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2004 120 PRO X
Polaris 2004 120 PRO X Manuals
Manuals and User Guides for Polaris 2004 120 PRO X. We have
1
Polaris 2004 120 PRO X manual available for free PDF download: Service Manual
Polaris 2004 120 PRO X Service Manual (99 pages)
Brand:
Polaris
| Category:
Snowmobiles
| Size: 7.78 MB
Table of Contents
Table of Contents
4
2007 Dragon 120
5
Chapter 1
5
Specifications
5
2006 120 Pro X
7
2005 Pro X 120
9
2004 120 Pro X - 2003 120Xc Sp
11
2002 120 XC Sp -2001 120 Xcr
13
2000 120 Xcr
15
Chapter 2 General 2
16
Abbreveations
17
Gearing
17
How to Use this Manual
17
Jetting
17
Models Listed
17
Snowmobile Number Designations
18
Model Number Designation Example
18
Vehicle Identification Number (Vin)
18
Tunnel Decal
18
Vin Number Designation
19
Publication Part Numbers
19
Misc. Publications
19
2007 Service Publications
19
General Reference
21
Standard Bolt Torque Specification
21
Stroke Gasoline / Oil Pre MIX
21
Gasoline Volatility
21
Sae Tap Drill Sizes
22
Metric Tap Drill Sizes
22
Decimal Equivalents
22
Glossary of Terms
23
Special Tools
24
Chapter 3 Maintenance
28
Maintenance Program
30
Lubrication
31
Clutch Greasing
31
Chain Maintenance
32
Oil Level
32
Suspension
32
Throttle Cable Lubrication
32
Choke Cable Lubrication
32
Chain Tensioner
33
Chain Tensioner Inspection
33
Fluid Change
33
Oil Change
33
Cable Inspection/Adjustment
34
Brake Cable Inspection
34
Brake Cable Adjustment
34
Throttle Lever Free Play
34
Track Maintenance
35
Track Maintenance Warnings
35
Track Alignment
35
Track Tension
35
Rear Idler Wheels
36
Track Warm up
36
Spark Plug
36
Spark Plug Selection
36
Steering System
37
Steering Inspection
37
Steering Adjustment
37
Carburetor
38
General Carburetor Information
38
Carburetor Adjustments
38
Cleaning
38
Air Filter
38
Electrical
38
Electrical Connections
38
Exhaust
38
Exhaust Inspection
38
Fuel Valve & Fuel Lines
38
Storage
39
Chassis and Hood
39
Front Suspension
39
Clutch and Drive System
39
Controls and Linkage
39
Electrical Connections
39
Carburetor/Throttle Body
39
Fuel System
39
Corrosion
39
Shocks
39
Chapter 4 Engine / Carburetor / Clutch
40
General Information
42
Warnings
42
Torque Specifications
43
Clearance Data & Limits
44
Cylinder Head
44
Cylinder / Piston
45
Connecting Rod
47
Cam Shaft / Valves
48
Engine Maintenance
50
Daily Maintenance
50
Initial 20 Hours Maintenance
50
Inital 50 Hours Maintenance
50
Every 100-200 Hours Maintenance
50
Every 500-600 Hours Maintenance
50
Every 1000 Hours Maintenance
50
Engine Removal
51
Removal
51
Engine Installation
53
Installing the Engine
53
Engine Components
55
Cylinder & Crankcase
55
Main Bearing Cover
55
Crankshaft
55
Connecting Rod and Piston
55
Piston Rings
56
Camshaft
56
Valve Arrangement
56
Cylinder Head
56
Governor System
56
Cooling System
56
Lubrication
57
Ignition System
57
Decompression System
57
Carburetor
57
Air Filter
57
Engine Component Locations
58
Engine Disassembly
59
Preperations & Suggestions
59
Engine Desassembly
59
Engine Assembly
61
Precautions for Reassembly
61
Engine Reassembly
61
Engine Break in
65
Decompression System
66
Fuel Delivery
67
Pilot System
68
Main System
68
Choke System
68
Disassembly and Reassembly
68
Recoil Starter
69
Dissassembly
69
Assembly
69
Clutch
71
Clutch Service
71
Fuel Tank
72
Fuel Tank Removal
72
Fuel Tank Installation
72
Trouble Shooting
72
Fuel System
72
Ignition System
72
Compression System
72
Engine Misfires
73
Engine Stops
73
Engine over Heats
73
Engine Knocks
73
Engine Backfires through Carburetor
73
Chapter 5 Body/Steering
74
Torque Applications
75
Handlebar Adjustment
76
Inspection
76
Rod End Engagement
76
Rod End Procedure
76
Steering
76
Toe Adjustment
77
Ski Spindle/Bushing Installation
78
Ski Spindle/Bushing Removal
78
Radius Rod Replacement
79
Skag Replacement
79
Tie Rod Replacement
79
Body
80
Ifs Shock Replacement
80
Trailing Arm Replacement
80
Decals
81
Troubleshooting
81
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