Polaris 2000 120 XCR User manual

BAR CODE
9920517
Cover_9920517 5/11/06 12:32 PM Page 1

2000-2007 120 YOUTH SNOWMOBILE
SERVICE MANUAL
FOREWORD
This service manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
proceduresinordertoperformtheworksafelyandcorrectly. Techniciansshouldreadthetextandbefamiliarwithservice
procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as
specified.
Comments or suggestions about this manual may be directedto: Service Publications Dept. @ Polaris Sales Inc. 2100
Hwy 55 Medina Minnesota 55340.
2000-2007 120 Youth Snomobile Service Manual PN 9920517
© Copyright 2006 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 forreference use only. No liability can be accepted for omissionsor 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.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS
Throughout this manual, important information is brought to your attention by the following symbols:
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or
person(s) inspecting or servicing the vehicle.
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle.
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE:
NOTE provides key information by clarifying instructions.
IMPORTANT:
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
MEASUREMENT provides a key for a determined measurement specification.
TORQUE provides a key for a required torque value.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
M-10, Registerd Trademark of FAST, Inc
Some Polaris factory publications can be downloaded from www.polarisindustires.com, purchased from www.purepolaris.com or
by contacting the nearest Polaris dealer.
WARNING
CAUTION
CAUTION
= In. / mm.
= T

MODEL SPECIFICATIONS
1.1
CHAPTER 1
MODEL SPECIFICATIONS 1
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2007 DRAGON 120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2
2006 120 PRO X. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4
2005 PRO X 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2004 120 PRO X - 2003 120XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8
2002 120 XC SP -2001 120 XCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2000 120 XCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

1.2
MODEL SPECIFICATIONS
SPECIFICATIONS
2007 DRAGON 120
ENGINE
Engine type Fuji
Engine displacement 121
Bore in/mm 2.36/60
Stroke in/mm 1.69/43
Piston to cylinder clearance in/mm .0006-.0029/.015-.074
Piston ring end gap in/mm .008-.016/.2-.4
Operating RPM±200 3600
Idle RPM±200 1650
Clutch engagement RPM ±200 1900
FUEL DELIVERY
Type Mikuni BV 18
Main Jet 70
Pilot Jet 50
Jet Needle/Clip position NA
Needle Jet NA
Throttle gap under cutaway in/
mm NA
Valve seat 1.6mm
Starter jet NA
Pilot air jet 1.3mm
Fuel screw setting 1.75 Turns
Air screw setting NA
Recommended fuel octane
(R+M/2) Min 87 non-oxy
JETTING
Altitude
meters (feet)
Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
0-600
(0-2000)
72.5
55
72.5
55
70
50
70
50
70
50
67.5
50
67.5
45
67.5
45
600-1200
(2000-4000)
70
50
70
50
70
50
67.5
50
67.5
50
67.5
50
65
45
65
45
1200-1800 (4000-
6000)
67.5
50
67.5
50
67.5
50
65
50
65
50
65
45
62.5
45
62.5
45
1800-2400 (6000-
8000)
65
50
65
50
65
50
65
50
65
45
62.5
45
62.5
45
60
45
2400-3000
(8000-10000)
65
50
65
50
62.5
50
62.5
45
60
45
60
45
60
45
60
45
3000-3700
(10000-12000)
62.5
50
62.5
50
60
45
60
45
60
45
57.5
45
57.5
45
57.5
45
Main jet is the first number and the pilot jet is the second number
CLUTCHING
Altitude meters (feet) Driven Helix Gearing
0-900
(0-3000) Red 10-42:74P #40
900-1800
(3000-6000) Red 10-42:74P
#40
1800-2700 (6000-9000) Red 10-42:74P
#40
2700-3700 (9000-12000) Red 10-42:74P
#40
CAPACITIES
Fuel gal/l .5/1.9
Oil qts/l .6/.6
Brake fluid type Mechanical
TRACK DIMENSIONS
Width in/cm 10/25
Length in/cm 69/175
Lug height in/cm .79/2.1
Track tension sag in/cm with
10 lbs/4.54kg placed 8 in/
20.3cm ahead of rear idler
shaft
.75/1.9

1.3
MODEL SPECIFICATIONS
1
FRONT SUSPENSION
Suspension type IFS
IFS shocks Arvin
IFS spring rate
lbs-in/kg-mm 80/1.43
IFS Spring installed length in/mm 6.75/17.1
Front vertical travel in/cm 3.0/7.62
Ski Center Distance 30/76.2
Camber in/mm N/A
Toe in/mm .125/.3175
REAR SUSPENSION
Suspension type Mini Indy
Front track shock (FTS) N/A
FTS Spring Rate
lbs-in/kg-mm N/A
FTS pre-load N/A
Rear track shock N/A
Rear travel in/cm 4.5/11.4
* notes that shock is rebuildable
Torsion spring PNs
(LH/RH)
7041844-067 LH
7041845-067 RH
Torsion spring diameter in/
mm .406
SLED DIMENSIONS
Width in/cm 34/86
Length in/cm 75/191
Height in/cm 31/79
Est dry weight lb/kg 145/65.8
ELECTRICAL
Ignition timing 23°@3600
Spark plug gap in/mm .028/.70
Spark plug NGK BR6ES
Voltage regulator/output 50w@3600

1.4
MODEL SPECIFICATIONS
2006 120 PRO X
ENGINE
Engine type Fuji
Engine displacement 121
Bore in/mm 2.36/60
Stroke in/mm 1.69/43
Piston to cylinder clearance in/mm .0006-.0029/.015-.074
Piston ring end gap in/mm .008-.016/.2-.4
Operating RPM±200 3600
Idle RPM±200 1650
Clutch engagement RPM ±200 1900
FUEL DELIVERY
Type Mikuni BV 18
Main Jet (Engine S# 0600001
and above) 70
Main Jet (Engine S# up to
0502779) 72.5
Pilot Jet 50
Jet Needle/Clip position N/A / N/A
Needle Jet N/A
Throttle gap under cutaway in/
mm N/A
Throttle slide cutaway 170 Throttle Valve
Valve seat 1.6mm
Starter jet N/A
Pilot air jet 1.3mm
Fuel screw setting (Engine S#
up to 0502779) 1.5
Fuel screw setting (Engine S#
0600001 and above) 1.75
Air screw setting N/A
Recommended fuel octane
(R+M/2)
87 Oct. Non oxy/89 Oct.
Oxy
JETTING FOR ENGINE S# 0600001 AND ABOVE
Altitude
meters (feet)
Ambient Temperature
< -25°F/<-35°C
-30°F to -10°F/-34°C to -23°C
-15°F to +5°F/-26°C to -15°C
0°F to +20°F/-18°C to -7°C
+15°F to +35°F/-9°C to +2°C
+30°F to +50°F/-1°C to +10°C
+45°F to +65°F/+7°C to +18°C
>+60°F/>+16°C
0-600
(0-2000)
72.5
55
72.5
55
70
50
70
50
70
50
67.5
50
67.5
45
67.5
45
600-1200
(2000-4000)
70
50
70
50
70
50
67.5
50
67.5
50
67.5
50
65
45
65
45
1200-1800 (4000-
6000)
67.5
50
67.5
50
67.5
50
65
50
65
50
65
45
62.5
45
62.5
45
1800-2400 (6000-
8000)
65
50
65
50
65
50
65
50
65
45
62.5
45
62.5
45
60
45
2400-3000
(8000-10000)
65
50
65
50
62.5
50
62.5
45
60
45
60
45
60
45
60
45
3000-3700
(10000-12000)
62.5
50
62.5
50
60
45
60
45
60
45
57.5
45
57.5
45
57.5
45
Main jet is the first number and the pilot jet is the second number
JETTING FOR ENGINE BELOW S# 0502779
Altitude
meters (feet)
Ambient Temperature
< -30°F/<-34°C
-30°F to -10°F/-34°C to -23°C
-10°F to +10°F/-23°C to -12°C
+10°F to +30°F/-12°C to -1°C
+30°F to +50°F/-1°C to +10°C
>50°F />+10°C
0-600
(0-2000) 75 72.5 72.5 72.5 70 70
600-1200
(2000-4000) 75 72.5 72.5 72.5 70 70
1200-1800 (4000-
6000) 72.5 70 70 70 67.5 67.5
1800-2400 (6000-
8000) 70 67.5 67.5 67.5 65 65
2400-3000
(8000-10000) 67.5 65 65 65 65 65
3000-3700
(10000-12000) 65 65 65 65 65 65
CLUTCHING
Altitude meters (feet) Driven Helix Gearing
0-900
(0-3000) Red 10-42:74P #40
900-1800
(3000-6000) Red 10-42:74P #40
1800-2700 (6000-9000) Red 10-42:74P
#40
2700-3700 (9000-12000) Red 10-42:74P
#40

1.5
MODEL SPECIFICATIONS
1
CAPACITIES
Fuel gal/l .5/1.9
Oil qts/l .6/.6
Brake fluid type Mechanical
TRACK DIMENSIONS
Width in/cm 10/25
Length in/cm 69/175
Lug height in/cm .79/2.1
Track tension sag in/cm with
10 lbs/4.54kg placed 8 in/
20.3cm ahead of rear idler
shaft
.75/1.9
FRONT SUSPENSION
Suspension type IFS
IFS shocks Arvin
IFS spring rate
lbs-in/kg-mm 80/1.43
IFS Spring installed length in/mm 6.75/17.1
Front vertical travel in/cm 3.0/7.62
Ski Center Distance 30/76.2
Camber in/mm N/A
Toe in/mm .125/.3175
REAR SUSPENSION
Suspension type Mini Indy
Rear travel in/cm 4.5/11.4
* notes that shock is rebuildable
Torsion spring PNs
(LH/RH)
7041844-067 LH
7041845-067 RH
Torsion spring diameter in/
mm .406
SLED DIMENSIONS
Width in/cm 34/86
Length in/cm 75/191
Height in/cm 31/79
Est dry weight lb/kg 145/65.8
ELECTRICAL
Ignition timing 23°@3600
Spark plug gap in/mm .028/.70
Spark plug NGK BR6ES
Voltage regulator/output 50w@3600

1.6
MODEL SPECIFICATIONS
2005 PRO X 120
ENGINE
Engine Model Number EH122PM015
Engine type Fuji
Engine displacement 121
Bore in/mm 2.36/60
Stroke in/mm 1.69/43
Piston to cylinder clearance in/mm .0006-.0029/.015-.074
Piston ring end gap in/mm .008-.016/.2-.4
Operating RPM±100 3600
Idle RPM±200 1600
Clutch engagement RPM ±200 1900
FUEL DELIVERY
Type Mikuni BV 18
Main Jet 72.5
Pilot Jet 50
Jet Needle/Clip position N/A / N/A
Needle Jet N/A
Throttle gap under cutaway
in/mm N/A
Throttle slide cutaway 170 Throttle Valve
Valve seat 1.6mm
Starter jet N/A
Pilot air jet 1.3mm
Fuel screw setting 1.5
Air screw setting N/A
Recommended fuel octane
(R+M/2)
87 Oct. Non oxy/89 Oct.
Oxy
JETTING
Altitude
meters (feet)
Ambient Temperature
< -30°F/<-34°C
-30°F to -10°F/-34°C to -23°C
-10°F to +10°F/-23°C to -12°C
+10°F to +30°F/-12°C to -1°C
+30°F to +50°F/-1°C to +10°C
>50°F />+10°C
0-600
(0-2000) 75 72.5 72.5 72.5 70 70
600-1200
(2000-4000) 75 72.5 72.5 72.5 70 70
1200-1800 (4000-
6000) 72.5 70 70 70 67.5 67.5
1800-2400 (6000-
8000) 70 67.5 67.5 67.5 65 65
2400-3000
(8000-10000) 67.5 65 65 65 65 65
3000-3700
(10000-12000) 65 65 65 65 65 65
CLUTCHING
Altitude meters (feet) Driven Helix Gearing
0-900
(0-3000) Red 10-42:74P #40
900-1800
(3000-6000) Red 10-42:74P #40
1800-2700 (6000-9000) Red 10-42:74P
#40
2700-3700 (9000-12000) Red 10-42:74P
#40
CAPACITIES
Fuel gal/l .5/1.9
Oil qts/l .6/.6
Coolant qts/l N/A
Chaincase oz/ml N/A
Brake fluid type Mechanical
TRACK DIMENSIONS
Width in/cm 10/25
Length in/cm 69/175
Lug height in/cm .79/2.1
Track tension sag in/cm with 10
lbs/4.54kg placed 8 in/20.3cm
ahead of rear idler shaft
.75/1.9

1.7
MODEL SPECIFICATIONS
1
FRONT SUSPENSION
Suspension type IFS
IFS shocks Arvin
REAR SUSPENSION
Suspension type Mini Indy
Rear travel in/cm 6.9/17.5
* notes that shock is rebuildable
Torsion spring PNs
(LH/RH)
7041844-067 LH
7041845-067 RH
Torsion spring diameter in/
mm .406
SLED DIMENSIONS
Width in/cm 34/86
Length in/cm 75/191
Height in/cm 31/79
Est dry weight lb/kg 147/67
ELECTRICAL
Ignition timing 26°@3600
Spark plug gap in/mm .028/.70
Spark plug NGK BR6ES
Voltage regulator/output 50w@3600

1.8
MODEL SPECIFICATIONS
2004 120 PRO X - 2003 120XC SP
ENGINE
Engine Model Number 2004-EH122PM014
2003-EH122PM013
Engine type Fuji
Engine displacement cc’s 121
Bore in/mm 2.36(60)
Stroke in/mm 1.57(43)
Piston to cylinder clearance in/mm .0006-.0029/.015-.074
Piston ring end gap in/mm .008-.016/.2-.4
Operating RPM±100 3600
Idle RPM±200 1600
Clutch engagement RPM ±200 1900
FUEL DELIVERY
Type Mikuni BV 18
Main Jet 72.5
Pilot Jet 50
Jet Needle/Clip position NA/NA
Needle Jet NA
Throttle gap under cutaway in/mm NA
Throttle slide cutaway 170 Throttle Valve
Valve seat 1.6mm
Starter jet NA
Pilot air jet 1.3mm
Fuel screw setting 1.5 Turns
Air screw setting NA
Recommended fuel octane (R+M/2) 87 Oct Non Oxy/89 Oct
Oxy
JETTING
Altitude
meters (feet)
Ambient Temperature
< -30°F/<-34°C
-30°F to -10°F/-34°C to -23°C
-10°F to +10°F/-23°C to -12°C
+10°F to +30°F/-12°C to -1°C
+30°F to +50°F/-1°C to +10°C
>50°F />+10°C
0-600
(0-2000) 75 72.5 72.5 72.5 70 70
600-1200
(2000-4000) 75 72.5 72.5 72.5 70 70
1200-1800 (4000-
6000) 72.5 70 70 70 67.5 67.5
1800-2400 (6000-
8000) 70 67.5 67.5 67.5 65 65
2400-3000
(8000-10000) 67.5 65 65 65 65 65
3000-3700
(10000-12000) 65 65 65 65 65 65
CLUTCHING
Altitude meters (feet) Driven Helix Gearing
0-900
(0-3000) Red 10-42:74P #40
900-1800
(3000-6000) Red 10-42:74P #40
1800-2700 (6000-9000) Red 10-42:74P
#40
2700-3700 (9000-12000) Red 10-42:74P
#40
CAPACITIES
Fuel gal/l .5/1.9
Oil qts/l .6/.6
Coolant qts/l N/A
Chaincase oz/ml N/A
Brake fluid type Mechanical
TRACK DIMENSIONS
Width in/cm 10/25
Length in/cm 69/175
Lug height in/cm .79/2.1
Track tension sag in/cm with 10
lbs/4.54kg placed 8 in/20.3cm
ahead of rear idler shaft
.75/1.9

1.9
MODEL SPECIFICATIONS
1
FRONT SUSPENSION
Suspension type IFS
IFS shocks Arvin
REAR SUSPENSION
Suspension type Mini Indy
Rear travel in/cm 6.9/17.5
* notes that shock is rebuildable
Torsion spring PNs
(LH/RH)
7041844-067 LH
7041845-067 RH
Torsion spring diameter in/
mm .406
SLED DIMENSIONS
Width in/cm 34/86
Length in/cm 75/191
Height in/cm 31/79
Est dry weight lb/kg 147/67
ELECTRICAL
Ignition timing 23°@3600
Spark plug gap in/mm .028/.70
Spark plug NGK BR6ES
Voltage regulator/output 50w@3600

1.10
MODEL SPECIFICATIONS
2002 120 XC SP -2001 120 XCR
ENGINE
Engine Model Number 2001-EH122PM012
2001-EH122PM011
Engine type Fuji
Engine displacement cc’s 121
Bore in/mm 2.36(60)
Stroke in/mm 1.57(43)
Piston to cylinder clearance in/mm .0006-.0029/.015-.074
Piston ring end gap in/mm .008-.016/.2-.4
Operating RPM±100 3600
Idle RPM±200 1600
Clutch engagement RPM ±200 1900
FUEL DELIVERY
Type Mikuni BV 18
Main Jet 72.5
Pilot Jet 50
Jet Needle/Clip position NA/NA
Needle Jet NA
Throttle gap under cutaway in/mm NA
Throttle slide cutaway 170 Throttle Valve
Valve seat 1.6mm
Starter jet NA
Pilot air jet 1.3mm
Fuel screw setting 1.5 Turns
Air screw setting NA
Recommended fuel octane (R+M/2) 87 Oct Non Oxy/89 Oct
Oxy
JETTING
Altitude
meters (feet)
Ambient Temperature
< -30°F/<-34°C
-30°F to -10°F/-34°C to -23°C
-10°F to +10°F/-23°C to -12°C
+10°F to +30°F/-12°C to -1°C
+30°F to +50°F/-1°C to +10°C
>50°F />+10°C
0-600
(0-2000) 75 72.5 72.5 72.5 70 70
600-1200
(2000-4000) 75 72.5 72.5 72.5 70 70
1200-1800 (4000-
6000) 72.5 70 70 70 67.5 67.5
1800-2400 (6000-
8000) 70 67.5 67.5 67.5 65 65
2400-3000
(8000-10000) 67.5 65 65 65 62.5 62.5
3000-3700
(10000-12000) 65 62.5 52.5 62.5 60 60
CLUTCHING
Altitude meters (feet) Driven Helix Gearing
0-900
(0-3000) Red 10-42:74P #40
900-1800
(3000-6000) Red 10-42:74P #40
1800-2700 (6000-9000) Red 10-42:74P
#40
2700-3700 (9000-12000) Red 10-42:74P
#40
CAPACITIES
Fuel gal/l .5/1.9
Oil qts/l .6/.6
Coolant qts/l N/A
Chaincase oz/ml N/A
Brake fluid type Mechanical
TRACK DIMENSIONS
Width in/cm 10/25
Length in/cm 69/175
Lug height in/cm .79/2.1
Track tension sag in/cm with 10
lbs/4.54kg placed 8 in/20.3cm
ahead of rear idler shaft
.75/1.9

1.11
MODEL SPECIFICATIONS
1
FRONT SUSPENSION
Suspension type IFS
IFS shocks Arvin
REAR SUSPENSION
Suspension type Mini Indy
Rear travel in/cm 6.9/17.5
* notes that shock is rebuildable
Torsion spring PNs
(LH/RH)
7041844-067 LH
7041845-067 RH
Torsion spring diameter in/
mm .406
SLED DIMENSIONS
Width in/cm 34/86
Length in/cm 75/191
Height in/cm 31/79
Est dry weight lb/kg 147/67
ELECTRICAL
Ignition timing 23°@3600
Spark plug gap in/mm .028/.70
Spark plug NGK BR6ES
Voltage regulator/output 50w@3600

1.12
MODEL SPECIFICATIONS
2000 120 XCR
ENGINE / DRIVETRAIN
Engine Model Number 2000-EH122PM010
Bore/Stroke (in/mm) 2.36x1.57 (60x43)
Cylinder Liner Iron
Displacement (cc)/Cylinders/
Type 121cc/1/Fan
Ignition Solid State
Exhaust Single
Induction Type 4 Stroke OHV
Brake System Mechanical Drum
Parking Brake N/A
FUEL DELIVERY
Type Mikuni BV 18
Main Jet 72.5
Pilot Jet 50
Jet Needle/Clip position NA/NA
Needle Jet NA
Throttle gap under cutaway in/mm NA
Throttle slide cutaway 170 Throttle Valve
Valve seat 1.6mm
Starter jet NA
Pilot air jet 1.3mm
Fuel screw setting 1.5 Turns
Air screw setting NA
Recommended fuel octane (R+M/2) 87 Oct Non Oxy/89 Oct
Oxy
SUSPENSION
FRONT
Type Mini IFS
Travel (in/cm) 3/7.6
IFS Shock/Spring Mini/Washer
Ski Type Composite
Torsion Bar N/A
Rear
Type Mini
Travel (in/cm) 6.9/17.5
Front Track Shock/Rear
Shock N/A
Track (WxLxLug)(in/cm) 10x69x.79 (25.4x175.3x2)
JETTING
Altitude
meters (feet)
Ambient Temperature
< -30°F/<-34°C
-30°F to -10°F/-34°C to -23°C
-10°F to +10°F/-23°C to -12°C
+10°F to +30°F/-12°C to -1°C
+30°F to +50°F/-1°C to +10°C
>50°F />+10°C
0-600
(0-2000) 75 72.5 72.5 72.5 70 70
600-1200
(2000-4000) 75 72.5 72.5 72.5 70 70
1200-1800 (4000-
6000) 72.5 70 70 70 67.5 67.5
1800-2400 (6000-
8000) 70 67.5 67.5 67.5 65 65
2400-3000
(8000-10000) 67.5 65 65 65 65 65
3000-3700
(10000-12000) 65 65 65 65 65 65
CLUTCHING
Altitude meters (feet) Driven Helix Gearing
0-900
(0-3000) Red 10-42:74P #40
900-1800
(3000-6000) Red 10-42:74P
#40
1800-2700 (6000-9000) Red 10-42:74P
#40
2700-3700 (9000-12000) Red 10-42:74P
#40
DIMENSIONS / CAPACITIES
Estimated Dry Weight (lb./kg) 140/63.5
Recommended Rider Weight
(lb./kg) 130/59
Length (in/cm) 75/191
Width (in/cm) 34/86.4
Ski Center (in/cm) 30/76.2
Height (in/cm) 31/78.7
Fuel Capacity (gal/l) .5/1.9
SUSPENSION

GENERAL
2.1
CHAPTER 2
GENERAL 2
HOW TO USE THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
MODELS LISTED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2
GEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2
JETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2
ABBREVEATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2
SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MODEL NUMBER DESIGNATION EXAMPLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
TUNNEL DECAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3
VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
MISC. PUBLICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4
2007 SERVICE PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4
GENERAL REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
2 STROKE GASOLINE / OIL PRE MIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9

2.2
GENERAL
HOW TO USE THIS MANUAL
MODELS LISTED
The set up of the specification section is grouped by engine size.
GEARING
Gearing that is called out in the clutching table is stated as TOP
GEAR (total number of teeth): BOTTOM GEAR (total number
of teeth) - CHAIN PITCH (total number of links)
Example 22:39-76
• Top Gear = 22 tooth
• Bottom Gear = 39 tooth
• Drive Chain = 76 pitch (links)
Production setting is designated in the shaded areas
JETTING
Jetting chart is called out in the Jetting table.
ABBREVEATIONS
The following chart explains the abbreviations that are used
throughout this section.
ABBREVIATION MEANING
PTO Power Take Off
MAG Magneto
RTA Rear Torque Arm
FTA Front Torque Arm
cc cubic centimeters
RPM Revolutions Per Minuet
PERC Polaris Electric Reverse
Control
ft-lb foot pounds
Nm newton meters
CDI Capacitor Discharge
Ignition
kg-mm kilograms per millimeter
lb.-in pounds per inch
FS Four Stroke (Non-Turbo)
FST Four Stroke Turbo

2.3
GENERAL
2
SNOWMOBILE NUMBER DESIGNATIONS
MODEL NUMBER DESIGNATION EXAMPLE
S06MC6FS (2006 600 HO DRAGON FUSION)
VEHICLE IDENTIFICATION NUMBER (VIN)
TUNNEL DECAL
The Tunnel Decal has the Model Number (1), V.I.N. Number (2), and the Manufactured Date (3).These numbers should be referred
to in any correspondence regarding warranty, service or replacement parts.The machine model and V.I.N. number identification decal
is located on the right front side of the tunnel. The V.I.N (2) number is permanently stamped into the tunnel. The model number is
embossed on the decal.
IDENTIFIER MODEL
YEAR MODEL LINE MODEL TYPE ENGINE MODIFIER VIN IDENTIFIER OPTION IDENTIFIER
1st digit 2/3rd digit 4th digit 5th digit 6th digit* 7th digit* 8th digit 9th digit**
S 06 P S 8 D S A
S=Snow
07=2007
06=2006
05=2005
04=2004
M=Race IQ
N=Edge
P= IQ
S=GenII
W=Mini Indy
C=Dragon 121
D=Classic
F=Classic LTD
J=136 RMK
K=144 RMK
L=155 Assault
M=155 RMK
N=166 RMK
P=Performance
S=Switchback
T=Touring
U=Utility
Touring Limited
1A=121 F/C OHV 4 Cycle Fuji
3A=340 F/C Piston Port
4B=488 L/C Piston Port
4C=440 EV L/C Piston Port
5B=544 F/C Cylinder Reed
5C=500 EV L/C Case Reed 2 Cyl Liberty
6F=600 EV L/C Case Reed HP 2 Cyl Liberty
6H=600 EV L/C Case Reed SDI 2 Cyl Liberty
7E=750 2 Cyl FS Webber
7F=750 Turbo2 Cyl FS Webber
7H=755 EV SDI Case Reed Liberty
7J=700 EV L/C Case Reed SDI 2 Cyl Liberty
8D=866 EV SDI Case Reed Liberty
E=Europe
Unit
M=Military
R=Rolling
Chassis
S=Standard
Production
Unit
V=
Validation
Option
Identifier
*=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
**=9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are sued in model number only. They are not used with the 17 digit VIN.
02'(/ 12
9,1 12
0)' '$7(
7+,6 9(+,&/( &21)2506 72 $// $33/,&$%/(
86 )('(5$/ $1' 67$7( 5(48,5(0(176 $1'
&$1$'$ 02725 9(+,&/( 6$)(7< 67$1'$5'6
,1 ())(&7 21 7+( '$7( 2) 0$18)$&785(
0$'( ,1 86$
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0IG E\ 3RODULV ,QGXVWULHV ,QF LQ 5RVHDX 01 XQGHU RQH RU
PRUH RI WKH IROORZLQJ SDWHQWV
86 3DWHQWV
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  
3$7(17 127,&(
3DWHQWHG &DQDGD
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1
2
3

2.4
GENERAL
2
VIN NUMBER DESIGNATION
PUBLICATION PART NUMBERS
Misc. Publications
2007 Service Publications
World Mfg. ID
Vehicle Descriptors Vehicle Identifiers
Body Style Type Engine Size Engine Modifier Series Check Digit Model Year Mfg. Location Individual Serial No.
1234567891011121314151617
SN1SB5BS022000000
YEAR PUBLICATION PART NUMBER
2007 2007 Specification/Quick Reference Manual 9920653
2007 2007 Wiring Diagrams 9920688
ALL Track Diagnosis Poster 9918459
2006 2006 Specification/Quick Reference Manual 9920147
2006 2006 Wiring Diagrams 9920672
ALL Monotube Shock Rebuilding Video 9917736
ALL Remote Reservoir Shock Rebuilding 9917737
2007 MODEL MODEL
NUMBER OWNER'S MANUAL
OWNER'S
MANUAL
SUPPLEMENT PARTS BOOK PARTS
MICROFISCHE ASSEMBLY INSTRUCTIONS SERVICE MANUAL
440 IQ S07MX4CS 9920432 9920433 9920434 9920435 9919882 9920436
340 Edge LX S07ND3AS 9920437 9920438 9920442 9920443 9916508 9920444
550 Edge LX S07ND5BS 9920437 9920439 9920445 9920446 9916508 9920444
Trail RMK S07NJ5BS 9920449 9920450 9920451 9920452 9919882 9920444
Supersport EDGE S07NP5BS 9920437 9920440 9920445 9920446 9916508 9920444
500 XCSP S07NP5CS 9920437 9920441 9920447 9920448 9916508 9920444
Indy 340 Touring S07NT3AS 9920449 9920453 9920454 9920455 9916508 9920444
Trail Touring Deluxe S07NT5BS 9920449 9920456 9920457 9920458 9916508 9920444
Trail Touring Deluxe Opt. S07NT5BSA 9920449 9920456 9920457 9920458 9916508 9920444
700 SDI IQ Dragon S07PC7JS 9920648 9920460 9920461 9920462 9919882 9920463
600 SDI IQ LX S07PD6HS 9920464 9920465 9920466 9920467 9916508 9920463
FST IQ LX S07PD7FS 9920468 9920473 9920474 9920475 9916508 9920472
FST IQ LX LTD S07PF7FS 9920468 9920473 9920474 9920475 9916508 9920472
600 RMK 144 S07PK6FS 9920476 9920477 9920478 9920479 9919882 9920463
700 RMK Dragon S07PL7JS
600 RMK 155 F/O S07PM6FS 9920476 9920483 9920478 9920479 9919882 9920463
600 RMK 155 Stock A S07PM6FSA 9920476 9920483 9920478 9920479 9919882 9920463
600 HO IQ S07PP6FS 9920459 9920460 9920461 9920462 9919882 9920463
600 HO IQ Stock A S07PP6FSA 9920459 9920460 9920461 9920462 9919882 9920463

2.5
GENERAL
2
600 HO IQ Stock B S07PP6FSB 9920459 9920460 9920461 9920462 9919882 9920463
600 SDI IQ S07PP6HS 9920464 9920487 9920466 9920467 9919882 9920463
600 SDI IQ Stock A S07PP6HSA 9920464 9920487 9920466 9920467 9919882 9920463
600 SDI IQ Stock B S07PP6HSB 9920464 9920487 9920466 9920467 9919882 9920463
FST IQ S07PP7FS 9920468 9920488 9920474 9920475 9919882 9920472
600 HO IQ Switchback F/ S07PS6FS 9920459 9920597 9920598 9920599 9916508 9920463
600 HO IQ Switchback F/ S07PS6FSA 9920459 9920597 9920598 9920599 9916508 9920463
600 SDI IQ Switchback F/ S07PS6HS 9920464 9920495 9920496 9920497 9916508 9920463
600 SDI IQ Switchback F/ S07PS6HSA 9920464 9920495 9920496 9920497 9916508 9920463
FST IQ Switchback S07PS7FS 9920468 9920498 9920499 9920500 9916508 9920463
600 SDI IQ Touring S07PT6HS 9920464 9920501 9920502 9920503 9916508 9920463
FS IQ Touring S07PT7ES 9920468 9920504 9920505 9920506 9916508 9920472
FST IQ Touring S07PT7FS 9920468 9920507 9920508 9920509 9916508 9920472
FST IQ Touring LTD S07PY7FS 9920468 9920507 9920508 9920509 9916508 9920472
Widetrak LX S07SU4BS 9920449 9920510 9920511 9920512 9916508 9920444
120 S07WB1AS 9920513 no supply. 9920515 9920516 9916891 9920517
2007 MODEL MODEL
NUMBER OWNER'S MANUAL
OWNER'S
MANUAL
SUPPLEMENT PARTS BOOK PARTS
MICROFISCHE ASSEMBLY INSTRUCTIONS SERVICE MANUAL