Polaris 120 XC SP Guide

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.
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
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.

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Our new web site. It’s designed just for YOU!
STechnical tips
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SParts and Service Manual information
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Check it out...
www.polarisindustries.com/owner

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FOREWORD TO PARENTS
Thank you for purchasing a Polaris snowmobile and welcome to our
world wide family of Polaris enthusiasts. Polaris takes great pride in
engineering a product for the youngsters of the sport. Afterall, kids
need a Way Out too.
Following the instructions and recommendations in this manual will
help assure safe and enjoyable operation of your vehicle. Your Owner’s
Manual also contains instructions for minor maintenance. Major
repairs are covered in the Polaris Service Manual and should be
performed by a Factory Certified MSD (Master Service Dealer)
Technician.
Before the snowmobile is used, take a few minutes to read through this
manual and familiarize yourself and your child with maintenance and
operation procedures. It may be the most important time spent in
knowing how to keep your machine running perfectly every day.
This manual also contains important pages devoted to safety and
environment. Since the operator will be a newcomer to this exciting
winter sport, make certain he understands his information.
Copyright 2001
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.
Comments and suggestions regarding this manual may be forwarded in
writing to: Polaris Industries Inc., Consumer Service, 2100 Highway
55Medina, MN 55340

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TABLE OF CONTENTS
RIDER’S SECTION R--1 - R--14
Understanding Warnings R--1 - R--2
Know Your Machine R--3 - R--7
Pre Operation Check R--8 - R--9
Riding Rules R--10 - R--14
ADULT SECTION A--1 - A--77
Understanding Warnings A--2 - A--3
Safety Decals
Pre Operation Check A--7 - A--9
Operation Warnings A--10 - A--21
Preservation of the Environment A--22 - A--23
Identification and Specifications A--24 - A--25
Engine Break-in A--26 - A--27
Operation A--28 - A--36
Maintenance A--37 - A--67
Troubleshooting A--68
Accessories and Paint Codes A--69
Speicifications and Jetting Chart A--70
Wiring Diagram A--71
Service and Warranty Information A--72 - A--73
Warranty A--74 - A--77

R--1
IMPORTANT NOTES FOR OWNERS AND
DRIVERS
nAfter you read this manual store it in the vehicle for convenient
reference. It should remain with the vehicle when sold.
nThis manual contains the latest information at the time of printing.
We reserve the right to make product changes and improvements
without further notice.
nThe drawings and photos used in this manual are general
representations. Your model may differ.
nFollow the maintenance program outlined in this manual.
Preventive maintenance ensures the critical components of the
snowmobile are inspected by your dealer at various mileage
intervals.
nYou and your dealer must complete the registration form included
with your snowmobile and forward it to us. This completed form is
necessary to insure warranty coverage.
nProtect and preserve your right to ride by joining your local trail
riding clubs.
nPolaris and Polaris The Way Out are registered trademarks.
nPolaris designs and manufactures a full line of personal
recreational vehicles. Visit our web site at
www.polarindustries.com for more exciting details on The Way
Out.
Parents should sit down with their child and read the Rider’s
Section with them before letting them use this snowmobile.
Parents should also read the Adult Section before allowing their
child to ride this snowmobile.
IMPORTANT

R--2
IMPORTANT NOTES FOR OWNERS AND
DRIVERS
PARENTS: Do not allow anyone under the age of 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.
CHILDREN: Before you ride your new Polaris snowmobile, there are
some important things you should know. How to keep safe is the most
important thing. You must also learn some things that will keep you
and those around you safe while you are riding.
Pay attention when you see these symbols and these words:
This is the safety alert symbol. When you see this
symbol on your machine or in this manual it means PAY
ATTENTION. If you don’t, you could get hurt very badly
or even killed. Your safety is involved!
Parents should sit down with their child and read the Rider’s
Section with them before letting them use this snowmobile.
Parents should also read the Adult Section before allowing their
child to ride this snowmobile.
IMPORTANT

R--3
KNOW YOUR MACHINE
Before you have an adult start the engine for you for the first time, let’s
learn about the controls on your new machine.
1. Engine Stop Switch - When the engine is running, you can push
this button and the engine will stop. The stop switch must be in
the “up” position to start the engine again.
2. Throttle Control - This 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 R--11.
3. Recoil Starter Handle - Pull this to start your snowmobile. An
adult will help you start it the first time.
4. Choke Knob - You may need to use this to help start your
snowmobile if the engine is cold.
5. Gas Cap - This is where the gas goes that will run your
snowmobile. Your snowmobile will not run without gas. Only
adults should fill the gas tank.
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Always have an adult put gas in your machine.

R--4
KNOW YOUR MACHINE
6. Brake Lever - Squeeze this towards the handle to make your
snowmobile slow down or stop.
7. Ignition Switch - The 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.
8. Tether Strap/Switch - This must always be attached snugly to
your wrist and your machine when you are riding. If you fall off your
snowmobile, the tether will pull off the switch and the engine will stop.
Put one end of the tether strap around your wrist. The other end must
be attached to the snowmobile. Always attach the tether strap before
you ride.
9. Hood Hold-Down - There are two straps to hold down the hood of
your snowmobile. They must always be latched before you start your
machine.
Always take your thumb off the throttle control when you pull
the brake lever.
Never ride without the tether strap attached to your wrist and
machine. Be careful not to get the cord tangled around the
handlebars or any part of your body.
Always make sure that these straps are latched before you ride.

R--5
KNOW YOUR MACHINE
Let’s learn more about your machine before we talk about riding.
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 are riding.
3. Windshield - Always keep your windshield clean to help you see
where you are 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 are riding your
snowmobile. Never remove the flag from your snowmobile.
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