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.

1
What’s the hottest thing on snow?
Our new web site. It’s designed just for YOU!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
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.
2
1
3
5
6
4
78
99
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.
1
2
34
5

R--6
KNOW YOUR MACHINE
6. Seat / Storage - You sit on the seat. When the engine isn’t running,
you can take the 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 are riding.
8. Snow Flap - The snow flap keeps snow, ice, or other things from
flying out behind your snowmobile.
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.
6
9
8
10
7
Never get close to a moving track.
Never wear clothing that could get caught in a moving track, like a
long scarf or clothing that is too big. Tie up long hair.

R--7
KNOW YOUR MACHINE
Let’s review the three ways to stop your
snowmobile.
1. Pushing down on the engine stop switch on the
right handlebar control will shut off the engine.
2. Disconnecting the tether strap will shut off the
engine.
3. Turning the key to off will shut off the engine.
1
2
3

R--8
PRE OPERATION CHECK
You are almost ready to have an adult start your snowmobile. Before
the snowmobile is started for the first time, you must do a
PRE-OPERATION 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.
nMake sure the throttle doesn’t stick. Check this by pushing the
lever toward the handlebar and then letting go. The lever should
come right back to where it was before you pushed it. If it comes
back slowly or stays open, you have a sticky throttle. This means
that something is wrong or broken.
nMake sure the brakes don’t stick. Check the brake lever by
squeezing the lever toward the handlebar and then letting it go. It
should come right back to where it was before you squeezed it. If
it goes back slowly or stays on, your brakes are sticking.
nIf you have used the storage area under the seat, make sure the seat
locking tabs are in place.
If you have a sticky throttle, do not start the engine. You could
get hurt if you ride when you have a sticky throttle. Have an
adult or your Polaris Dealer fix the throttle.
If you have sticky brakes, do not start the engine. You could get
hurt if you ride when you have sticky brakes. Have an adult or
your Polaris Dealer fix the sticky brakes.

R--9
PRE OPERATION CHECK
nMake 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.
nHave an adult check the gas level to see if your snowmobile needs
more. Children should never add their own gasoline. This should
always be done by an adult. Before anyone adds gasoline to your
snowmobile they must read the instructions and warnings on pages
A--29 and A--30 in this Owner’s Manual.
nHave 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 you.
Children should never check the oil on their own. An adult should
be in charge of keeping the gas and oil levels to the full marks.
nMake sure your hood is latched tight before starting your machine.
nThis last check is done with the engine running. You must check
to make certain that ALL THREE WAYS TO STOP your
snowmobile are working the way they should. Do you remember
what they are? If you cannot list them, go back to page R--10 and
review.
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.
Always have an adult put gas in your machine.

R--10
RIDING RULES
Any operator of this machine must be at least 6 years old. Now you are
ready to learn about riding a snowmobile. You will learn what you can
do and what you cannot do. The adult with you is your teacher. You
must listen and pay attention or you won’t be safe when you ride.
Remember that safety while you ride is the most important thing. Let’s
learn how to ride!
"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 are going to drive when your
snowmobile is started. Make sure the area is safe all around your
snowmobile.
You must always follow the safe riding rules found on the next
pages. If you do not, you could be hurt really bad or even killed.
You must always follow the safe riding rules found on the next
pages. If you do not, you could be hurt really bad or even killed.

R--11
RIDING RULES
"Always wear the right kind of clothing when you are riding your
snowmobile. You will need a good helmet with a face shield or
goggles. Wear a warm jacket and snowpants. Make sure your clothing
fits properly. If it is too small, it could keep you from moving easily.
If it is 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. Make sure your boot laces are tied. If
you have long hair, be sure to tie it up.
"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.
Helmet
Face Shield
Gloves
Boots
Jacket
Pants

R--12
RIDING RULES
"Always drive your snowmobile while sitting down. Keep both
hands on the handlebars and keep both feet on the running boards.
"When you are 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 one, you could get
hurt.
"Don’t ride at night. The headlight on your snowmobile is there only
so that others can see you driving during the day.
Both Hands on
Handlebars
Sit Down
Feet on Running Boards

R--13
RIDING RULES
"Learn where there are lakes, rivers, ponds and ditches in your
driving 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 are driving. Pay
attention to other drivers and be even more careful around them
because you don’t know what they’re going to do.
"Never follow another snowmobile too closely. Always allow lots of
time and space to stop your snowmobile.
"Only ride your snowmobile where you know it is safe to drive. No
driving over the flower garden or on the little trees you planted. Be
careful of the things around you.
"Always attach the tether strap to your wrist and machine before
riding.
You must always follow the safe riding rules found on the next
pages. If you do not, you could be hurt really bad or even killed.

R--14
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

A--1
-NOTES-