Polaris 120 Guide

Owner's Manual
for Maintenance
and Safety
2006
Owner's Manual
for Maintenance
and Safety
2006

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone] Fax [phone]
Part No. 9919675
Printed in USA

WARNING
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.
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
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
manual contains instructions for minor maintenance, but information
about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!

2
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 84. 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.

3
WELCOME
Dear Children:
Before you ride your new Polaris snowmobile, there are some
important things that you need to know. Your parents and Polaris want
you to enjoy riding your new snowmobile, and 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
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris
Industries Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in U.S.A.
2006 120 Snowmobile Owner’s Manual P/N 9919675

5
TABLE OF CONTENTS
Introduction 7...............................
Important Notes for Owners and Drivers 8...........
Preservation of the Environment 9..................
Vehicle Identification Numbers 11...................
Safety 12....................................
YOUTH SECTION 17..........................
Know Your Snowmobile 17.........................
Pre-Ride Check 21................................
Riding Rules 23...................................
ADULT SECTION 27..........................
Pre-Ride Check 27................................
Operation Warnings 31............................
Component Identification 44........................
Break-In Period 46................................
Operation 48.....................................
Emission Control Information 53....................
Maintenance 54..................................
Accessories 81...................................
Troubleshooting 81................................
Specifications 82.............................
Polaris Products 84..........................
Warranty 85.................................
Maintenance Log 93..........................
Index 96.....................................

6

7
INTRODUCTION
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile when sold.
nThis manual contains the latest information at the time of printing.
We reserve the right to make product changes and improvements
without notice.
nThe illustrations and photos used in this manual are general
representations. Your model may differ.
nFollow 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.
nA table of Polaris-recommended products for your snowmobile is
provided on page 84.
nYou 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.
nProtect 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.

8
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.

9
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.

10
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.

11
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:
1. Tunnel VIN (lower right side of the tunnel)
________________________________________________________________
2. Engine Serial Number (right front side of engine crankcase)
________________________________________________________________
3. Key Number:
________________________________________________________________
1
31XX
3

12
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.

13
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.

14
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.

15
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
Acaution indicates a situation that may result in damage to the
vehicle.
IMPORTANT
IMPORTANT will alert you to important information or
instructions.
NOTE: Anote will alert you to key information or instructions.

16
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.
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 21.
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 50.
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.
2
1
3
5
6
4
78
99

17
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.