Polaris 120 XC SP Instruction Manual

Rider’s Safety Manual
and Owner’s Operation
and Maintenance Manual
2001
120 XC
Snowmobile
Part No. 9916124
PRINTED IN THE U.S.A.

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 de-
fects 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.

FOREWORD TO PARENTS
Thank you for purchasing a Polaris snowmobile. We believe it is the standard of
excellence for all snowmobiles manufactured in the world today. Many years of
experience in engineering, design, and development have gone into making your
Polaris snowmobile the finest machine we have ever produced.
All machines, no matter how well engineered, require a certain amount of mainte-
nance. 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.
Your Polaris dealer will register your new snowmobile with Polaris Industries
Inc. electronically. No confirmations or validations of warranties will be is-
sued by Polaris.
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.
Operators must be aware of risks involved when traveling on icy or hard packed
surfaces, at night or in unfamiliar terrain. Young novice riders who do not have the
ability or experience to physically control the machine in difficult situations should
be instructed to reduce their speed until they become skilled riders.
Keep the running boards free of ice and snow and in good condition. The safe and
courteous operation of the snowmobile - with respect for the environment and pri-
vate property - will ensure the the continued enjoyment of the sport of snowmobil-
ing.
If you should experience any problems with your snowmobile, please return it to
your dealer. Dealers have received training which will enable them to perform any
required repairs. Should any additional assistance be required, your dealer will
work with our technical services department to resolve any problems.
All of us at Polaris would like to extend our best wishes for plenty of fun-filled, safe
snowmobiling pleasure with this new Polaris.
All information in this manual is based upon the latest product data and specifica-
tions available at the time of printing. Polaris Industries Inc. reserves the right to
make product changes and improvements which may affect illustrations or ex-
planations.
No part of this manual shall be reproduced or used without the written permission
of Polaris Industries Inc.
Comments and suggestions regarding this manual may be forwarded in writing to:
Polaris Industries Inc.
Consumer Service
2100 Highway 55
Medina, MN 55340

The Polaris Preferred
Registered Owners
(PRO) Family
Your Owners Program
As the owner of a new Polaris vehicle, you are entitled to a FREE two-year mem-
bership in the Polaris PRO Family----the Preferred Registered OwnersFamily. This
is an owners’ program for Polaris consumers like you, people who have chosen
the finest recreational vehicle available, and who share an interest in Polaris and
its products.
Once your new vehicle’s warranty is registered, you will receive a PRO Family
membership packet. Your packet will be mailed to the address on your warranty
registration. Membership packets are mailed quarterly.
Your packet will include:
A letter of welcome to the PRO Family.
A PRO Family card with your name and membership number.
A colorful sticker of the PRO logo.
A PRO merchandise brochure and order form.
As a PRO Family member, you’re entitled to opportunities such as:
A free subscription to PRO Spirit, the official magazine of the PRO Family.
The chance to buy insurance for your Polaris vehicle. The toll-free insurance
telephone number is: 1-800-473-0111
The chance to arrange travel through the Polaris Travel Center. The toll-free
travel telephone number is: 1-800-267-1915
The chance to apply to serve on PRO Consumer Councils that provide input
into the Polaris vehicles of the future.
The chance to serve as a PRO Field Evaluator and provide feedback on your
new vehicle.
The chance to take part in national PRO snowmobile, ATV or personal water-
craft rides.
The chance to purchase exclusive PRO Family merchandise.
And more!
To order PRO merchandise, complete the order form you receive with your mem-
bership packet. Take the form to your Polaris dealer and pay for the merchandise.
The merchandise will be shipped directly to yourhome from the PRO merchandise
fulfillment center.
Watch for your PRO membership packet and the next issue of PRO Spirit maga-
zine. This quarterly magazine will keep you informed about Polaris news and
events, and special PRO merchandise, travel, and ride opportunities.
Enjoy your new Polaris vehicle and welcome to the family-- --The Polaris PRO Family.

TABLE OF CONTENTS
RIDER’S SECTION R-1 - R-11................................
Understanding Warnings R-1............................
Know Your Machine R-2 - R-6...........................
Pre Operation Check R-7 - R-8...........................
Riding Rules R-9 - R-13.................................
ADULT SECTION A-1 - A-63................................
Understanding Warnings A-1.............................
Safety Warning and Operation Decals A-2 - A-3.............
Pre Operation Check A-4................................
Operation Warnings A-5 - A-15..........................
Preservation of the Environment A-16.....................
Identification and Specifications A-17 - A-18...............
Engine Break-in A-19 - A-20..............................
Operation A-21 - A-29..................................
Maintenance A-30 - A-55................................
Troubleshooting A-56...................................
Clutching Chart A-57....................................
Specifications A-58......................................
Wiring Diagram A-59....................................
Service and Warranty A-60..............................
Warranty A-61 - A-63...................................
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--1
PARENTS: Review the information in this manual with any
child who may be operating the snowmobile. It is up to you
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.
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:
RIDER’S
SECTION
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!

R--2
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--7.
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--3
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--4
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--5
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--6
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--7
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.
Make 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.
Make 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.
If 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--8
PRE OPERATION CHECK
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 too, have an adult help you.
Have 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 page A--23 in this Owner’s Manual.
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 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.
Make sure your hood is latched tight before starting your
machine.
This 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--6 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--9
RIDING RULES
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.
Helmet
Face Shield
Gloves
Boots
Jacket
Pants

R--10
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.
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 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--12
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.
Respect your snowmobile;
respect your environment;
and you will earn
the respect of everyone. To Wrist
To Machine

R--13
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
UNDERSTANDING WARNINGS
SAFETY ALERT
The following precautionary signal words are used throughout this manual to con-
vey the following messages: It is very important this owner’s manual is read and
thoroughly explained to each operator(s) of this machine.
The operator(s) should know and understand the risk if these important warnings
and cautions are not heeded.
This is the safety alert symbol. When you see this
symbol on your machine or in this manual, be
alert to the potential for personal injury. Your
safety is involved!
WARNING Indicates a potential haz-
ard which could result in
serious injury or death.
CAUTION
Indicates a potential hazard
which may result in personal
injury or damage to the snow-
mobile.
NOTE The word “NOTE:” in this manual will
alert you to key information or in-
structions.
ADULT SECTION

A--2
SAFETY WARNING AND OPERATION DECALS
As with all snowmobiles, caution must be observed to ensure operator safety. Par-
ticular caution mustbe taken to make sure thatthe snowmobile is in excellent oper-
ating condition at all times. It is strongly recommended that the operator as well
as an adult check major and vital safety components each time before riding.
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 which increase speed or power.
There is a significant possibility of loss of control at higher speeds.
Due to our concern for the safety of our customers and the general public, Polaris
hereby requests that consumers do not install on a Polaris snowmobile any equip-
ment which is intended to increase the speed or power of the machine, or make
any other modifications to the machines for these purposes. Any modifications to
the original equipment or the snowmobiles substantially increase the risk of bodily
injury. Be aware that these modifications may create a substantial safety hazard.
Polaris hereby informs you that the warranty on a snowmobile is terminated on the
entire machine if any such equipmenthas been added to the machine or any modi-
fications have been made to the machine which increase its speed or power.
We also advise you to strictly follow the recommended maintenance program out-
lined on pages A--30-A--55. This preventive maintenance program is designed to
ensure that all critical components on the snowmobile are thoroughly inspected by
your dealer at various mileage intervals.
Your snowmobile is not a toy. It is a well-engineered and well-constructed recre-
ational vehicle. The following information is provided to aid you in its safe opera-
tion.
NOTE: Warning decals have been placed on the vehicle for the operator’s protec-
tion. Make certain the operator understands the information on all the decals. In
the event 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: Although your Polaris has been designed to provide operators with a
safe, reliable snowmobile, much ofits safety depends on the operator and parents.
Improper use ofthis snowmobile or failure to maintain it in good operating condition
can result in injury. To reduce this possibility, read the following important safety
information and make certain the operators and guests are familiar with all the
warnings, cautions and safe operating procedures. They must also understand
the consequences and risks if they choose to ignore or neglect this information.