Service Manual: Polaris 120, 120 XC SP Youth Snowmobile - Detailed Service Procedures & Maintenance Guide 2000-2008

Polaris 120 Youth Snowmobile Service Manual - 2000-2008

This official Service Manual provides engineering-level technical instructions for the maintenance and repair of the Polaris 120 series youth snowmobiles. A critical technical detail for operational reliability is the specific ignition coil air gap, which must be maintained between .012"-.020" (.3-.5mm) to ensure consistent spark timing and engine performance. Following the prescribed lubrication intervals for the steering post lower pivots and spindle bushings using Polaris Premium All Season Grease is vital for maintaining precise handling and maximizing vehicle uptime.

Technical Applicability & Serial Groups

121cc 4-Cycle OHV Chassis Generation

• Model Year 2008: S08WB1AS, S08WB1AE, S08WB1ASA, S08WBIAEA
• Model Year 2007: S07WBIAS
• Model Year 2006: S06WBIAS (Applicable to units with Engine S# 0600001 and above, and units up to S# 0502779)
• Model Years 2000–2005: S00WB1AS, S01WB1AS, S02WB1AS, S03WB1AS, S04WB1AS(E), S05WB1AS(E)

Operational Integrity & Safety Benchmarks

• Precision Mikuni BV 18 carburetor calibration data ensures optimal stoichiometric ratios across varied elevations (0–12,000 ft).
• Detailed track tensioning and alignment procedures prevent premature wear of the molded track clips and rail sliders.
• Comprehensive testing protocols for the throttle lever safety switch (TSS) and tether system ensure all emergency cut-off circuits function within factory tolerances.

Document Metadata

• Print No: 9921077
• Page Count: 84 Pages
• Engine Type: Fuji EH122PM015

Technical Depth & Factory Benchmarks

• Cylinder Geometry: Standard bore diameter of 2.36" (60mm) with a service limit for piston-to-cylinder clearance set at 0.010" (0.25mm).
• Valve Train Parameters: Intake and exhaust valve clearances must be adjusted to .0031"-.0047" (.08-.12mm) while the engine is cold.
• De-Compression System: Mechanical flyweight-actuated cam lift specifications for reduced starter rope pull effort.

System Architecture & Visual Navigation

• Suspension Geometry: IFS spring rates of 80 lbs/in and specific ski toe-out settings of 1/8" (3.175mm) for directional stability.
• Torque Sequences: Multi-stage cylinder head torque pattern (3.6 / 7.2 / 17-20 ft. lbs) to prevent thermal warping.
• Circuit Schematics: Full-scale wiring diagrams for both early (2000-2007) and late (2008) electrical configurations.

Table of Contents

• Chapter 1: Model Specifications (Dimensions, Gearing, Jetting Charts)
• Chapter 2: General Information (Torque Principles, VIN Locations, Fuel Requirements)
• Chapter 3: Maintenance (Lubrication, Tool Requirements, Storage Procedures)
• Chapter 4: Engine & Fuel Systems (Carburetor Service, Recoil Disassembly, Engine Overhaul)
• Chapter 5: Chassis & Steering (IFS Components, Ski Alignment, Handlebars)
• Chapter 6: Final Drive & Suspension (Track Adjustment, Drive Chain, Slide Rails)
• Chapter 7: Electrical (Ignition Timing, Lighting, Safety Switches)

Operational Limits & Fluid Specifications

• Crankcase Lubricant: 20 oz. (0.6L) Polaris Premium 4 Synthetic 0W-40.
• Drive Chain Lubrication: Polaris Premium Chaincase Lubricant.
• Fuel Grade: 87 Octane minimum (non-oxygenated preferred).
• Spark Plug Gap: NGK BR6ES set to .028" (0.70mm).