UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: &The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person in- specting or servicing the snowmobile. Failure to follow WARNING instructions could result in se- vere injury or death to the operator, bystander or person inspecting or servicing the snowmobile. A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks GENERAl MAINTENANCE ENGINE/CARBURETOR/ClUTCH BODY AND STEERING SUSPENSION ElECTRICAl Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation

CHAPTER 1 GENERAL INFORMATION 120 Publication Part Numbers .................. 1.1 120 Paint Codes ............................. 1 .1 Standard Torque Specifications ................ 1.1 Model Specifications .......................... 1.2 - 1.5 Model Identification Numbers .................. 1.6 Vehicle Identification Numbers ................. 1. 7 Decimal Equivalents .......................... 1.8 Tap Drill Sizes ................................ 1.9 Conversion Table ............................. 1.10 Glossary ..................................... 1.11 - 1.13 Service Tips ................................. 1.14 Service Tools ................................ 1.15

GENERAL INFORMATION Notes @POLRRIS' 1.1

GENERAL INFORMATION Publication Numbers Model Model No. Owner's Manual Parts Parts (Supplement) Book Microfiche 2006 120 PRO X S06WB1AS N/A 9920515 9920516 2005 120 PRO X S05WB1A(E,S) 9919072 9919296 9919297 2004 120 PRO X S04WB1AS 9918224 9917841 9917842 (9918485) 2003 120 XC SP S03WB1AS 9917596 9917841 9917842 2002 120 XC SP S02WB1AS 9916888 9916889 9916890 2001120XCSP S01WB1AS 9916125 9916126 9916127 2000 120 XC SP SOOWB1AS 9915512 9915619 9915620 Polaris Snowmobile Paint Codes Model Trailing Arm Color Polaris Spring Color Polaris "P" Description "P" No. Description No. ALL 120 Indy Red P293 Indy Red P293 Dealer orders can be placed through Midwest Industrial Coatings using the Polaris "P" number. Phone (952-942-1836). Mix as directed. Standard Torque Specifications The following torque specifications are to be used as a general guideline when torque value is not specified. There are exceptions in the steering, suspension, and engine areas. Always consult the torque chart and the specific manual section for torque values of fasteners. 0 Bolt Size Threads/In (MM/Thread) Grade 2 Grade 5 Grade 8 Torgue in. lbs. INml #1 0 24 .............. 27 (3.1) ................ 43 (5.0) .. .. . .. .. .. .. . 60 (6.9) #1 0 32 .............. 31 (6.3) ................ 49 (5.6) . .. .. .. . . .. . .. 68 (7.8) Torgue ft. lbs. INml* 1/4 20 .............. 5 (7) .................. 8 (11) ................ 12 (16) 1/4 28 .............. 6 (8) .................. 10 (14) .............. 14 (19) 5/16 18 .............. 11 (15) ................ 17 (23) .............. 25 (35) 5/16 24 .............. 12 (16) ................ 19 (26) .............. 29 (40) 3/8 16 .............. 20 (27) ................ 30 (40) .. .. . .. .. .. .. . 45 (62) 3/8 24 .............. 23 (32) ................ 35 (48) . . . . . . . . . . . . . . 50 (69) 7/16 14 .............. 30 (40) ................ 50 (69) .. .. . . .. .. . .. . 70 (97) 7/16 20 .............. 35 (48) ................ 55 (76) .............. 80 (110) 1/2 13 .............. 50 (69) ................ 75 (104) ............. 110 (152) 1/2 20 .............. 55 (76) ................ 90 (124) .. .. .. .. .. .. . 120 (166) 6mm x 1.0mm .............. 72-78 in. lbs (8.3-9.0 Nm) 8mm x 1.25mm ............. 14-18 ft.lbs (19.0-25.0 Nm) 10mm x 1.25mm ............ 26-30 ft.lbs (36.0-41.0 Nm) *To convert ft. lbs. to Nm multiply foot pounds by 1.356. *To convert Nm to ft.lbs. multiply Nm by .7376. 1.2 @PDLRRIS

GENERAL INFORMATION 2006 Model Specifications Model Number S06WB1AS Chassis Kids - Estimated Dry Weight 145165.8 (lb/kg) Recommended Rider 130159 Weight Overall Length (in/em.) 751191 Width (in/em.) 34186 Ski Center (in/em.) 30176.2 Height (in/em.) 31179 Fuel Capacity (US Gai/L) .511.9 Oil Capacity US QtJL) .6/.6 ~ IRIIm:(~ Carburetor Model Mikuni BVI18 Main Jet Pilot Jet Jet Needle I Clip Position • Jet Cutaway Throttle Gap Under Cut- away (mm) Fuel Screw 70 {Eng Sl/0600001and above) 72.5 (Eng S#0502779) 50 N/A/ N/A N/A 170 Throttle Valve N/A 1 .75 Turns (Eng S/10600001 and above) 1.5 TurnS(Eng S#0502779J ~~~UN~~~.~~~~t---~A~ir~S~c;re:w~---t------~NU./A~-----l Engine Model Number EH122PM016 Pilot Air Jet 1.3mm Spark Plug NGK BR6ES Idle RPM 1600 Spark Plug Gap (mm/in) Bore I Stroke (in/mm) Cylinder Liner Displacement(cc) I Cylin- ders I Type Ignition Exhaust Type Travel (in/em.) IFS Shock/Spring Adj. 0.70 I 0.28 2.36x1.57 (60 x 43) Iron 121 cc I 1 I Fan Solid State Single Mini IFS 317.6 Arvin I Washer Ski Type Composite Ignition Timing 26° @ 3600 Brake "Y"'"'" Mechanical Drum Parking Brake Type Travel (in/em.) Front Shock I Rear Shock Y<·'·····•·· fi';''.,/\:'<'·L·c:·· NIA Rear Mini Indy 6.9117.5 NIA 1-S_k_i _R_un_n_e_r ---------1-----W_e_l_d-_S_k_a_g ____ -l Track (W x L x Lug) (in/ Torsion Bar NIA em.) 10 X 69 X .79 (25.4x175.3x2) @POLARIS 1.3

GENERAL INFORMATION Below -30"F -30" to -10°F -10°!0 +10"F Below -34°C -34°to -23°C -23" to -12"C 75 72.5 72.5 75 72.5 72.5 72.5 70 70 Meters 1800-2400 (Feet) (6000-8000) 70 67.5 67.5 2400-3000 (8000-1 0000) 67.5 65 65 3000-3700 (1 0000-12000) 65 65 65 Jetting Chart for Eng S# 0600001 and above Main jet is the first number and the pilot jet is the second number. 0-600 Meters (Feet} 1800-2400 (6000-8000) 2400-3000 (8000-1 0000) 3000-3700 (1 0000-12000) Meters (Feet) 1.4 <-25°F/<-35° c 72.5 55 70 50 67.5 50 65 50 65 50 62.5 50 NA NA NA 72.5 70 70 55 50 50 70 70 50 50 67.5 67.5 65 50 50 50 65 65 65 50 50 50 65 62.5 62.5 50 50 45 62.5 60 60 50 45 45 N/A N/A N/A +10°10 +30°F +30°10 +50°F Above +50"F -12"to -1"C -1"1o+10"C Above +10°C 72.5 70 70 72.5 70 70 70 67.5 67.5 67.5 65 65 65 65 65 65 65 65 -1¢to+10"C >+16"C 70 67.5 67.5 67.5 50 50 45 45 67.5 67.5 65 50 50 45 65 65 62.5 62.5 50 45 45 45 65 62.5 62.5 60 45 45 45 40 60 60 60 60 45 45 45 45 60 57.5 57.5 57.5 45 45 45 45 NA 10-42; 74 #40 NA 10-42:74 #40 NA 10-42; 74 #40 @PCLRRIS"

GENERAL INFORMATION 2005 Model Specifications Model Number S05WB1AE I S05WB1AS Chassis Kids Estimated Dry Weight (lb/kg) Recommended Rider 130159 Main Jet 72.5 Weight Overall Length (in/em.) 751191 50 Width (in/em.) 34186 Position N/A/ N/A Ski Center (in/em.) 30176.2 Needle Jet N/A Height (in/em.) 31179 170 Fuel Capacity (US Gai/L) .511.9 N/A Oil Capacity US Qt/L) i .5 Turns Air Screw Engine Model Number EH122PM015 Spark Plug NGK BR6ES Idle RPM 1600 Spark Plug Gap (mm/in) 0.70 I 0.28 Ignition Bore I Stroke (in/mm) 2.36x1.57 (60 x 43) Cylinder Liner Iron Brake System Mechanical Drum Displacement(cc) I Cylin- 121 cc I 1 I Fan ders I Type Ignition Solid State Parking Brake NIA Exhaust Single Induction Type 4 Stroke OHV Front Rear Type Mini IFS Mini Indy Travel (in/em.) 317.6 Travel (in/em.) 6.9117.5 IFS Shock/Spring Adj. Arvin I Washer NIA Shock Ski Type Composite Ski Runner Weld-Skag Track (W x L x Lug) (in/ 10 X 69 X .79 Torsion Bar NIA em.) (25.4x175.3x2) @PCILRRIS 1.5

GENERAL INFORMATION 0-600 (0-2000) Meters 1800-2400 (Feet) (6000-8000) 2400-3000 (8000-10000) 3000-3700 (10000-12000) Meters (Feet) 1.6 Below -30°F -30° to -10°F Below -34°C -34°10 -23°C 75 72.5 75 72.5 72.5 70 70 67.5 67.5 65 65 65 NA NA NA -10°!0 +10°F +10°!0 +30°F +30°10 +50°F Above +50°F -23° to -12°C -12~10 -1 oc -1°I0+10°C Above+10°C 72.5 72.5 70 70 72.5 72.5 70 70 70 70 67.5 67.5 67.5 67.5 65 65 65 65 65 65 65 65 65 65 N/A NA 10-42 74 #40 N/A NA 10-42 74 #40 N/A NA 10-42 74 #40 @PCI..FIRIS