Polaris 120 User manual

Pantone 426C
Snowmobile Owner's Manual
for Maintenance and Safety

Pantone 426C
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]
Part No. 9922313 Rev 01
Printed in USA

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

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

1
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-
wide family of Polaris enthusiasts. Visit us online at www.polarisindus-
tries.com for the latest news, new product introductions, upcoming
events, career opportunities and more.
At Polaris we proudly produce an exciting line of utility and recreational
products.
• Snowmobiles
• All-terrain vehicles (ATVs)
•RANGER®utility vehicles
• Victory Motorcycles®
We believe Polaris sets a standard of excellence for all utility and recre-
ational vehicles manufactured in the world today. Many years of experi-
ence have gone into the engineering, design, and development of your
Polaris vehicle, making it the finest machine we've ever produced.
We also take great pride in our complete line of apparel, parts and acces-
sories, 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 supervi-
sion.
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 Master Service Dealer®(MSD) techni-
cian. Be sure to return to your dealership for all of your service needs
during, and after, the warranty period.
The preventive maintenance program outlined in this manual is
designed to ensure that all critical components on your child's snowmo-
bile are thoroughly inspected at various intervals. If you have any ques-
tions about the snowmobile, contact a Polaris dealer for assistance. See
page 82 for the part numbers of Polaris products.

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 THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2009 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 discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. 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.
2010 120 Snowmobile Owner's Manual
P/N 9922313

5
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Important Notes for Owners and Drivers. . . . . . . . . . . . 6
Preservation of the Environment. . . . . . . . . . . . . . . . . . 7
Vehicle Identification Numbers . . . . . . . . . . . . . . . . . . . 9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Youth Section . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Know Your Snowmobile . . . . . . . . . . . . . . . . . . . . . . . 14
Pre-Ride Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Riding Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adult Section . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pre-Ride Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Component Identification. . . . . . . . . . . . . . . . . . . . . . . 40
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Emission Control Information . . . . . . . . . . . . . . . . . . . 48
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 79
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 80
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 82
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 94
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

6
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient ref-
erence. It should remain with the snowmobile when the snowmobile is
sold.
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.
NOTE: The illustrations and photos used in this manual are general represen-
tations. Your model may differ.
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. Never
exceed the maximum rider weight capacity. See page 80.
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:
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.
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.

7
INTRODUCTION
Preservation of the Environment
Teach your child to drive their snowmobile with consideration for the
protection and preservation of the environment.
Noise
One of the most publicized subjects with regard to snowmobiles is
noise. The Society of Automotive Engineers (SAE), which is the stan-
dard-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 top-
ics. We will continue to participate in this type of study so that someday
we may find the answers to these difficult issues.

8
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 protec-
tion 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. Protect and preserve your right to ride by joining
your local trail riding clubs. Teach your child the following:
Respect your snowmobile;
respect your environment;
and you will earn
the respect of everyone.

9
INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile's identification numbers in the spaces pro-
vided.
Vehicle Model Number: ____________________________________________________
Tunnel VIN: _____________________________________________________________
(lower right side of the tunnel)
Engine Serial Number: ____________________________________________________
(right front side of engine crankcase)
Tunnel VIN

10
SAFETY
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols 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 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
injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE
A note will alert you to important information or instructions.

11
SAFETY
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 is a significant possibility of loss of con-
trol 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 cre-
ate 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 equip-
ment has been added to the vehicle, or if any modifications have been
made to the vehicle, that increase its speed or power.
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 warning decals
before operating a Polaris snowmobile. Adults must thoroughly explain this
information, including all safe operating procedures, to all operators of the
snowmobile. All operators must be at least six (6) years old and must under-
stand the consequences and risks if they choose to ignore or neglect this
information.

12
SAFETY
Maintenance Program
This snowmobile is not a toy. The information in this manual is pro-
vided to aid you in its safe operation.
For the safety of the operator, always 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 com-
ponents 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.

13
SAFETY
Safety Decals
Safety and warning decals have been placed on the vehicle for the oper-
ator'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. Replacement safety decals are provided
by Polaris at no charge. The part number is printed on the decal.
General Warning Decal
WARNING
• Read and understand warnings and
the Owner’s Manual before operation.
Severe injury or death can result from
not heeding the warnings.
• This vehicle is intended for daylight use
in restricted off-road areas clear of
obstacles, primarily on snow and not
on frozen bodies of water, by a child of
not less than 6 years of age who is in
the presence of, and in active supervi-
sion of an adult. Use of this vehicle on
public trails, streets, roads, and high-
ways can be hazardous and is prohib-
ited by law in most cases.
• Do not start or operate this vehicle without guards and shields in position, or
with hood not latched in place.
• This vehicle is intended for one operator only, no passenger. Passengers,
cargo, or towed objects can cause loss of control.
• Verify proper operation of all controls before starting the engine.
• When operating this vehicle, the operator shall wear suitable protective cloth-
ing including an approved safety helmet and shield or goggles.
• Securely attach the safety lanyard to the child’s body before starting the
engine.
• This vehicle can be operated between 0 and 8 mph (13 km/h). However, it is
recommended that the adult supervising the child regulate the maximum
speed to match the experience and ability of the child. Instructions for regulat-
ing maximum speed are provided in the Owner’s Manual.
• The Auxiliary Shut Off Switch is the primary means of stopping this vehicle in
case of emergency and is located on the top of the throttle control assembly.
Depress the switch to stop the engine. Routinely check this switch for proper
function with the engine idling.
• If Owner’s Manual is missing, contact a Polaris Dealer for a replacement.
General
Warning
Decal

14
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 snowmobile.
Engine Stop Switch
When the engine is running, push this button down to stop the engine.
Pull the stop switch up before trying to start the engine again.
Throttle Lever
The throttle lever makes your snowmobile go forward when you press it
with your thumb. Before you drive your snowmobile, always make sure
the throttle lever does not stick. Read more about it on page 19.
Brake Lever
Squeeze the brake lever toward the handlebar to make your snowmobile
slow down or stop.
Always take your thumb off the throttle lever when you squeeze the
brake lever.
Gas
Cap
Recoil Starter
Handle
Brake Lever
Throttle Lever
Engine Stop Switch
Choke
Knob
Hood
Hold-Down
Strap

15
YOUTH SECTION
Know Your Snowmobile
Gas Cap
An adult will take the gas cap off to put gas in your snowmobile. Never
take the gas cap off. Always make sure it's tightly closed.
Recoil Starter Handle
Pull the recoil starter handle to start your snowmobile. An adult will
help you start it the first time.
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 45.
Hood Hold-Down Strap
Two straps hold down the hood of your snowmobile. Always make sure
both hood straps are securely latched before you start the engine.
Tether Strap/Switch
Always attach the tether
strap to your body and to
the switch on your snow-
mobile every time you
drive. If you fall off your
snowmobile, the tether
strap will pull away from
the switch and the engine
will stop.
When you attach the strap
to your body, you can clip
it to a loop on your cloth-
ing, or you can wrap the
strap around your right
wrist and attach the clip to
the strap.
Always have an adult put gas in your snowmobile. Never try to do it
yourself.
Never ride without the tether strap attached to your body and to your
snowmobile. Be careful not to let the cord get tangled around the han-
dlebars or any part of your body.
Attach to
Switch
Attach to Loop or Wrist

16
YOUTH SECTION
Know Your Snowmobile
Let's learn more about the parts of your snowmobile before we learn
about riding.
Snow
Flap
Ski
Handlebar
Seat and
Storage
Hood
Headlight
Windshield
Trac k
Taillight