Owner's Manualfor Maintenanceand Safety2006Owner's Manualfor Maintenanceand Safety2006
7INTRODUCTIONAfter reading this manual, store it in the snowmobile for convenientreference. It should remain with the snowmobile when sold.n This manu
8INTRODUCTIONImportant Notes for Owners and DriversPARENTS: Do not allow anyone under the age of six (6) to operatethis machine. Review the informatio
9INTRODUCTIONPreservation of the EnvironmentTeach your child to drive their snowmobile with consideration for theprotection and preservation of the en
10INTRODUCTIONPreservation of the EnvironmentEnvironmental ProtectionAs part of the continuing environmental education campaign, we areencouraging sta
11INTRODUCTIONVehicle Identification NumbersThe frame vehicle identification number (VIN) and engine serialnumber are important for model identificati
12SAFETYWARNINGFailure to follow the warnings in this manual can result in severeinjury or death. Read and understand the owner’s manual and allwarnin
13SAFETYMaintenance ProgramAs with all snowmobiles, caution must be observed to ensure operatorsafety. Particular caution must be taken to make sure t
14SAFETYSafety DecalsSafety and warning decals have been placed on the vehicle for theoperator’s protection. Make sure the operator understands theinf
15SAFETYThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these wordsand symbols a
16YOUTH SECTIONKnow Your SnowmobileBefore you have an adult start the engine for you for the first time, let’slearn about the controls on your new mac
For your nearest Polaris dealer, call 1-800-POLARISor visit www.polarisindustries.comPolaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340Phone (763) 41
17YOUTH SECTIONKnow Your SnowmobileAlways take your thumb off the throttle lever when you squeezethe brake lever.6. Brake Lever - Squeeze the brake le
18YOUTH SECTIONKnow Your SnowmobileLet’s learn more about the parts of your snowmobile before we talkabout riding.12345698107
19YOUTH SECTIONKnow Your Snowmobile1. Hood - The hood covers the moving and hot parts of the engineand must be securely latched before you ride the sn
20YOUTH SECTIONKnow Your SnowmobileLet’s review the three ways to stop your snowmobile:1. Push the stop switch down.2. Pull off the tether strap.3. Tu
21YOUTH SECTIONPre-Ride CheckYou’re almost ready to have an adult start your snowmobile. Beforethe snowmobile is started for the first time, you must
22YOUTH SECTIONPre-Ride CheckAlways have an adult put gas in your snowmobile. Never try to doit yourself.n Have an adult check the gas level to see if
23YOUTH SECTIONRiding RulesNow you’re ready to learn about driving your Polaris snowmobile.There are some things you can do and there are some things
24YOUTH SECTIONRiding Rules" Always wear the right kind of clothing when you’re riding yoursnowmobile. You’ll need a good helmet with a face shie
25YOUTH SECTIONRiding Rules" Always drive your snowmobile while sitting down. Keep bothhands on the handlebars and keep both feet on the running
26YOUTH SECTIONRiding RulesLearn how to ride safely and correctly. Learn how to use your handsand arms as signals. Read and understand your Owner’s Ma
WARNINGWARNINGRead, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the
27ADULT SECTIONPre-Ride CheckIt’s up to you, the adult, to teach your child the proper and safe way toride a snowmobile. You must set boundaries and a
28ADULT SECTIONPre-Ride CheckBefore Starting The Enginen Read and Understand Your Owner ’s ManualRead and make sure the operators understand the Owner
29ADULT SECTIONPre-Ride Checkn Check throttle safety switchTest the throttle safety switch systemon a daily basis before the machineis used.While seat
30ADULT SECTIONPre-Ride Checkn Check engine stop switchTest the engine stop switch beforeeach use of the snowmobile. Tostop the engine in an emergency
31ADULT SECTIONOperation W arningsn Do not carry passengersThis snowmobile is designed for a single operator.n Do not operate with intake silencer rem
32ADULT SECTIONOperation W arningsn Do not touch the engine after it’s been runningWARNINGHot components can cause serious burns to skin. Do not touch
33ADULT SECTIONOperation W arningsn Check brake lever travelMeasure the clearancebetween the lever and brakeblock. Inspection should bemade with the l
34ADULT SECTIONOperation W arningsn Check surroundings to verify clear operating areaIt’s important to make sure there’s a clear area all around thesn
35ADULT SECTIONOperation W arningsn Stop engine before attempting adjustmentsWARNINGThe snowmobile engine compartment contains moving parts.Shields an
36ADULT SECTIONOperation W arningsn Know limitations of machine and skills of driverThe operator should be aware that there are state and local lawsgo
1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili
37ADULT SECTIONOperation W arningsWire fences are a serious hazard. Teachyour child to always be on the alert forfences. Single strands are especially
38ADULT SECTIONOperation W arningsWindchill/Temperature ChartsThe following information i s provided to help you determine whentemperatures become dan
39ADULT SECTIONOperation W arningsWindchill/Temperature ChartsWIND CHILL CHART (°C)WindSpeedinKPHActual Thermometer Reading (°C)5 2 -1 -4 -7 -10 -13 -
40ADULT SECTIONOperation W arningsCold Weather Drive-AwayWhenever the machine has been parked for some length of time,especially overnight, always sha
41ADULT SECTIONOperation W arningsSnow and Ice Build-UpSnow and ice buildup in the underhood area can interfere with thesteering.WARNINGBefore allowin
42ADULT SECTIONOperation W arningsDriving on IceIt is dangerous to operate on ice or under slippery conditions. If ice orslippery conditions are unavo
43ADULT SECTIONOperation W arningsDriving DownhillWhen riding downhill, the operator must keep the speed at a minimum.It is important to apply just en
44ADULT SECTIONComponent Identification1. Hood 8. Rear Suspension2. Headlight 9. Nosepan3. Windshield 10. Trailing Arm4. Handlebar 11. Skis5. Seat 12.
45ADULT SECTIONComponent Identification1. Stop S witch2. Tether Strap3. Throttle Control4. Recoil Starter Handle5. Hood Hold-Down6. Choke Button7. Gas
46ADULT SECTIONBreak-In PeriodEngine Break-InThe break-in period for your new snowmobile is defined as the first tenhours of operation, or the time it
2WELCOMEDear Par ents:We believe your children should have the opportunity to enjoy TheWay Out experience along with you. We’ve provided this owner’sm
47ADULT SECTIONBreak-In PeriodCAUTIONMixing brands or using a non-recommended oil may causeserious engine damage. We recommend the use of PolarisPremi
48ADULT SECTIONOperationFuelWhen refueling, use either leaded or unleaded gasoline with aminimum pump octane number of 87=(R+ M)/2 octane.Fuel SafetyW
49ADULT SECTIONOperationSpeed/Performance Regu lationAdults have the responsibility for teaching children the proper and safeway to ride a snowmobile.
50ADULT SECTIONOperationStarting the EngineNever start the snowmobile without checking all components to be sureof proper operation. Refer to the Pre-
51ADULT SECTIONOperationEmergency Stopping ProceduresThe following chart lists methods for stopping the engine in the eventof an emergency.SYSTEM WHAT
52ADULT SECTIONOperationPre-Ride W arm- UpAlways warm up the engine, drive train and track before operating thesnowmobile. With the snowmobile securel
53ADULT SECTIONEmission Control InformationEmission Control LabelYour snowmobile is equipped at t he time of sale with an emissioncontrol information
54ADULT SECTIONMaintenancePolaris Recommended Maint en an ce ProgramPlease read and follow the recommended maintenance programillustrated on the follo
55ADULT SECTIONMaintenanceCareful periodic m aintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adjustment and
56ADULT SECTIONMaintenanceITEM DAILY WEEKLY ORBEFOREEXTENDEDPERIOD OFOPERATION50HRS100HRS150HRSSEEPAG ECheck track alignment X 71Check drive chain ten
3WELCOMEDear Children:Before you ride your new Polaris snowmobile, there are someimportant things that you need to know. Your parents and Polaris want
57ADULT SECTIONMaintenanceSpark PlugsA new engine can cause temporary spark plug fouling even though theheat range is proper, due to the preservative
58ADULT SECTIONMaintenanceSpark PlugsSpark Plug Removal and Replacement1. Remove the spark plug cap.2. Using the special wrench provided in the tool p
59ADULT SECTIONMaintenanceCarburetorProper carburetor adjustment is critical, since a mixture too lean (toomuch air, too little fuel) will result in o
60ADULT SECTIONMaintenanceThrottle Cable LubricationWith the engine off, lubricate the throttlecable occasionally. Turn the handlebarsto the left and
61ADULT SECTIONMaintenanceBrake AdjustmentIf excessive brake lever to brake block clearance is evident, the brakecable should be adjusted. If proper a
62ADULT SECTIONMaintenanceChain TensionerInspect the chain. The chain should have 1″ of deflection as s hown. Ifnot, l oosen the nut on the chain tens
63ADULT SECTIONMaintenanceLubricationNOTE: Driveline noise is normal and inherent in a chain drivesystem such as this machine uses.To ensure long life
64ADULT SECTIONMaintenanceOil LevelMaintain the oil level between thesafe marks (A) on the dipstick.Oil ChangeChange the oil after the initial 20hours
65ADULT SECTIONMaintenanceControls and Linkag eAll bushings, spindle shafts, and tie rod ends should be coated with alight coat of oil or grease. Thro
66ADULT SECTIONMaintenanceEngineProper off-season preparation of the engine and fuel system is vital tothe prevention of rust and corrosion formation
4POLARIS a nd POLARIS THE WAY OUT are registered trademarks of PolarisIndustries Inc.Copyright 2005 Polaris Sales Inc. All information contained withi
67ADULT SECTIONMaintenanceCarburetor Protection During Off-Season StorageWhen preparing your snowmobile for off-season storage werecommend that you ad
68ADULT SECTIONMaintenanceTransporting the SnowmobileWhenever the snowmobile is transported the following measuresshould be taken:1. Turn the fuel val
69ADULT SECTIONMaintenanceWARNINGYour snowmobile is propelled by a revolving track, which must bepartially exposed for proper operation. Serious injur
70ADULT SECTIONMaintenanceTrack AdjustmentIf the track needs adjustment:1. Loosen rear idler shaft bolt (D).2. Tighten or loosen the track adjusting s
71ADULT SECTIONMaintenanceTrack AlignmentA periodic check should be made t o see that the track is centered andrunning evenly on the slide rails. Misa
72ADULT SECTIONMaintenanceTrack Warm UpWhen storing your snowmobileoutside overnight, it isrecommended t hat the track bewarmed up prior to driving th
73ADULT SECTIONMaintenanceTrack InspectionWARNINGInspecting the track while the engine is running can result inserious personal injury if the track sh
74ADULT SECTIONMaintenanceSlider ReplacementThe 120 snowmobile usesXTRA Lite style slider.When any area of the slider isworn to 7/16″ (1.1 cm), itshou
75ADULT SECTIONMaintenanceTrack LubricationTrack failure, loss of vehicle control and braking ability can result fromextended use of this vehicle on s
76ADULT SECTIONMaintenanceSteering Inspection and Adju stmentThe steering assembly of themachine should be checkedperiodically for loose nuts andbolts
5TABLE OF CONTENTSIntroduction 7...Important Notes for Owners and Drivers 8...Preservation of the Environment 9...
77ADULT SECTIONMaintenanceHandlebar Adjustment6. Slide the handlebar padupward to access the adjusterbolts. If additional room isrequired, unzip one o
78ADULT SECTIONMaintenanceSki SkagsThe skag (A) is a replaceable barattached to the underside ofthe ski. The purpose of theskag is to assist in turnin
79ADULT SECTIONMaintenanceSuspension LubricationTo maintain rider comfort and to retard wear of the pivot shafts, thesuspension pivot shafts should be
80ADULT SECTIONMaintenanceSuspension ComponentsSuspension Lubrication points are indicated by a L.1. Front Limiter Strap 8. Rail Bumper2. Torsion Spri
81ADULT SECTIONAccessoriesMaintenance Items and AccessoriesThe tools and maintenance items mentioned in this book, as well as along line of other Pola
82SPECIFICATIONSJetting ChartEngine Serial # up to 0502779AmbientTemperatureBelow-30_F(-34_C)-30_to-10_F(-34_to-23_C)-10_to+10_F-23_to-12_C+10_to+30_F
83SPECIFICATIONSCapacities and DimensionsBody Style Mini IndyRiders/Weight 1/150 lbs. (68 kg) maximumEngine Oil .6 qts. (.57 l)Dry Weight (est.) 147.5
84POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.)Gearcase / Transmission Lubricants287
85WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warrantyinform
86WARRANTYLimited W arrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar
87WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND FI
88WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if appl
89WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that we
90WARRANTYExported Veh iclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL
91WARRANTYSnowmobile Engine Emissions Limited WarrantyThis snowmobile engine emissions limited warranty is in addition to the Polaris standardlimited
92WARRANTYSnowmobile Engine Emissions Limited WarrantySome states do not allow limitations on how long an implied warranty lasts, so the abovelimitati
93MAINTENANCE LOGPresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future owners with
94MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
95MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS
96INDEXAAccessories 81......Auto Chain Tensioner 62....BBrake Adjustment 61.....Brake Lever Travel 60.....
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