Polaris Offroad Vehicle 120 Pro X User Manual

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WARNING  
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  
which they operate. Keep this engine  
properly tuned and avoid unnecessary  
idling and spillage during fueling.  
WARNING  
The engine exhaust from this  
product contains chemicals known  
to cause cancer, birth defects or  
other reproductive harm.  
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Copyright 2004 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. Printed in U.S.A.  
2005 120 PRO X Owner’s Manual P/N 9919072  
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TABLE OF CONTENTS  
Welcome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Important Notes for Owners and Drivers . . . . . . . . . . . 6  
Preservation of the Environment . . . . . . . . . . . . . . . . . . 7  
Vehicle Identification Numbers . . . . . . . . . . . . . . . . . . . . 9  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
YOUTH SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Know Your Snowmobile . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Pre-Ride Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
Riding Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
ADULT SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
Pre-Ride Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
Operation Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . 42  
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79  
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80  
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 82  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89  
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WELCOME  
Dear Parents:  
We believe your children should have the opportunity to enjoy The  
Way Out experience along with you. We’ve provided this owner’s  
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 child’s  
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 82. If you have  
any questions about the snowmobile, contact a 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.  
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 that’s why you need to  
read and understand the information in your owner’s manual.  
Ask your parents to explain anything you don’t 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 you’re riding. So read your manual,  
and then enjoy riding your new Polaris snowmobile!  
4
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INTRODUCTION  
After reading this manual, store it in the snowmobile for convenient  
reference. It should remain with the snowmobile when sold.  
n This manual contains the latest information at the time of printing.  
We reserve the right to make product changes and improvements  
without notice.  
n The illustrations and photos used in this manual are general  
representations. Your model may differ.  
n Follow the maintenance program outlined in this manual.  
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. This completed form  
is necessary to ensure warranty coverage.  
n Protect and preserve your right to ride by joining your local trail  
riding clubs.  
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.  
5
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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 operator’s 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).  
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.  
As the driver of the snowmobile, you must learn how to keep yourself  
and those around you safe while you’re riding.  
Pay attention when you see this symbol:  
This is the safety alert symbol. When you see this  
symbol on your snowmobile or in this manual it means  
PAY ATTENTION because you could die or be seriously  
hurt if you don’t follow the instructions.  
6
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INTRODUCTION  
Preservation of the Environment  
Teach your child to drive their snowmobile with consideration for the  
protection and preservation of the environment.  
Noise Level  
One of the most publicized subjects with regard to snowmobiles is  
noise. The Society of Automotive Engineers (SAE), which is the  
standard-setting body for snowmobiles, has recommended that  
snowmobiles conform to prescribed sound levels. This Polaris  
snowmobile has been engineered to conform to these SAE standards.  
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.  
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.  
The four-stroke engine used in this snowmobile produces less exhaust  
emissions and reduces noise, as well.  
In addition to technological research, we also suggest that  
governmental agencies, manufacturers, distributors, dealers, ecologists,  
and other interested parties work together to develop data on  
environmental topics. We will continue to participate in this type of  
study so that someday we may find the answers to these difficult  
issues.  
7
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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:  
Respect your snowmobile;  
respect your environment;  
and you will earn  
the respect of everyone.  
8
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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.  
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. See your Polaris dealer.  
Please record your snowmobile identification numbers below for future  
reference:  
31XX  
3
1. Tunnel VIN (lower right side of the tunnel)  
________________________________________________________________  
2. Engine Serial Number (right front side of engine crankcase)  
________________________________________________________________  
3. Key Number:  
________________________________________________________________  
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SAFETY  
WARNING  
Failure to follow the warnings in this manual can result in severe  
injury or death. Read and understand the owner’s manual and all  
warnings before operating a Polaris snowmobile. Adults must  
thoroughly explain this information to all operators of the  
snowmobile.  
All operators must be at least six (6) years old and must  
understand the risk involved if these important warnings and  
cautions are not heeded.  
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. There’s 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.  
10  
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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.  
We also recommend that you strictly follow the maintenance schedule  
outlined in this manual to ensure that all critical components on the  
snowmobile are thoroughly inspected by your dealer at various mileage  
intervals.  
This snowmobile is not a toy. It is a well-engineered and  
well-constructed recreational vehicle. The information in this manual  
is provided to aid you in its safe operation.  
11  
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SAFETY  
Safety Decals  
Safety and warning decals have been placed on the vehicle for the  
operator’s protection. Make sure the operator understands the  
information on all decals. 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.  
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.  
12  
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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.  
The safety alert symbol, on your vehicle or in this manual, alerts  
you to the potential for personal injury.  
WARNING  
The safety alert warning indicates a potential hazard that may  
result in serious injury or death.  
CAUTION  
The safety alert caution indicates a potential hazard that may  
result in minor personal injury or damage to the vehicle.  
CAUTION  
A caution indicates a situation that may result in damage to the  
vehicle.  
IMPORTANT  
IMPORTANT will alert you to important information or  
instructions.  
NOTE: A note will alert you to key information or instructions.  
13  
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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.  
8
7
6
2
3
5
9
9
4
1. Engine Stop Switch - When the engine is running, you can push  
this button down and the engine will stop. The stop switch must  
be in the UP position to start the engine again.  
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 19.  
3. Recoil Starter Handle - Pull the recoil starter handle to start your  
snowmobile. An adult will help you start it the first time.  
4. Choke Knob - You may need to use the choke to help start your  
snowmobile if the engine is cold. Read more about it on page 48.  
Always have an adult put gas in your snowmobile. Never try to do  
it yourself.  
5. Gas Cap - The gas cap has to be taken off when an adult puts gas in  
your snowmobile. Never take the gas cap off. Always make sure  
it’s tightly closed.  
14  
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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.  
You can also use this key to turn off the engine.  
Never ride without the tether strap attached to your right wrist and  
to your snowmobile. Be careful not to let the cord get tangled  
around the handlebars or any part of your body.  
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.  
Always make sure the hood hold-down straps are latched before  
you ride.  
9. Hood Hold-Down Strap - There are two straps to hold down the  
hood of your snowmobile. They must always be latched before you  
start your machine.  
15  
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YOUTH SECTION  
Know Your Snowmobile  
Let’s learn more about the parts of your snowmobile before we talk  
about riding.  
6
7
8
9
10  
16  
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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. 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. Drive your snowmobile only in the daylight.  
3. Windshield - Always keep your windshield clean so you can see  
where you’re driving.  
4. Handlebar - The handlebar is connected to the skis. When you  
turn the handlebar, the skis turn in the same direction.  
5. Flag - The flag helps other people see where you’re riding. Your  
snowmobile is smaller than an adult snowmobile, so it’s harder to  
see. Never remove the flag from your snowmobile.  
6. Seat and Storage - When the engine isn’t running, you can take  
the seat cushion off and put things under the seat in the special  
compartment.  
7. Taillight - The taillight is always on when the engine is running.  
It will help others see you when you’re riding.  
8. Snow Flap - The snow flap keeps snow, ice or other things from  
flying out behind your snowmobile.  
Never get close to a moving track. Never wear clothing that  
could get caught in a moving track, like a long scarf or baggy  
clothing. Tie up long hair.  
9. Track - The engine makes the track turn. The turning track makes  
your snowmobile go forward.  
10. Skis - The skis turn your snowmobile in the same direction that  
you turn the handlebar.  
17  
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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.  
2
3
1
18  
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YOUTH SECTION  
Pre-Ride Check  
You’re almost ready to have an adult start your snowmobile. Before  
the snowmobile is started for the first time, you must do a PRE-RIDE  
CHECK. In fact, every time you ride your snowmobile you must have  
an adult help you check these things before starting it. Let’s learn  
about these things now.  
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 throttle doesn’t 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. Don’t start the snowmobile  
until an adult fixes the sticky throttle.  
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. It should come right back to  
where it was before you squeezed it. If it goes back slowly or stays  
close to the handlebar, your brakes are sticking.  
n If you’ve used the storage area under the seat, make sure the seat  
locking tabs are in place.  
n Make sure your hood is latched tight before starting your machine.  
Never check the track or skis when the engine is running. You  
could get hurt. Never stand behind or in front of any snowmobile  
when the engine is running.  
n Make sure your track and skis are not frozen to the snow. Stand  
behind the machine and lift up on the back of the sled. This will  
free the track if it is frozen to the ground. Turn the handlebars to  
move the skis back and forth to make sure they aren’t frozen. If  
any of this is hard to do, have an adult help you.  
19  
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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. Before anyone adds gasoline to your  
snowmobile they must read the instructions and warnings on page  
46 in this Owner’s Manual.  
n Have an adult check the engine oil level when the engine is cold.  
The engine is very hot after it has been running. It could burn your  
skin. Children should never check the oil. Only an adult should  
be responsible for keeping the gas and oil levels to the full marks.  
n The last check is done with the engine running. Always check to  
make sure that ALL THREE WAYS TO STOP THE  
SNOWMOBILE are working the way they should. Do you  
remember what they are? If you can’t list them, go back to page  
18 and review.  
20  
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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.  
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.  
Let’s learn how to ride!  
Always follow the safe riding rules found on the next pages. You  
or others around you could be seriously hurt or killed if you don’t  
follow the safe riding rules.  
"
Your snowmobile is made for one person. Never carry a passenger.  
A passenger will make the snowmobile harder to drive. You may  
lose control and hurt yourself and your passenger.  
"
"
Never pull anything behind your snowmobile.  
Make sure you know where you’re going to drive when your snow-  
mobile is started. Make sure the area is safe all around your snow-  
mobile.  
"
Never ride alone. An adult should always be watching you in case  
you need help. Always drive within the sight of an adult.  
"
"
"
Never ride on public trails.  
When you’re a beginner, always stay on level ground.  
Don’t ride your snowmobile on roads or over railroad tracks. Your  
snowmobile makes noise that will keep you from hearing cars,  
trucks or trains that may be coming towards you.  
"
"
Fences and snowmobiles don’t mix. Make sure you know where all  
the fences are before you ride. If you drive into a fence, you could  
get hurt.  
Don’t ride at night. The headlight on your snowmobile is there only  
so others can see you driving during the day.  
21  
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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. If it’s too small, it could keep you from moving  
easily. If it’s 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.  
"
"
Learn where there are lakes, rivers, ponds and ditches in your driv-  
ing area. Stay away from them. Never ride on frozen water. You  
could get hurt or you could even die. All ice can be dangerous!  
Always be alert and pay attention to where you’re driving. Pay  
attention to other drivers and be even more careful around them be-  
cause you don’t know what they’re going to do.  
22  
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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  
time and space to stop your snowmobile.  
Ride your snowmobile only  
where you know it’s safe to  
drive and where you have per-  
mission to drive. Be careful of  
To Machine  
To Wrist  
the things around you.  
"
"
Always be a polite driver. (No  
driving through the flower gar-  
den or over the little trees you  
planted.)  
Always attach the tether strap to  
your wrist and machine before  
riding.  
23  
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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 Owner’s Manual.  
Left Turn  
Right Turn  
Stop  
24  
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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.  
WARNING  
Teach the operators to perform the following Pre-Ride Check  
before each use of the snowmobile. Serious injury or death could  
result if they do not check the machine properly before riding.  
n Check the throttle for proper operation.  
n Check the brake for proper operation.  
n Check for proper operation of steering system.  
n Check the throttle safety switch for proper operation.  
n Make sure all three ways to stop the engine are functioning.  
n Inspect the track.  
n Make sure the seat is locked into place.  
n Make sure the track and skis are not frozen to the ground.  
n An adult should check the gas and oil levels for the rider and add  
more if necessary.  
n Make sure the hood is latched.  
n Make sure headlight and taillight are working properly.  
These checks should become automatic for your children before each  
ride. It’s up to you, the adult, to instill in your children the importance  
of performing this Pre-Ride Check before they operate the  
snowmobile.  
25  
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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. We’ve attempted to provide you with as much  
information as possible to alert you to the safety requirements of  
snowmobiling.  
WARNING  
The throttle and brake are the primary controls of the  
snowmobile. If either should malfunction, the operator could lose  
control, which could lead to serious injury or death. Always check  
the throttle and brake levers for proper operation before operating  
the vehicle.  
n Check throttle for proper operation  
When checking the throttle, make sure the control lever compresses  
evenly and smoothly. When the lever is released, it should  
immediately return to the idle position without binding or hesitation.  
If the throttle does not function smoothly, do not attempt to start the  
engine. Have the throttle serviced before starting the engine.  
n Check brake for proper operation  
The need for a properly functioning brake is critical. The brake must  
be checked for correct operation before starting the engine. See page  
31 for brake lever travel specifications.  
n Check for proper operation of steering system  
Check for proper operation of the steering system by manually turning  
the skis completely to the right and to the left. If difficulty is  
encountered, check for ice and snow buildup which may be obstructing  
the steering linkage. Make sure all greasable components are properly  
lubricated.  
26  
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ADULT SECTION  
Pre-Ride Check  
n Check throttle safety switch  
A
Test the throttle safety switch system  
on a daily basis before the machine  
is used.  
While seated in a normal riding  
position, and with the engine idling,  
hold the throttle lever pin stationary  
by exerting pressure on the pivot pin  
in the direction shown in the  
illustration (A). Apply a slight  
amount of throttle opening. A properly functioning switch must shut  
down the engine.  
The throttle safety switch is designed to stop the engine whenever all  
pressure is removed from the throttle lever and the throttle cable or  
valve does not return to the normal closed position.  
If excessive play develops in the  
throttle cable, the safety switch may  
be activated and will prevent the  
engine from starting. If the engine  
doesn’t start and throttle safety switch  
malfunction is suspected, return the  
machine to an authorized Polaris  
dealer for service. If an adult must  
.03 in.  
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.  
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.  
27  
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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.  
To restart the engine, the switch  
must be pulled up to the ON  
position.  
A
n Inspect the track  
Driving for extended periods of time with marginal lubrication could  
severely damage the track. Driving on icy trails or driving when there  
is little or no snow are two examples of situations that would provide  
marginal lubrication and are not recommended.  
WARNING  
Operating the snowmobile with a damaged track will increase the  
possibility of additional track damage and/or failure. This could  
cause loss of control, resulting in severe injury or death. Always  
inspect for damage before using the snowmobile.  
NOTE: Track damage or failure caused by operation under poor  
lubrication conditions will void the track warranty.  
28  
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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.  
n Stay clear of track  
WARNING  
During warm-up and operation, stand clear of the rotating track.  
Entanglement and serious injury or death may result. Use just  
enough throttle to rotate the track and warm up the engine.  
n Do not operate with drive chain guard removed  
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.  
29  
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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. 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.  
30  
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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  
A
firmly depressed.  
Distance A should be no  
more than 3/4(1.9 cm).  
Excessive travel indicates  
a need to adjust the brake cable.  
Refer to the mechanical brake adjustment information on page 59.  
n Make sure the hood is securely latched  
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 operated with  
the hood open or removed.  
n Test stop switch operation  
Start the engine and push the stop switch down to test for proper  
operation. The engine should immediately stop running.  
n Test tether switch operation  
Start the engine and disconnect the tether switch to test for proper  
operation. The engine should immediately stop running.  
n Remove the ignition key  
Don’t tempt someone to steal or ride your snowmobile without  
permission by leaving the key in the ignition.  
n Check lights  
Start the engine and check that both the headlight and taillight are  
operating.  
31  
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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. Teach the operator to check the operating area before riding.  
n Sit properly on the snowmobile  
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  
child’s 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.  
WARNING  
Never hold the snowmobile up or  
stand behind it while warming up the  
track. A loose track or flying debris  
could cause serious personal injury  
or death.  
This snowmobile is propelled by a revolving track, which must be  
partially exposed for proper operation. Serious injuries may be caused  
by operator carelessness, resulting in hands, feet, hair or clothing  
becoming entangled in the track. Teach your child to respect this  
machine and all the moving parts. Stress that being properly seated  
keeps the child clear of the track.  
32  
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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. 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.  
n Always wear clothing designed for snowmobiling  
Clothing designed for snowmobiling is warm, comfortable and safe.  
WARNING  
Always make sure the operator is wearing an approved helmet  
and eye protection. Do not allow the child to wear loose clothing  
or long scarves because they can easily become entangled in  
moving parts. If your child has long hair, be sure it is always tied  
up securely and tucked into the helmet or jacket.  
Extremely cold weather can cause frostbite and/or hypothermia.  
Always be aware of weather conditions, especially the wind chill.  
See the table on page 36.  
33  
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ADULT SECTION  
Operation Warnings  
n Know limitations of machine and skills of driver  
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.  
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.  
34  
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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.  
Teach your child that the sound of the  
machine will make it difficult to hear  
the sound of approaching vehicles. Do  
not allow your child to operate the snowmobile on or near roads and  
railroad tracks.  
Teach your child what it means to drive defensively. Never tailgate  
and always allow ample stopping distances.  
Your child must be taught to always be alert and pay attention to the  
driving area ahead.  
When teaching inexperienced operators to ride, set up a nearby  
predetermined course. Establish boundaries and make sure the  
operator(s) know and understand them. Make sure they know how to  
drive and control the snowmobile before you allow them to make  
supervised longer distance runs. Teach them proper snowmobile  
courtesy.  
It’s a good idea to predetermine some hand signals as a way to  
communicate with your child while giving instruction. It may be  
difficult for your child to hear your voice over the sound of the  
snowmobile and through a helmet.  
35  
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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  
Wind  
Speed  
in MPH  
Actual Thermometer Reading (°F)  
20 10 -10  
50  
40  
30  
0
-20  
-3 -4 -5 -6  
0
0
0
0
Equivalent Temperature (°F)  
Calm  
5
50  
48  
40  
36  
32  
30  
28  
27  
26  
40  
37  
28  
22  
18  
16  
13  
11  
10  
30  
27  
16  
9
20  
10  
0
-10  
-15  
-33  
-45  
-53  
-59  
-63  
-67  
-69  
-20  
-26  
-46  
-58  
-67  
-74  
-79  
-82  
-85  
-3 -4 -5 -6  
0
0
0
0
16  
6
-5  
-3 -4 -- 5 -6  
6
7
7
8
10  
15  
20  
25  
30  
35  
40  
4
-9  
-21  
-36  
-39  
-44  
-48  
-49  
-53  
-5 -7 -8 -9  
8
0
3
5
-5  
-18  
-25  
-29  
-33  
-35  
-37  
-7 -8 -9 -1  
12  
2
5
9
4
-10  
-15  
-18  
-20  
-21  
-8 -9 -1 -1  
10 24  
2
6
0
-8 -1 -1 -1  
04 18 33  
8
-2  
-4  
-6  
-9 -1 -1 -1  
09 25 40  
4
-9 -1 -1 -1  
13 29 45  
8
-1 -1 -1 -1  
00 16 32 48  
Wind  
Speeds  
Greater  
Than  
Little Danger  
(For Properly  
Clothed Person)  
Increasing  
Danger  
Great  
Danger  
40 MPH  
Have  
Little  
Danger From Freezing of Exposed Flesh  
Added  
Effect  
36  
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ADULT SECTION  
Operation Warnings  
WIND CHILL CHART (°C)  
Esti-  
mated  
Wind  
Speed  
in KPH  
Actual Thermometer Reading (°C)  
-10 -15 -20 -25  
Equivalent Temperature (°C)  
5
0
-5  
-30  
-35  
-40  
0
5
1
0
-5  
-10  
-16  
-23  
-28  
-32  
-34  
-35  
-36  
-15  
-22  
-29  
-35  
-39  
-41  
-43  
-44  
-20  
-27  
-36  
-42  
-47  
-49  
-51  
-52  
-25  
-33  
-42  
-48  
-53  
-57  
-59  
-60  
-30  
-38  
-48  
-55  
-61  
-64  
-66  
-68  
-35  
-45  
-54  
-63  
-69  
-73  
-75  
-76  
-40  
-50  
-61  
-69  
-76  
-80  
-82  
-84  
10  
20  
30  
40  
50  
60  
70  
-4  
-11  
-17  
-21  
-24  
-26  
-27  
-28  
-4  
-9  
-7  
-13  
-16  
-18  
-19  
-20  
-9  
-11  
-12  
-13  
Wind  
Speeds  
Greater  
Than  
Little Danger  
(For Properly  
Clothed Person)  
Increasing  
Danger  
Great  
Danger  
70 KPH  
Have  
Little  
Danger From Freezing of Exposed Flesh  
Added  
Effect  
37  
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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.  
Powder Snow Operation  
This snowmobile is designed to operate best on snow. Maneuverability  
is attained by the steering, skis, and the shifting of the driver’s body  
weight. Maximum control will be attained by shifting body weight.  
Maneuverability will change for lighter operators.  
If the machine becomes stuck in snow, free the running board area and  
step down the snow in front of the machine so that when the throttle is  
opened the machine will be able to climb out. The operator can then  
get back on the machine and continue. It is best to encourage the  
operator to stay on established riding areas to avoid the possibility of  
getting stuck.  
Track Lubrication  
Do not operate for prolonged periods in conditions of marginal  
lubrication.  
CAUTION  
It’s essential that this machine be operated under conditions with  
adequate snow cover, as snow provides the only lubrication for  
the track. Failure to do so will result in excessive wear and  
damage to the slide rail and track.  
38  
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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. If difficulty is encountered, check for ice  
and snow buildup which may be obstructing the steering linkage.  
Hard Packed Snow  
Teach your child to reduce speed as required to maintain control in all  
driving conditions. If necessary, maximum speed may be regulated by  
using the procedure outlined on page 47.  
WARNING  
Steering and braking control are substantially reduced when  
operating on on hard surfaces, hard-packed snow or icy surfaces.  
39  
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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. 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.  
Teach your child to respect the unknown. Children must be taught that  
they are not to venture out on their own in unapproved territory. They  
must learn that they must never ride a snowmobile on a frozen body of  
water. You and the driver of the machine should know and understand  
that severe injury or death can result if the snowmobile and its  
occupant break through the ice.  
Driving in Hilly Terrain  
WARNING  
Traveling on hilly terrain is not recommended. It takes some  
maneuvering of body weight that a child may not be capable of,  
which will leave the child at risk. If traveling on hilly terrain is  
unavoidable, teach your child to exercise extreme caution as well  
as the proper operating procedure as outlined below.  
Driving Uphill  
Riding uphill requires extreme caution and should be attempted only  
by experienced operators. The operator should assume a standing  
position with body weight kept low and forward, accelerating before  
the start of the climb and then releasing throttle pressure enough to  
prevent track slippage.  
When reaching the crest of the hill, the operator must slow down and  
be prepared to react to obstacles, sharp drops, or other people or  
vehicles which may be on the other side of the hill.  
40  
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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.  
WARNING  
Teach your child to never stand or get off the machine on the  
downhill side of the machine. Serious injury or death could result.  
Driving Responsibly  
It is 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.  
41  
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ADULT SECTION  
Component Identification  
1
8
11  
1. Hood  
2. Headlight  
8. Rear Suspension  
9. Nosepan  
3. Windshield  
4. Handlebar  
5. Seat  
6. Storage (under seat)  
7. Taillight  
10. Trailing Arm  
11. Skis  
12. Front Bumper  
13. Rear Bumper  
14. Snow Flap  
15. Track  
42  
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ADULT SECTION  
Component Identification  
2
3
9
4
7
5
5
6
8
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  
43  
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ADULT SECTION  
Break-In Period  
Engine Break-In  
The break-in period for your new snowmobile is defined as the first ten  
hours of operation, or the time it takes to use the first two tanks full of  
gasoline. No single action on your part is as important as a proper  
break-in period. Careful treatment of a new engine will result in more  
efficient performance and longer life for the engine. Perform the  
following procedures carefully.  
1 Drive slowly at first. Select an area that’s open and will allow room  
to familiarize yourself with vehicle operation and handling.  
2 Vary the throttle positions. Do not operate at sustained idle.  
3 Perform regularchecks on fluid levels, controls and all important areas  
on the vehicle, as outlined in the maintenance section.  
4 Break in the oil. Change the oil after the first 20 hours of operation.  
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.  
44  
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ADULT SECTION  
Break-In Period  
CAUTION  
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  
A
Before checking or refilling engine  
oil, be sure the engine is stopped and  
the vehicle is positioned on a stable,  
level surface.  
NOTE: Always change the oil if  
it’s become contaminated.  
1. Remove the dipstick and wipe it  
dry with a clean shop towel.  
C
2. Insert the dipstick (A) into the oil  
fill hole, then remove it and read  
the oil level.  
NOTE: Do not thread the dipstick into  
the hole to perform the oil check.  
3. If the oil level is below the lower  
level mark (B) on the dipstick,  
add the recommended oil to the  
upper mark (C).  
B
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.  
45  
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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.  
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.  
WARNING  
The engine exhaust from this product contains chemicals known  
to cause cancer, birth defects or other reproductive harm.  
Operate this vehicle only outdoors or in well-ventilated areas.  
46  
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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 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. Use the following procedure to set the  
performance level.  
CAUTION  
Hot engine components can cause serious burns to skin. Always  
perform the following procedures when the engine is cool.  
For maximum performance,  
move governor spring (A) to  
hole #3.  
For minimum performance  
move governor spring to hole  
#1.  
3
1
A
47  
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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  
25.  
Starting a Cold Engine  
1. Turn the key to ON.  
2. Pull the engine stop switch (shut-off switch) up to the RUN  
position.  
3. Pull the choke lever completely outward to the FULL ON position.  
NOTE: Do not depress the throttle while starting.  
4. Grasp the starter handle and pull slowly until the recoil engages,  
then pull abruptly to start.  
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.  
5. If the engine slows or stops, position the choke knob half way in to  
allow proper engine warm-up.  
6. Apply the brakes and vary the engine RPM slightly with the  
throttle to aid in warm-up. When the engine idles smoothly, push  
the choke all the way in.  
NOTE: To prevent excessive wear on the clutch components, don’t  
engage the clutch while performing the warm-up.  
Starting a Warm Engine  
1. Turn the key to ON.  
2. Pull the engine stop switch (shut-off switch) up to RUN.  
3. Grasp the starter rope handle and pull slowly until the recoil  
engages, then pull abruptly to start.  
48  
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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.  
SYSTEM  
WHAT IT DOES  
THROTTLE  
CONDITION  
Engine Stop Switch  
Ignition Switch  
Tether Switch  
Throttle Safety Switch  
Choke  
Interrupts ignition circuit  
Interrupts ignition circuit  
Interrupts ignition circuit  
Interrupts ignition circuit  
Floods engine  
All  
All  
All  
All  
1/2 throttle or less  
All  
Brake  
Slows drive shaft  
Daily Storage  
Whenever the machine is placed in  
overnight or daily storage the  
following steps must be taken:  
1. Park the snowmobile on a level  
surface and support it at the rear  
so the track is suspended  
approximately 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.  
49  
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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. 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.  
1. Start the engine and allow it to warm up two to three minutes.  
2. Engage the drive system abruptly and allow it to rotate the track  
several revolutions.  
NOTE: The outside temperature will determine the amount of track  
warm-up required.  
3. Shut off the engine and remove the rear support.  
4. Grasp the skis by their front loops and move from side to side.  
This will loosen frozen snow from the ski bottoms, allowing the  
machine to move forward more easily.  
5. The engine, drive system and track are now properly warmed up  
and the machine can be driven following normal safety practices.  
50  
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ADULT SECTION  
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.  
The Polaris Recommended Maintenance Program is intended to assist  
you in performing routing maintenance that will ensure trouble-free  
enjoyment of your Polaris snowmobile. If the recommended regular  
maintenance and service checks are followed, you will be doing your  
part in keeping this snowmobile in excellent operating condition at all  
times.  
The recommended maintenance schedule for your snowmobile calls for  
a service and maintenance inspection at 50 hours, at 100 hours and at  
150 hours. These inspections should be performed by a qualified  
service technician.  
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.  
Please read and follow the recommended maintenance program  
illustrated on the following pages to maintain the performance and  
reliability of your Polaris snowmobile.  
51  
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ADULT SECTION  
Maintenance  
Careful periodic maintenance will help keep your vehicle in the safest,  
most reliable condition. Inspection, adjustment and lubrication of  
important components are explained in the following chart and in the  
maintenance section of this manual.  
Service and adjustments are critical. If you’re not familiar with safe  
service and adjustment procedures, have a qualified dealer perform  
these operations.  
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  
DAILY  
WEEKLY OR  
BEFORE  
EXTENDED  
PERIOD OF  
OPERATION  
50  
HRS  
100  
HRS  
150  
HRS  
SEE  
PAGE  
Check brake operation and  
adjustment  
X
X
58-59  
28  
Test engine stop switch  
(auxiliary shut-off switch)  
Test throttle safety switch  
Test tether switch  
X
X
X
X
X
27  
31  
26  
26  
26  
Test throttle lever operation  
Test brake lever operation  
Check steering system  
operation  
Check operation of headlight  
and taillight  
X
X
X
X
X
31  
Clean dust and chaff from  
engine  
Check ski skags, replace when  
worn to 1/2 original diameter  
76  
56  
62  
Inspect fuel lines, replace if  
needed  
Check engine oil level  
Oil the drive chain  
Every 10 Hrs  
Every 10 Hrs  
Check track tension, tighten if  
necessary  
67  
Grease the clutch  
Change oil  
Every 15 Hrs  
At 20 Hrs  
61  
62  
X
X
X
52  
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ADULT SECTION  
Maintenance  
ITEM  
DAILY  
WEEKLY OR  
BEFORE  
EXTENDED  
PERIOD OF  
OPERATION  
50  
100  
HRS  
150  
HRS  
SEE  
PAGE  
HRS  
Check track alignment  
X
X
X
69  
60  
77  
Check drive chain tension  
Check and tighten any loose  
suspension mounting bolts  
Tighten ski saddle and spindle  
bolts if loose  
X
X
74  
78  
Check front and rear limiter  
strap condition, tighten loose  
bolts  
Check hi-fax thickness, replace  
when worn (see dealer)  
X
X
72  
69  
Tighten rear idler wheel bolts if  
loose  
Check spark plug condition  
X
X
61  
58  
Check for brake cable wear  
and adjustment  
Throttle cable pivot slug  
X
X
X
X
X
X
58  
63  
Lubricate steering post support  
bracket and pivot (aerosol)  
Grease ski spindles  
X
X
X
X
X
X
63  
63  
Lubricate ski bushings to  
spindle area  
Grease lower steering post  
pivot  
X
X
X
X
X
X
77  
77  
Grease rear suspension pivot  
shafts  
Lubricate throttle cable  
X
X
X
X
X
X
58  
58  
56  
Lubricate choke slide and cable  
Inspect exhaust pipe for cracks  
or damage  
X
53  
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ADULT SECTION  
Maintenance  
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  
Authorized Polaris Servicing Dealer  
Servicing Technician  
Date  
Mileage  
150 Hour Maintenance Inspection  
Authorized Polaris Servicing Dealer  
Servicing Technician  
Date  
Mileage  
Additional Services Performed  
Authorized Polaris Servicing Dealer  
Servicing Technician  
Date  
Mileage  
Type of Service  
Additional Services Performed  
Authorized Polaris Servicing Dealer  
Servicing Technician  
Date  
Mileage  
Type of Service  
54  
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ADULT SECTION  
Maintenance  
Spark Plugs  
A new engine can cause temporary spark plug fouling even though the  
heat range is proper, due to the preservative which has been added  
during assembly of the engine to combat rust and corrosion. Avoid  
prolonged idle speeds, as plug fouling and carbonization will result.  
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).  
S Always carry spare spark plugs  
Spark plug condition is indicative of engine operation. The spark plug  
firing end condition should be read after the engine has been warmed  
up and the vehicle has been driven. Immediately check the spark plug  
for correct color.  
WARNING  
A hot exhaust system and engine can cause serious burns. Wear  
protective gloves when removing a spark plug for inspection.  
1. Normal  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This  
indicates the proper type and heat range for the engine and the service.  
NOTE: The tip should not be white. A white insulator tip indicates  
overheating, caused by use of an improper spark plug or  
incorrect carburetion adjustments.  
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.  
55  
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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. lbs. (16-19 Nm).  
Fuel Valve/Fuel Lines  
The fuel valve and the fuel lines should be  
inspected regularly. Special attention  
should be given to the system’s fuel line  
condition after periods of storage. Normal  
deterioration from weather and fuel  
compounds can occur.  
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.  
CAUTION  
Serious burns may occur if this inspection is performed without  
allowing adequate time for the exhaust system to cool. Exhaust  
system temperatures can exceed 900° F (500° C). Never  
perform this procedure with the engine running or shortly after it’s  
been running.  
56  
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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.  
All carburetors have been pre-set at the factory for adequate fuel  
supply. 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
1. Engine  
2. Carburetor  
2
Correct setup provides engine RPM  
within its given power band at full  
throttle settings and also provides  
maximum efficiency and operation  
at all other throttle openings. See  
your dealer for carburetor  
adjustments, which may include the following:  
S Carburetor component changes for specific altitude and ambient  
temperatures;  
S Choke adjustment;  
S Air screw settings, if applicable;  
S Idle RPM adjustments;  
S Throttle safety switch checks and servicing;  
S Throttle block to throttle flipper clearance adjustment  
CAUTION  
Improper carburetor adjustments can result in safety hazards as  
well as serious engine damage. We recommend that all  
carburetor adjustments be performed by your Polaris dealer.  
57  
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ADULT SECTION  
Maintenance  
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. This draws moisture out of the choke  
plunger area and reduces the possibility of  
the choke becoming frozen.  
Throttle Cable Pivot Slug  
Lubricate the throttle cable pivot  
slug (A) every 50 hours or twice  
a year using an aerosol lubricant.  
A
Brake Lever Travel  
B
Measure the clearance between the lever  
and brake block. Inspection should be  
made with the lever firmly depressed.  
Distance B should be no more than 3/4″  
(1.9 cm)  
Excessive travel indicates a need for brake  
cable adjustment.  
58  
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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.  
WARNING  
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.  
2. Using an 8mm wrench to hold the barrel nut (B), loosen the jam  
nut (C) with a 10mm wrench.  
3. With your left hand, grasp the cables (D) as close to the adjuster as  
possible. Use your right hand to rotate the barrel nut until you have  
reached the proper brake lever adjustment.  
A
D
A
D
C
B
4. Check the actuator linkage to  
ensure there is adequate freedom  
of movement for positive brake  
operation and that all floating parts  
move freely and that all parts are  
mounted securely. Tighten  
hardware as required.  
1/4-3/8(6-10 mm)  
5. Tighten the adjuster jam nut and  
slide the rubber protectors back  
onto the adjuster.  
6. The brake band is adjusted correctly when  
there’s 1/4” - 3/8” (6-10mm) brake lever  
freeplay and clearance between the brake  
lever and block with the lever fully  
depressed is no more than 3/4” (1.9cm).  
Torque the band bolt nut (E) to 6 ft. lbs.  
(8 Nm).  
E
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ADULT SECTION  
Maintenance  
Chain Tensioner  
Inspect the chain. The chain should have 1of 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(C) of the muffler mount bracket  
(D) on the chassis, the chain has stretched and must be replaced.  
Inspect the sprockets as they also become worn and often need  
replacement when the chain is replaced.  
B
C
60  
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ADULT SECTION  
Maintenance  
Lubrication  
NOTE: Driveline noise is normal and inherent in a chain drive  
system such as this machine uses.  
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.  
A
1
1. Engine  
6
B
2. Torque Converter  
(Centrifugal Clutch)  
5
3. Chain  
4. Drive Shaft  
5. Track  
6. Carburetor  
3
4
2
61  
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ADULT SECTION  
Maintenance  
Oil Level  
A
Maintain the oil level between the  
safe marks (A) on the dipstick.  
Oil Change  
Change the oil after the initial 20  
hours of operation and again after each 50 hours.  
Washing Your Snowmobile  
Keeping your snowmobile clean will not only improve its appearance  
but it can also extend the life of various components. With a few  
precautions, your sled can be cleaned much like an automobile.  
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.  
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. Many expensive repair bills can result from using high  
pressure detergent systems.  
NOTE: If a high pressure car wash is used, grease all zerk fittings  
immediately after washing. Also run the vehicle to evaporate  
any water that might have entered the engine or exhaust  
system.  
Waxing Your Snowmobile  
Your snowmobile can be waxed with any high quality brand of  
automotive paste wax. Avoid the use of harsh cleaners since they can  
scratch the body finish.  
62  
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ADULT SECTION  
Maintenance  
Controls and Linkage  
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.  
Bearings  
To prevent corrosion which will destroy the bearings, always grease  
drive shaft clutch side bearings with a high quality bearing grease.  
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.  
Front Suspension  
To minimize fatigue on the front shocks and springs during extended  
storage, it is recommended that the front end of the machine be safely  
blocked off the ground to remove tension from the shocks and springs.  
63  
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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. 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.  
NOTE: This procedure is performed best when the front of the  
machine is elevated and the engine is tilted rearward.  
Storage  
Off season or extended storage of your snowmobile requires you to  
take preventative measures to aid against deterioration and to prolong  
the useful life of many components.  
Your snowmobile should be stored in a dry garage or shed, out of  
direct sunlight, and covered with a fabric snowmobile cover. Plastic  
tarp can cause condensation to form and may damage some  
snowmobile components.  
64  
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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.  
If stabilizer is not used, make sure the fuel valve is OFF and drain the  
carburetor. Catch fuel in a container or shop cloth.  
Remove the spark plug and pour approximately 5cc of engine oil into  
cylinder. Slowly pull the recoil starter so the engine turns over two or  
three times. Reinstall plug securely. Position piston at bottom dead  
center (BDC). Observe all fire safety rules when draining carburetor.  
See gasoline warnings on page 46.  
Slowly pull the recoil starter handle until resistance is felt. Leave it in  
that position. Clean the engine thoroughly with an oiled cloth.  
If stabilizer is not used, turn the fuel valve to OFF. Remove the  
strainer cup, place the strainer over a container, and open the strainer  
cock to discharge fuel from the fuel tank. Remove the carburetor float  
chamber bolt from the bottom and discharge fuel from the carburetor.  
Replace bolt.  
65  
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ADULT SECTION  
Maintenance  
Transporting the Snowmobile  
Whenever the snowmobile is transported the following measures  
should be taken:  
1. Turn the fuel valve off.  
2. Be sure the fuel cap is installed correctly.  
3. Always tie the snowmobile to the transporting unit securely using  
suitable straps.  
NOTE: Transportation to and from a Polaris dealer is the  
responsibility of the snowmobile owner. Any expenses  
involved will not be reimbursed.  
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.  
Towing  
Do not use this snowmobile to tow.  
If a situation arises requiring the snowmobile to be towed by another  
snowmobile, attach the tow rope to the spindles, not to the ski toe  
loops.  
For Your Protection  
For your added protection it is a good idea to carry the following items  
in your snowmobile when traveling farther than a five-minute walk  
from home.  
S Extra Spark Plugs  
S First Aid Kit  
S Winter Survival Kit  
S Extra Gloves  
S Owner’s Manual  
66  
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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  
be maintained during summer  
storage. The rear of the  
machine should be supported  
off the ground to allow free  
hanging of the track.  
Track Tension  
Track adjustment is critical for  
proper handling. Always  
B
maintain correct tension and  
alignment.  
Tension adjustments should be  
made only after the track is  
warmed up and limber.  
1. Turn the machine off.  
D
E
2. Lift the rear of the machine  
and safely support it off the  
C
A
ground.  
8″  
3. Hang a 10 pound weight (A)  
8 inches from the center of  
the rear idler wheel. The deflection at this point with this amount of  
weight should measure 3/4between the bottom of hi-fax (B) and  
the inside of the track.  
NOTE: Measure at the point where the weight is hanging.  
4. Check for specified slack between the wear surface of the track clip  
and the plastic hi-fax (C).  
67  
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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.  
4. Start machine and slowly rotate the track at least five revolutions,  
let the track stop rotating by itself (do not apply brakes).  
5. Check track alignment (side to side) by comparing the distance  
from the drive lug to the Hi-fax on both sides. Readjust until  
centered.  
6. Tighten idler shaft bolt.  
7. Readjust the toe block to proper spacing and tighten.  
68  
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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.  
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.  
1. Safely support the rear of the machine  
with the track off the ground using a  
jackstand.  
2. Start the engine and apply a small  
amount of throttle until the track  
turns slowly at least five complete  
revolutions. Stop the engine.  
3. Inspect track alignment by looking  
through the track windows to make  
sure the rails (A) are evenly spaced  
on each side. If the track runs to the  
left, loosen the left idler wheel  
mounting bolt and tighten the left  
track adjusting bolt. If the track runs  
to the right, loosen the right idler  
wheel mounting bolt and tighten the  
right track adjusting bolt.  
A
4. After adjustments are complete, be  
sure to tighten locknuts and idler  
shaft bolts. Torque to 35-40 ft. lbs.  
(47-54 Nm).  
Hi-fax  
5. Repeat step 2 to verify proper alignment.  
69  
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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.  
WARNING  
Never hold the snowmobile up or  
stand behind it while warming up the  
track. A loose track or flying debris  
could cause serious personal injury  
or death.  
70  
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ADULT SECTION  
Maintenance  
Track Inspection  
WARNING  
Inspecting the track while the engine is running can result in  
serious personal injury if the track should being to move. Never  
inspect the track with the engine running  
Using a hoist or jackstand,  
2
1
3
1
2
safely lift and support the  
rear of the snowmobile off  
the ground. Rotate the track  
by hand to check for any  
possible damage.  
To inspect track rods,  
carefully examine the track  
along the entire length of  
each rod, bending the track  
and inspecting for breakage.  
The three most common  
places where breakage  
occurs are shown in the  
illustration.  
Lug  
Track window  
Check the track clips and tighten if loose. If any rod damage is found,  
the track should be replaced.  
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 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 during initial use.  
71  
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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  
on other vital components.  
16(1.1 cm)  
XTRA Lite  
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 Hi-fax replacement.  
72  
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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 hi-fax and track guide clips. Examples of marginal lubrication  
would include lakes without snow cover, icy trails and no-snow  
conditions.  
The slide rail is designed to operate in conditions with adequate snow  
cover in order to provide sufficient lubrication. Excessive wear  
indicates insufficient lubrication. New hi-fax can cause faster heat  
build up in limited lubrication than used hi-fax, resulting in excessive  
wear.  
NOTE: Track damage or failure caused by operation on ice or poor  
lubrication conditions may void the track warranty.  
Steering System  
WARNING  
Improper alignment or adjustment may cause loss of steering  
control, resulting in serious injury or death. 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.  
73  
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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.  
G
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.  
F
E
NOTE: This measurement  
should be taken with  
the vehicle weight  
compressing the  
suspension. If the  
skis are misaligned,  
we recommend that  
your dealer make the  
necessary  
adjustments.  
I
74  
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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.  
8. Loosen the lower flange nut  
only enough so the bracket can  
move freely.  
9. Position the handlebar to the desired height and re-install the upper  
carriage bolt and flange nut.  
10. Torque the flange nuts to 15-17 ft. lbs. (20-23 Nm).  
11. Reinstall the handlebar pad.  
75  
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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  
A
recommend that skags be checked  
once a week to maintain positive  
steering characteristics. Skags must be replaced when worn to half  
their original diameter.  
NOTE: See dealer track studding and skag chart for recommended  
skags.  
WARNING  
Worn skis and/or skags will adversely affect handling and can  
cause loss of vehicle control, which can lead to serious injury or  
death. Replace worn skis and/or skags when inspection reveals  
wear.  
Skag Replacement  
1. Raise and support the front of the machine so the skis are  
approximately 6(15.2 cm) from the ground.  
2. Remove the attaching nuts and pry the skag downward.  
3. Remove the forward portion of the skag.  
Reverse this procedure for new skag installation.  
NOTE: If the rear idler wheel  
assembly (1) washers  
are removed, be sure  
they are reinstalled with  
the domed side of the  
1
washer facing out (2) as  
2
shown.  
76  
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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.  
NOTE: A grease gun kit complete with grease and adaptors is  
available to lubricate all fittings on Polaris snowmobiles. See  
page 82.  
IMPORTANT: Make it a weekly practice to check for loose bolts and  
nuts on the suspension system. If any loose bolts are found on the rail  
be sure to clean the threads and apply Loctite 262 before tightening.  
77  
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ADULT SECTION  
Maintenance  
Suspension Components  
Suspension Lubrication points are indicated by a L.  
1. Front Limiter Strap  
2. Torsion Spring Sleeves  
3. Torsion Spring  
4. Carrier Wheel  
8. Rail Bumper  
9. Torque Arm  
10. Rail  
11. Hi-fax  
5. Rear Limiter Strap  
6. Spacer  
12. Toe Guard  
13. Idler Wheel  
7. Adjuster Bolts  
4
3
5
6
2
1
L
13  
12  
11  
7
8
9
10  
L
78  
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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.  
Paint Codes  
Color Description  
Indy Red  
Polaris “P” No.  
P293  
Raw Material No.  
8520297  
Indy Black  
P067  
8520246  
Paints can be ordered direct from Midwest Industrial Coatings (612)  
942-1836. Mix as directed.  
Troubleshooting  
Contact your Polaris dealer for service if you’re unable to identify  
solutions using the following chart.  
Engine Turns Over, Fails to Start  
Possible Cause  
Solution  
Tether switch not engaged  
Engine stop switch not on  
Throttle safety switch malfunction  
Out of fuel  
Install tether switch/strap  
Pull stop switch up to RUN position  
See your Polaris dealer  
Refuel  
Clogged fuel valve or filter  
Water is present in fuel  
Fuel valve is turned off  
Old or non-recommended fuel  
Fouled or defective spark plug(s)  
No spark to spark plug  
Overuse of choke  
Inspect and clean or replace  
Drain the fuel system and refuel  
Turn the fuel valve on  
Replace with new fuel  
Inspect plug(s), replace if necessary  
Inspect plug(s), verify stop switch is on  
Inspect, clean and/or replace spark plugs  
See your Polaris dealer  
Mechanical failure  
79  
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SPECIFICATIONS  
Jetting Chart  
Ambient  
Temperature  
Below  
-30_F  
(-34_C)  
-30_ to  
-10_F  
(-34_ to  
-23_C)  
-10_ to  
+10_F  
-23_ to  
-12_C  
+10_ to  
+30_F  
-12_ to  
-1_C  
+30_ to  
+50_ F  
-1_ to  
Above  
+50_F  
Above  
+10_C  
+10_C  
Altitude  
in  
Meters  
(Feet)  
0-600  
75  
75  
72.5  
72.5  
70  
72.5  
72.5  
70  
72.5  
72.5  
70  
70  
70  
70  
70  
(0-2000)  
600-1200  
(2000--4000)  
1200--1800  
(4000-6000)  
72.5  
70  
67.5  
65  
67.5  
65  
1800-2400  
(6000-8000)  
67.5  
65  
67.5  
65  
67.5  
65  
2400-3000  
(8000-10000)  
67.5  
65  
62.5  
60  
62.5  
60  
3000-3600  
(10000-12000)  
62.5  
62.5  
62.5  
80  
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SPECIFICATIONS  
Capacities and Dimensions  
Body Style  
Mini Indy  
Riders/Weight  
Engine Oil  
1/150 lbs. (68 kg) maximum  
.6 qts. (.57 l)  
Dry Weight (est.)  
Fuel Tank  
147.5 lbs. (67 kg)  
.5 gal. (1.9 l)  
Height  
Length  
Ski Center Distance  
Width  
Brake Type  
Clutch Type  
Track Length  
Track Width  
Drive Chain Length  
31 in. (78.7 cm)  
75 in. (190.5 cm)  
30 in. (76.2 cm)  
34 in. (86.4 cm)  
Mechanical  
Centrifugal  
69 in. (175.3 cm)  
10 in. (25.4 cm)  
#40  
Suspension  
Front Type  
IFS  
IFS Shock Type  
Rear Type  
Mini  
Mini Indy  
Engine and Cooling  
Engine Model Number  
Alternator Output  
Bore x Stroke  
Displacement  
Carburetor Model  
Main Jet  
EH122PM013  
50 watt @ 3600 rpm  
60 x 43 mm  
121 cc  
Mikuni BV18  
72.5  
Pilot Jet  
50  
Cutaway  
170 Throttle Valve  
Fuel Screw  
1.5 Turns  
Pilot Air Jet  
1.3  
Idle RPM  
1600 +/- 200  
Cooling  
Air  
Cylinders  
1
Ignition Timing  
Ignition Type  
Oil Injection  
Spark Plug  
23_ BTDC @ 3600 rpm  
Flywheel Magneto (solid state)  
0W-40 Synthetic  
NGK BR6ES  
Spark Plug Gap  
Minimum Fuel Requirement  
.028 in. (.70 mm)  
87 Octane Non-Oxygenated or 89 Octane Oxygenated  
81  
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POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricant  
2871281  
Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.)  
Gearcase / Transmission Lubricants  
Premium Synthetic Gearcase Lubricant (qt.)  
Premium Front Gearcase Lube (8 oz.)  
Premium Drive Hub Fluid (8 oz.)  
2873602  
2871653  
2871654  
Grease / Specialized Lubricants  
Grease Gun Kit, Premium All Season (3 oz.)  
Premium All Season Grease (3 oz. cartridge)  
Premium All Season Grease (14 oz. cartridge)  
Starter Drive Grease (2 oz.)  
2871312  
2871322  
2871423  
2871460  
2871515  
2871551  
2871329  
Premium U-Joint Lube (3 oz.)  
Premium U-Joint Lube (14 oz.)  
Dielectric Grease (Nyogelt)  
Coolant  
2871323  
2871534  
60/40 Coolant (gal.)  
60/40 Coolant (qt.)  
Additives / Miscellaneous  
Fogging Oil (12 oz. Aerosol)  
Carbon Clean Plus (12 oz.)  
Fuel Stabilizer (16 oz.)  
2870791  
2871326  
2870652  
2870990  
2872893  
DOT3 Brake Fluid (12 oz.)  
Engine Degreaser (12 oz.)  
82  
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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:  
1. Serial number 5. Details of trouble experienced  
2. Model number 6. Length of time and conditions of operation  
3. Dealer name  
7. Previous correspondence  
4. Date of purchase  
Use the page provided near the front of your Owner’s Manual to record  
the identification numbers of your snowmobile and its engine.  
Polaris Customer Service  
United States: 1-763-417-8650  
Canada: 1-204-925-7100  
Polaris Anti-Theft System  
The Polaris anti-theft system (PATS) monitoring program is designed  
to aid owners of registered snowmobiles in recovery of stolen  
machines.  
Administration  
1. Polaris snowmobile owner reports theft.  
A. In addition to notifying the proper law enforcement offi-  
cials, the owner must call Polaris Customer Service.  
B. Owners must provide their name, address, telephone num-  
ber and the model and serial number of stolen machines.  
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.  
83  
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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. The warranty begins on  
the date of purchase. This warranty is transferrable to another consumer, during the war-  
ranty period, through a Polaris dealer.  
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 entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and set-up of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
set-up will void your warranty coverage.  
Warranty Coverage and Exclusions  
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.  
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. THE REM-  
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-  
ABLE 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 CONTRACT, NEG-  
LIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-  
sion or limitation of incidental or consequential damages or implied warranties, so the  
above limitations or exclusions may not apply to you if inconsistent with controlling  
state law.  
84  
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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.  
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). Polaris recommends 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. Your dealer will contact the  
appropriate personnel at Polaris if additional assistance is needed.  
This warranty gives you specific legal rights, and you may also have other rights which  
vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty terms  
will remain in effect.  
Engine Oil  
1. Mixing oil brands or using non-recommended oil may cause engine damage. We  
recommend the use of Polaris engine oil.  
2. Damage resulting from the use of non-recommended lubricants may not be covered  
by warranty.  
85  
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WARRANTY  
Conditions and Exclusions  
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. Failure to provide proof of re-  
quired periodic maintenance upon request may result in denial of warranty coverage. Use  
of the recommended Polaris products for lubrication and maintenance as directed by the  
Owner’s manual is highly recommended. Should a failure occur during the warranty  
period resulting from the use of non-recommended products, warranty coverage may be  
denied.  
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental  
conditions and/or contamination. The following items are excluded from warranty con-  
sideration if the failure was due to wear or not the direct result of a defect:  
Skis  
Tracks  
Ski wear rods  
Slide rails  
Suspension components  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
Idler wheels  
Warranty applies to the product only and does not allow for coverage of personal loss.  
Some items are considered “consumable,” meaning they are considered part of normal  
maintenance or part of completing an effective repair. The following items are excluded  
from warranty coverage in the event of a warranty claim:  
Spark Plugs  
Filters  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Fuel  
Sealants  
Hotel fees  
Towing charges  
Mileage  
Meals  
Shipping/ handling fees  
Product pick-up/delivery  
Rentals/Loss of product use Loss of vacation/personal time  
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.  
86  
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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.  
Consumer Exclusions  
S
Each repair visit after the first twelve months of standard warranty coverage is subject  
to a $50 deductible.  
S
The free Second Year Engine Service Contract applies to the first 5,000 miles or two  
(2) calendar years from date of purchase, whichever comes first. Tampering with the  
odometer shall void all warranties/service contracts. No extensions to coverage under  
this engine service contract can be given. Used snowmobiles are not eligible under  
this program.  
S
Snowmobiles used for commercial purposes or for racing are excluded from cover-  
age.  
Coverage  
Coverage for second year engine failures due to defects in materials and workmanship  
will be determined by Polaris in its sole discretion. Coverage is automatic with no  
additional paperwork required. The free Second Year Engine Service Contract is subject  
to a $50 deductible per visit. Regular, documented service maintenance visits are  
required to validate this warranty.  
A partial list of items excluded from coverage includes:  
S
S
S
S
S
Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.  
Damage caused by the failure of other components of the snowmobile.  
Failures caused by improper fuel or oil.  
Piston seizures, unless caused by a defective engine component.  
Failures caused due to improper adjustments.  
S 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
S
Failure due to use of unauthorized parts or modifications.  
Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,  
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and  
exhaust manifolds excluding paint coverage.  
S
S
Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring  
and other electrical components are excluded from coverage.  
Cooling system coverage is limited to the water pump assembly and components, fan,  
fan bearings, temperature sensor, gasket and seals.  
S
S
Non wear related throttle body parts are covered. The fuel pump is covered.  
Clutches and related clutch parts, including but not limited to, the drive belt, are ex-  
cluded from coverage.  
S
S
Electrical components are excluded from coverage.  
Gearcases and transmissions are excluded from coverage.  
87  
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WARRANTY  
Exported Vehicles  
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-  
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD  
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-  
TION.  
This policy does not apply to vehicles that have received authorization for export from  
Polaris Industries. Dealers may not give authorization for export. You should consult an  
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you  
have any questions.  
This policy does not apply to vehicles registered to government officials or military per-  
sonnel on assignment outside the country of the selling dealer’s authorized location.  
This policy does not apply to Safety Recalls.  
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 dealer’s 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.  
Notice  
If your vehicle is registered outside of the country where it was purchased, and you have  
not followed the procedure set out above, your vehicle will no longer be eligible for war-  
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-  
cials or military personnel on assignment outside of the country where the vehicle was  
purchased will continue to be covered by the basic warranty.)  
For questions call Polaris Customer Assistance (see page 83).  
88  
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INDEX  
A-B  
R
Accessories . . . . . . . . . . . . . . . . . . . . . 79  
Auto Chain Tensioner . . . . . . . . . . . . . 60  
Brake Adjustment . . . . . . . . . . . . . . . . 59  
Brake Lever Travel . . . . . . . . . . . . . . . 58  
Break-In Period . . . . . . . . . . . . . . 44-45  
Riding Rules . . . . . . . . . . . . . . . . . 21-24  
S
Safety . . . . . . . . . . . . . . . . . . . . . . 10-13  
Safety Decals . . . . . . . . . . . . . . . . . . . 12  
Second Year Engine Service Contract 87  
Service And Warranty Information . . 83  
Signal words . . . . . . . . . . . . . . . . . . . . 13  
Skag Replacement . . . . . . . . . . . . . . . 76  
Ski Skags . . . . . . . . . . . . . . . . . . . . . . 76  
Spark Plug Removal and Replacement 56  
Spark Plugs . . . . . . . . . . . . . . . . . . 55-56  
Specifications . . . . . . . . . . . . . . . . 80-81  
Speed Regulation . . . . . . . . . . . . . . . . 47  
Starting a Cold Engine . . . . . . . . . . . . 48  
Starting a Warm Engine . . . . . . . . . . . 48  
Starting the Engine . . . . . . . . . . . . . . . 48  
Steering Inspection and Adjustment . 74  
Steering System . . . . . . . . . . . . . . . . . 73  
Storage . . . . . . . . . . . . . . . . . . . . . 63-64  
Storage, Daily . . . . . . . . . . . . . . . . . . . 49  
Maintenance . . . . . . . . . . . . . . . . . 51-78  
Suspension Components . . . . . . . . . . 78  
Suspension Lubrication . . . . . . . . . . . 77  
Symbols . . . . . . . . . . . . . . . . . . . . . . . 13  
C
Carburetor . . . . . . . . . . . . . . . . . . . . . 57  
Carburetor Protection . . . . . . . . . . . . . 65  
Checking Engine Oil . . . . . . . . . . . . . 45  
Choke and Cable Lubrication . . . . . . . 58  
Component Identification . . . . . . . 42-43  
E
Electrical Connections . . . . . . . . . . . . 63  
Emergency Stopping Procedure . . . . . 49  
Engine Break-In . . . . . . . . . . . . . . . . . 44  
Engine Stop Switch . . . . . . . . . . . . . . 28  
Equipment Modifications . . . . . . . . . . 10  
Exhaust System . . . . . . . . . . . . . . . . . 56  
F
Fall Tune-Up . . . . . . . . . . . . . . . . . . . 66  
Front Suspension . . . . . . . . . . . . . . . . 63  
Fuel Safety . . . . . . . . . . . . . . . . . . . . . 46  
H-M  
T
Hi-Fax Inspection/Replacement . . . . . 72  
Jetting Chart . . . . . . . . . . . . . . . . . . . . 80  
Know Your Snowmobile . . . . . . . 14-18  
Lubrication . . . . . . . . . . . . . . . . . . . . . 61  
Maintenance Inspection . . . . . . . . . . . 54  
Maintenance Program . . . . . . . . . 11, 51  
Throttle Cable Lubrication . . . . . . . . . 58  
Throttle Cable Pivot Slug . . . . . . . . . . 58  
Throttle Safety Switch . . . . . . . . . . . . 27  
Towing . . . . . . . . . . . . . . . . . . . . . . . . 66  
Track Adjustment . . . . . . . . . . . . . . . . 68  
Track Alignment . . . . . . . . . . . . . . . . . 69  
Track and Suspension . . . . . . . . . . . . . 67  
Track Inspection . . . . . . . . . . . . . . . . . 71  
Track Lubrication . . . . . . . . . . . . . . . . 73  
Track Tension . . . . . . . . . . . . . . . . . . . 67  
Track Warm Up . . . . . . . . . . . . . . . . . 70  
Transporting . . . . . . . . . . . . . . . . . . . . 66  
Troubleshooting . . . . . . . . . . . . . . . . . 79  
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45  
Oil Change . . . . . . . . . . . . . . . . . . . . . 62  
Oil Level . . . . . . . . . . . . . . . . . . . . . . . 62  
Operation . . . . . . . . . . . . . . . . . . . 46-50  
Operation Warnings . . . . . . . . . . . 29-41  
Oxygenated Fuels . . . . . . . . . . . . . . . . 46  
V-W  
P
Vehicle Identification Numbers . . . . . . 9  
WARRANTY . . . . . . . . . . . . . . . . 83-88  
Washing . . . . . . . . . . . . . . . . . . . . . . . 62  
Waxing . . . . . . . . . . . . . . . . . . . . . . . . 62  
Welcome . . . . . . . . . . . . . . . . . . . . . . . . 4  
Windchill/Temperature Charts . . . . . . 36  
Paint Codes . . . . . . . . . . . . . . . . . . . . . 79  
Polaris Products . . . . . . . . . . . . . . . . . 82  
Pre-Ride Warm Up . . . . . . . . . . . . . . . 50  
Pre-Ride Check . . . . . . . . . . . . . . 19-20  
Preservation of the Environment . . . 7-8  
89  
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