Essential Snowmobile Service Manual: Polaris 120 XC SP and 120 PRO X (2000-2005)

Polaris 120 XC SP & 120 PRO X Snowmobile Service Manual (2000-2005)

Keep your Polaris youth snowmobile running like new with this professional-grade service manual. This is the definitive technical resource for the 120cc series, covering every model from the classic 2000 120 XC SP to the performance-oriented 2005 120 PRO X. Whether you are a parent maintaining your child's first sled or a technician performing a complete engine overhaul, this manual provides the exact specifications and step-by-step procedures required for safe and reliable operation.

Model Coverage & Identification This manual is specifically tailored for the following Polaris 120 models:

• 2000-2005 120 XC SP (Model S00WB1AS through S03WB1AS)
• 2004-2005 120 PRO X (Model S04WB1AS and S05WB1AE/S)

For accurate part ordering and warranty support, refer to the identification numbers located on your machine:

• Vehicle Identification Number (VIN): Stamped on the right front side of the tunnel (17-digit format starting with 4XA).
• Model Number: Embossed on the tunnel decal.
• Engine Serial Number: Laser engraved on the intake side of the crankcase.

Technical Highlights & Engine Specifications The heart of these machines is the Fuji 121cc 4-stroke OHV engine (EH122PM series). This manual provides deep-dive data including:

• Engine Architecture: Air-cooled, single-cylinder, 4-cycle design with splash-type lubrication.
• Performance Tuning: Complete jetting charts for various altitudes (0 to 12,000+ feet) and ambient temperatures (below -30°F to above +50°F).
• Precision Data: Cylinder bore (60mm), stroke (43mm), and exact torque values for connecting rods (6.5-8.3 ft. lbs.) and cylinder heads.
• Decompression System: Detailed explanation of the automatic decompressor on the camshaft that ensures easy recoil pulling for young riders.

Comprehensive Service Sections

• Periodic Maintenance: Detailed schedules for 10, 20, 50, and 100-hour intervals, including oil changes using Polaris Premium 4 Synthetic 0W-40.
• Drive System: Service procedures for the centrifugal clutch, drive chain tensioning, and track alignment to prevent excessive Hi-Fax wear.
• Suspension & Steering: Complete guides for the Mini IFS (Independent Front Suspension) and Mini Indy rear suspension, including ski skag replacement and spindle lubrication.
• Electrical & Safety: Full wiring diagrams and testing procedures for the Speed Control Assurance system (Rev Limiter), throttle safety switches, and the transistor-controlled ignition (U.T.C.I.).
• Off-Season Storage: Essential steps to prevent rust and fuel gumming during summer months, ensuring a first-pull start next winter.

Valuable Technical Reference This manual also includes an extensive glossary of terms, standard torque specifications for all bolt grades, and conversion tables (Metric/SAE). It identifies specialized maintenance products like Nyogel grease for electrical connectors and Polaris Premium All Season Grease for pivot points.

Equip yourself with the same information used by factory-trained technicians. This manual is designed to help you perform work safely and correctly, protecting both the rider and the longevity of the snowmobile.