Snowmobile Polaris 120. Instruction - part 15

56

ADULT SECTION

Maintenance

Brake Lever Travel

Firmly depress the brake lever. 

Measure the clearance between 

the lever and brake block.
If clearance is more than 3/4" 

(19 mm), adjust the brake 

cable as outlined below. 

Brake Cable Adjustment

If proper adjustment cannot be achieved using the following methods, 

check the brake band. If the brake band has excessive wear, see your 

Polaris dealer for installation of a new band.

1. Slide the two rubber protector covers back to expose the cable 

adjuster.

2. Using an 8mm wrench to hold the barrel nut, loosen the jam nut 

with a 10mm wrench.

3. With your left hand, grasp the cables as close to the adjuster as pos-

sible. Use your right hand to rotate the barrel nut until you have 

reached the proper brake lever adjustment.

WARNING

Improper brake adjustment can result in brake failure, which could result in 

severe injury or death. Perform the adjustment procedures exactly as outlined, 

or see your Polaris dealer for service.

3/4" (19 mm)

Rubber Covers

Cables

Barrel Nut

Jam Nut

57

ADULT SECTION

Maintenance

Brake Cable Adjustment

4. Check the actuator linkage to 

ensure there is adequate 

freedom of movement for 

positive brake operation and 

that all floating parts move 

freely and that all parts are 

mounted securely. Tighten 

hardware as required.

5. Tighten the adjuster jam nut and 

slide the rubber protectors onto 

the adjuster.

6. The brake band is adjusted 

correctly when brake lever 

freeplay is 1/4- 3/8" (6-10 mm) 

and clearance between the brake 

lever and block with the lever 

fully depressed is no more than 

3/4" (19 mm). Torque the band 

bolt nut to 6 ft. lbs. (8 Nm).

1/4-3/8" (6-10 mm)

Band Bolt Nut

58

ADULT SECTION

Maintenance

Throttle Cable Lubrication

With the engine off, lubricate the 

throttle cable occasionally. Turn 

the handlebars to the left and 

lubricate liberally with Polaris All 

Season Grease.

Choke/Cable Lubrication

Lubricate the choke slide and 

cables occasionally as shown. 

Operate the choke intermittently 

before turning the engine off. This 

draws moisture out of the choke 

plunger area and reduces the possi-

bility of the choke becoming fro-

zen.

Throttle Cable Pivot Slug

Lubricate the throttle cable pivot 

slug every 50 hours or twice a year 

using an aerosol lubricant.

Pivot Slug

59

ADULT SECTION

Maintenance

Chain Tensioner

Inspect the chain. Proper deflection is one inch (25 mm). Adjust the 

chain if deflection is incorrect.
1. Loosen the nut on the chain tensioner.
2. Raise the tensioner until the correct deflection is attained.
3. Tighten the nut to 15-18 ft. lbs. (20-24 Nm).

NOTE:

When the chain has stretched to within 1/8" (3 mm) of the muffler 

mount bracket on the chassis, replace the chain. Inspect the sprockets 

as they also wear and often need replacement when the chain is 

replaced.

Chain Tensioner

1" (25 mm)

1/8" (3 mm)

Muffler Mount Bracket