anyone to operate this snowmobile... Its also a good idea to review it periodically to reinforce the information... Its very important to familiarize the operator and guests with the cautions and warnings pertaining to the machine as well as safe operating procedures... Weve attempted to provide you with as much information as possible to alert you to the safety requirements of snowmobiling...

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If excessive play develops in the throttle cable, the safety switch may be activated and will prevent the engine from starting... If the engine doesnt start and throttle safety switch malfunction is suspected, return the machine to an authorized Polaris dealer for service... If an adult must start the engine in an emergency situation, the throttle safety switch and engine stop switch may be disconnected from the wire harness... In this situation, the ignition key switch must be used to shut off the engine... Be sure to reconnect the safety switches and have the snowmobile serviced before operating the vehicle again...

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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... To restart the engine, the switch must be pulled up to the ON position...

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WARNING The drive chain guard is designed to protect the operator from metal parts in the event of a drive chain failure... Although the chance of failure is extremely remote, do not defeat the purpose of the guard by removing it... It is provided for the safety of the child...

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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...

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The hood of the snowmobile protects the operator from moving and hot parts as well as aiding in sound emission control and various other func- tions... Under no circumstances should your snowmobile be operatedwith the hood open or removed...

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Improper operator position on the snowmobile can be the source of serious injury... Operating a snowmobile does require skill and balance for proper control, and an improper position can seriously reduce the childs ability to control the snowmobile... The riding position may vary as the operator becomes more skilled, but under most conditions the proper position is to be seated with both feet on the running boards, in a comfortable position for proper throttle, brake and steering control...

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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... For this reason never attempt adjustments with the engine running... Serious personal injuries can result... The proper method is to turn off the ignition, raise the hood, make the adjustment, secure shields and guards, secure the hood, and then re-start the engine to check its operation... The same is true of track alignment... If the track must be re-aligned, it is recommended that this service be performed by your dealer...

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The operator should be aware that there are state and local laws governing snowmobile operation and that these laws should be followed... They have been established for the protection of all snowmobile riders... Most states offer a snowmobile safety course for children... Check your state or county agencies for this service...

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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... Teach your child to reduce speed when traveling near poles, posts, or other obstacles...

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Calm 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 5 36 31 25 19 13 7 1 -5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63 10 34 27 21 15 9 3 -4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72 15 32 25 19 13 6 0 -7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77 20 30 24 17 11 4 -2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81 25 29 23 16 9 3 -4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84 30 28 22 15 8 1 -5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87 35 28 21 14 7 0 -7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89 40 27 20 13 6 -1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91 45 26 19 12 5 -2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93 50 26 19 12 4 -3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95 55 25 18 11 4 -3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97 60 25 17 10 3 -4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

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Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46 8 3 0 - -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 16 2 -2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 24 1 -3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 32 0 -4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 40 -1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69 48 -1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70 56 -2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72 64 -2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73 72 -2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74 80 -3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75 88 -3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76 96 -3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

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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...

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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... If difficulty is encountered, check for ice and snow buildup which may be obstructing the steering linkage...

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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... The chance of spin-out increases under these conditions... Being able to turn a snowmobile depends primarily on the skis being in snow... On hard surfaces, such as ice, the ability to turn is reduced and the machine will not turn very well... In this situation it may be best to dismount and move either the front or rear of the machine to point it in the proper direction...

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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 engines compression to help slow the machine, and keep the snowmobile from rolling freely downhill...

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1... Hood 8... Rear Suspension 2... Headlight 9... 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

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CAUTION Never mix brands of oil... Serious chemical reactions can cause oil passage blockage, resulting in severe engine damage and voiding of engine warranty... 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... Do not operate at prolonged full throttle for the first three hours of operation... Vary the throttle openings and machine speeds... This will reduce friction on all close fitting machined parts and allow them to break in slowly without damage... Avoid operating on ice or hard-packed surfaces, roads, etc... The absence of lubrication and cooling by snow will lead to overheating of the slide rail and track resulting in premature wear and failure... Reduce speeds and frequently drive into fresh snow to allow adequate cooling and lubrication of the slide rail and track surfaces... Drive with extra caution during the break-in period... Perform regular checks on fluid levels, lines, and all important areas of the machine...

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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 ambient temperature is high...

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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... Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored... Do not overfill the tank... Do not fill the tank neck... If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing... If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately... Never start the engine or let it run in an enclosed area... Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time... Turn the fuel valve off whenever the vehicle is stored or parked...

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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 childs safety foremost in your mind... Never allow a child to operate this machine without adult supervision...

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CAUTION Extending the starter rope too far or allowing it to snap back into the housing will cause damage to the recoil assembly... Do not extend the starter rope to its maximum length, and do not drop the rope handle during starting...

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ADULT SECTION Operation Emergency Stopping Procedures The following chart lists methods for stopping the engine in the event of an emergency...

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WARNING A loose track or flying debris could cause serious personal injury or death... Be sure the rear support is stable... Stand clear of the front of the machine and the moving track... Never hold the snowmobile up or stand behind it while performing this procedure... Do not use too much throttle during warm-up or when the track is free-hanging...

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ADULT SECTION Emission Control Information Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang tag... These items are required by U... S... Environmental Protection Agency regulations... The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover... The ECI label should not be removed, even after you purchase the snowmobile... You may remove the factory-installed emissions information hangtag, which is intended solely for your use in making a purchasing decision...

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NOTE: Any replacement parts and labor incurred, with the exception of authorized warranty repairs, are the responsibility of the registered owner... If parts failures occur during the course of the warranty period as a result of owner neglect in performing the recommended periodic maintenance, the cost of repairs shall be the responsibility of the owner...

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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...

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Check front and rear limiter strap condition, tighten loose bolts

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2... Wet Fouled The wet fouled insulator tip is black... A damp oil film covers the firing end... There may be a carbon layer over the entire nose... Generally, the electrodes are not worn... General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect carburetion adjustments...

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Exhaust System At approximately 50 hours, check the exhaust system for wear or damage... To inspect, allow the 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...

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ADULT SECTION Maintenance Carburetor 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 failure... A lean mixture can be the result of fuel line restrictions, foreign matter in the carburetor, etc... A mixture too rich (too much fuel, too little air) is also unfavorable because it can foul plugs and cause generally poor engine performance...

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Choke/Cable Lubrication Lubricate the choke slide and cables occasionally as shown... Operate the choke intermittently before turning the machine off... This draws moisture out of the choke plunger area and reduces the possibility of the choke becoming frozen...

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ADULT SECTION Maintenance Brake Adjustment If excessive brake lever to brake block clearance is evident, the brake cable should be adjusted... If proper adjustment cannot be achieved by using the following methods, check the brake band for excessive wear... Your snowmobile dealer can install a new brake band when necessary...

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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)...

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To ensure long life of the snowmobiles driveline, lubricate as follows: S Lubricate Point A every 15 hours of operation with a small amount of Polaris Premium All Season Grease...

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The best and safest way to clean your sled is with a garden hose and a pail of mild soap and water... Use a professional type washing mitten, cleaning the upper body first and the lower parts last... Rinse with water frequently and dry with a chamois to prevent water spots...

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Electrical Connections Separate electrical connector blocks and clean corrosive build up from connectors... Lubricate or pack connector blocks with Nyogelt grease and re-connect... Replace worn or frayed electrical wire and connectors... Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust...

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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... Follow the instructions on the can... Run the engine for five minutes to get additives through the entire fuel system... Then top off the tank with fresh fuel...

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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... Then top off with fresh fuel and turn the fuel valve to OFF...

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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...

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WARNING Your snowmobile is propelled by a revolving track, which must be partially exposed for proper operation... Serious injuries may be caused by the operators hands, feet or clothing becoming entangled in the track... Be alert... Always sit properly on the seat...

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5... Check track alignment (side to side) by comparing the distance from the drive lug to the slider on both sides... Readjust until centered...

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WARNING When performing the following checks and adjustments, stay clear of all moving parts to avoid serious personal injury... Before checking track tension, make sure the track contains no objects that could be thrown out while the track is rotating... Keep clear of track... This includes but is not limited to hands, tools, feet and clothing... Make sure no one is standing close to the machine while the track is rotating...

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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... Allow the track to turn for a short time... Release the throttle, apply the brakes and shut the engine off prior to lowering it to the ground...

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WARNING Serious personal injury or death may occur if the snowmobile is operated with a damaged track... Broken track rods are a serious hazard, since they can cause a rotating track to come off the machine... Never operate the snowmobile or rotate under power a track thats torn or damaged...

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The slide rail is designed to operate in conditions with adequate snow cover to provide sufficient lubrication... Excessive wear may be due to improper alignment, improper track adjustment or machine operation on surfaces without snow... Take the machine to your dealer for slider replacement...

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ADULT SECTION Maintenance Track Lubrication Track failure, loss of vehicle control and braking ability can result from extended use of this vehicle on surfaces providing marginal lubrication between the slider and track guide clips... Examples of marginal lubrication would include lakes without snow cover, icy trails and no-snow conditions...

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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 than point I, as shown on the following page...

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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...

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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... We recommend that skags be checked once a week to maintain positive steering characteristics... Skags must be replaced when worn to half their original diameter...

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ADULT SECTION Maintenance 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...

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1... Front Limiter Strap 8... Rail Bumper 2... Torsion Spring Sleeves 9... Torque Arm 3... Torsion Spring 10... Rail 4... Carrier Wheel 11... Slider 5... Rear Limiter Strap 12... Toe Guard 6... Spacer 13... Idler Wheel 7... Adjuster Bolts

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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...

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NOTE: Main jet is the first number in each cell; Pilot jet is the second number (in italics)

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Carburetor Model Mikuni BV18 NOTE: The following carburetor settings are to be used in conjunction with the jetting charts on the previous page...

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2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt... )

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WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual... Contact your Polaris dealer for replacement parts, service or warranty... Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual... Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you... When contacting us about parts, service, or warranty, always provide the following information:

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Limitations of warranties and remedies This warranty excludes any failures not caused by a defect in material or workmanship... The warranty does not cover accidental damage, normal wear and tear, abuse or improper handling... The warranty also does not cover any snowmobile that has been structurally altered, neglected, improperly maintained, used for racing or used for purposes other than for which it was manufactured... The warranty does not cover any damages that oc- cur during trailer transit or as a result of unauthorized service or parts... In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or punc- turing of upholstery material, corrosion or defects in parts, components or the snowmo- bile due to fire, explosions or any other cause beyond Polaris control...

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WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM- PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU- LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD... POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR- RANTIES NOT STATED IN THIS WARRANTY... Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law...

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This warranty also excludes failures resulting from improper lubrication; improper en- gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjust- ment or altitude compensation; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermar- ket components resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes... Warranty will not apply to any product which has been dam- aged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship...

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WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion... The free Second Year Engine Service Contract is honored by all authorized Polaris snowmobile dealers in North America and is transferable 120 days after the original purchase date, free of charge, through any Polaris snowmobile dealer... Coverage on Snow Check units is automatic... Although you do not receive a warranty card, your dealership should have printed a copy of the warranty registration form... This form is your proof of warranty...

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How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer... If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle... Outside the Country where your vehicle was purchased: If you are traveling temporarily outside the country where your vehicle was purchased, you should take your vehicle to an authorized Polaris dealer... You must show the dealer photo identification from the country of the selling dealers authorized location as proof of residence... Upon residence verification, the servicing dealer will be authorized to per- form the warranty repair... If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move... Vehicles importation rules vary considerably from country to country... You may be required to present docu- mentation of your move to Polaris Industries in order to continue your warranty cover- age... You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country... 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...

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WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles... Polaris Industries Inc... warrants that at the time it is first purchased, this emissions--certified snowmobile engine meets current U... S... Environmental Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068... Polaris warrants that the engine is free from defects in materials and workmanship that would cause it to fail to meet these regulations... Thewarranty period for this emissions certi- fied snowmobile engine starts on the date when the engine is first purchased and continues for 4000 kilometers (2485 miles) of vehicle travel, 200 hours of operation, or 30 calendar months, whichever comes first... This engine emissions limited warranty covers the parts and labor charges for repair or re- placement of defective parts that are covered by this warranty... This includes components whose failure increases the snowmobile engines emissions... To the extent they are present on your snowmobile engine, this includes electronic controls, fuel injection components, exhaust--gas recirculation system components, and aftertreatment system components... Re- placing or repairing other components not covered by this warranty is the responsibility of the snowmobile owner... The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products... THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON- TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE... ALL IMPLIED WAR- RANTIES (INCLUDING BUTNOT LIMITED TO ANY IMPLIEDWARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIM- ITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN... PO- LARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY...

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WARRANTY Snowmobile Engine Emissions Limited Warranty Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law... This limited war- ranty excludes failures not caused by a defect in material or workmanship... This limited war- ranty does not cover damage due to accidents, abuse or improper handling, maintenance or use... This limited warranty also does not cover any engine that has been structurally altered, or any engine that has been used in racing competition... This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of Polaris... Owners are responsible for performing the scheduledmaintenance identified in the owners manual... Polaris can deny an emissionswarranty claim if any specified critical emissions--re- latedmaintenance is not performed... Performance of other scheduledmaintenance is strong- ly recommended, but is not necessary to keep the emissions--related warranty valid... Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile... Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary... It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicles emission controls... Tampering with emission controls is prohibited by federal law and may result in civil penalties...

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MAINTENANCE LOG 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...

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DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

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DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

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S Safety 12-15... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Safety Decals 14... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Second Year Engine Service Contract 89 Service And Warranty Information 85... ... Signal words 15... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Skag Replacement 78... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Ski Skags 78... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Slider Inspection/Replacement 74... ... ... ... ... ... Spark Plugs 57-58... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Specifications 82-83... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Speed Regulation 49... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Starting the Engine 50... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Steering Inspection and Adjustment 76... Steering System 75... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Storage, Seasonal 66... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Storage, Daily 51... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Maintenance 54-80... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Suspension Components 80... ... ... ... ... ... ... ... ... ... Suspension Lubrication 79... ... ... ... ... ... ... ... ... ... ... Symbols 15... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

Manualsnet FAQs

If you want to find out how the 120 Polaris works, you can view and download the Polaris 120 v5 Owner's Manual on the Manualsnet website.

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