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Table of Contents
Related Manuals for Polaris PHOENIX Phoenix 200
Summary of Contents for Polaris PHOENIX Phoenix 200
- Page 3 Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
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Page 4: Welcome
S Watercraft S Victory motorcycles S RANGER utility vehicles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever... -
Page 6: Table Of Contents
EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION SPECIFICATIONS POLARIS PRODUCTS TROUBLESHOOTING WARRANTY ...... -
Page 7: Vehicle Identification Numbers
VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers in the spaces provided. Remove the spare key and store it in a safe place. If both keys are lost, the ignition switch must be replaced. Vehicle Model Number: Frame VIN (1): Engine Serial Number (2):... -
Page 8: Safety
Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. -
Page 9: Operator Safety
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. - Page 10 S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.
- Page 11 SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
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Page 12: Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. - Page 13 ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV.
- Page 14 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
- Page 15 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.
- Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
- Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.
- Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
- Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
- Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual.
- Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill.
- Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill.
- Page 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in...
- Page 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
- Page 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
- Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or...
- Page 27 Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions.
- Page 28 SAFETY Operator Safety WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.
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Page 29: Safety Decals And Locations
ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. - Page 30 Safety Decals and Locations WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. Location B WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.
- Page 31 SAFETY Safety Decals and Locations Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate: ALWAYS: Location G MANUFACTURED IN TAIWAN DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.
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Page 32: Safe Riding Gear
Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. -
Page 33: Fuel Safety
SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. -
Page 34: Features And Controls
Electrical Switches 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main key switch is on. 2. Engine Stop Switch - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. -
Page 35: Throttle Lever
Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle... -
Page 36: Master Cylinder
If the fluid level is low, add DOT 3 brake fluid. DO NOT OVERFILL. See page 99 for the part numbers of Polaris products. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. - Page 37 FEATURES AND CONTROLS Brakes WARNING Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time. Brake Lever (Right) Squeeze the right brake lever (1) toward the handlebar to apply the hydraulic front wheel brakes.
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Page 38: Foot Brake
Brakes Foot Brake The foot brake (1) is a mechanical rear wheel brake. The foot brake is located on the inside of the right footrest. Apply the brake with your right foot. This is identical to squeezing the left brake lever on the handlebar. NOTE: If the rear wheels slide while using the... -
Page 39: Parking Brake
FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. -
Page 40: Fuel Valve
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. See page 44 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle. Turn the valve off before storage and when transporting. - Page 41 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.
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Page 42: Kick-Start Lever
Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Lock the parking brake. 3. Place the transmission in neutral. 1. -
Page 43: Operation
OPERATION Break-In Period The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. - Page 44 Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Item Brake system / lever travel Brake fluid Foot brake Front suspension Rear suspension...
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Page 45: Starting The Engine
OPERATION Cold Weather Operation for 4-Cycle Engines Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the crankcase, which can lead to engine damage. Any condensation must be drained. - Page 46 Starting the Engine 6. Squeeze the left brake lever. NOTE: The starter will not engage unless the rear brake is applied. Always squeeze and hold the left brake lever before attempting to start the engine. 7. Press the start button. 8.
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Page 47: Driving Safely
OPERATION Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. -
Page 48: Making Turns
Driving Safely Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. - Page 49 70 lbs. (31.7 kg) If the Polaris accessory rear rack or hitch are installed on your ATV, the ATV may carry or tow a maximum of 300 lbs. (136 kg) with a maximum tongue weight of 30 lbs. (13 kg). Maximum rear rack capacity is 70 lbs.
- Page 50 Driving Safely Hauling Cargo and Towing WARNING S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. S When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. S CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Car- rying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition.
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Page 51: Driving On Slippery Surfaces
OPERATION Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Use extra caution. 3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward. -
Page 52: Driving Uphill
Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25_ maximum). 3. Avoid hills with excessively slippery or loose surfaces. 4. Keep your feet on the footrests. 5. Shift your weight uphill. 6. -
Page 53: Driving Downhill
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive straight downhill. 2. Shift your weight rearward. 3. Slow down. 4. Never go down a hill at high speed. 5. Squeeze the (left- -hand) rear brake lever slightly to aid in slowing. Do not apply the front brakes. - Page 54 Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Avoid crossing the side of a hill (sidehilling) if possible.
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Page 55: Turning Around On A Hill
OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. - Page 56 Driving Safely K-Turn/Turning Around on a Hill 1. Squeeze the front (right) brake lever to stop the vehicle. 2. Keep your weight uphill. 3. Lock the parking brake. 4. Leave the transmission in forward gear and shut off the engine. 5.
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Page 57: Driving Through Water
OPERATION Driving Safely Driving Through Water Follow these procedures when operating through water: 1. Check water depths and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests (1). If it’s unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. -
Page 58: Driving Over Obstacles
Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. -
Page 59: Driving In Reverse
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. -
Page 60: Parking On An Incline
OPERATION Driving Safely Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear and lock the parking brake. 2. Always block the rear wheels on the downhill side. 3. -
Page 61: Emission Control Systems
Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. -
Page 62: Maintenance And Lubrication
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. -
Page 63: Periodic Maintenance Chart
Engine breather " filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride... -
Page 64: Periodic Maintenance Chart
100 H Ignition Timing 100 H Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 500 (800) - Page 65 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M...
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Page 66: Lubrication Guide
MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Engine Oil Brakes Transmission Rear Gearcase... -
Page 67: Premium 4 Synthetic Lubricant
+49° C.) Its exceptional frictional properties result in more efficient operation, more power output and lower fuel consumption. Although Polaris Premium 4 is the only oil recommended for use in this engine, use of any API certified SH oil is allowable as long as it’s 0W-40. -
Page 68: Engine Oil Check
MAINTENANCE AND LUBRICATION Engine Oil Check Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Maintain the oil level at the center of the sight glass. Do not overfill. 1. Position the vehicle on a level surface. -
Page 69: Oil And Filter Change
MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil. - Page 70 MAINTENANCE AND LUBRICATION Oil and Filter Change 7. Reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove. 9. Using a clean, dry cloth, clean the filter sealing surface on the crankcase.
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Page 71: Gearcase Specification Chart
1/4 and 3/4 on the sight glass. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. Refer to the gearcase specifications chart on page 70. See page 99 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. -
Page 72: Rear Gearcase Oil
Periodic Maintenance Chart beginning on page 61. Maintain the oil level at the bottom of the check plug hole. We recommend the use of Polaris Premium ATV Angle Drive Fluid. Refer to the gearcase specifications chart on page 70. See page 99 for the part numbers of Polaris products. -
Page 73: Headlight Lamp Replacement
MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled sufficiently. - Page 74 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws (1). 2. Remove the lens cover and set aside for reassembly. 3. Remove the lamp (2). 4.
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Page 75: Spark Plugs
CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. -
Page 76: Vehicle Immersion
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. -
Page 77: Spark Arrestor Clean-Out
MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out WARNING Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Wear eye protection and gloves. Never run the engine in an enclosed area. -
Page 78: Cvt Drying
Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This CVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the CVT housing is securely in place during operation. -
Page 79: Battery Removal
MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. -
Page 80: Battery Charging
NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. Battery... - Page 81 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action charger @ standard amps specified on top of battery)
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Page 82: Brakes (Front)
Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. 2. Check the brake system for fluid leaks. -
Page 83: Brakes (Rear)
MAINTENANCE AND LUBRICATION Adjustments Brakes (Rear) Periodically measure the freeplay of the rear brakes. To adjust rear brake freeplay, turn the adjuster nuts (1) at the rear brake drum. (10-20 mm) Brake Lever Travel (Rear) Service the brakes when brake lever travel reaches 2 1/2″... -
Page 84: Toe Alignment
Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. -
Page 85: Steering Assembly
Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. - Page 86 Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference.
- Page 87 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
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Page 88: Throttle Cable Freeplay
MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay The throttle cable adjuster is located at the right handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. -
Page 89: Wheel Removal
MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner’s manual beginning on page 96. -
Page 90: Wheel Installation
Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. Position the vehicle on a level surface. -
Page 91: Front Wheel Hub Tightening
Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (3 mm) or less. -
Page 92: Air Filter Service
MAINTENANCE AND LUBRICATION Adjustments Air Filter Service 1. Remove the seat. 2. Release the clips and remove the air box cover (1). 3. Loosen the clamp and remove the filter. 4. Remove the pre-filter (2) from the main filter (3). Wash the pre-filter in soapy water, then rinse and let dry. -
Page 93: Cleaning And Storage
If warning and safety labels are damaged, contact your a Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. -
Page 94: Storage Tips
It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts. -
Page 95: Fluid Levels
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 99 for the part numbers of Polaris products. Fluid Levels Inspect fluid levels and change fluids if necessary. S Transmission S Brake Fluid Engine Fogging Use Polaris Engine Fogging Oil. Follow label directions carefully. -
Page 96: Transporting An Atv
MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly and securely. -
Page 97: Specifications
SPECIFICATIONS 2005 Phoenix 200 Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Length Width Height Seat Height Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement... - Page 98 2005 Phoenix 200 Drive System Type Shift Type Front Drive (ratio) Front Tires Rear Tires Front Suspension Rear Suspension Shock Adjustment Front Brake Rear Brake Foot Brake Park Brake Headlight Taillight Brake Light Battery DC Plug-In (Rear) Electric Start Windshield Neutral Indicator Reverse Indicator Tool Kit...
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Page 99: Jetting Chart
SPECIFICATIONS 2005 Phoenix 200 Jetting Chart Altitude AMBIENT TEMPERATURE Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Clutching Chart Altitude Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000-12000) Below 40° F +40°F and above (Below 5° C) (+5°C and above) Roller Weight Grams Each 6 @ 14.5 grams Driven Clutch Spring... -
Page 100: Polaris Products
Grease Gun Kit 2871329 Dielectric Grease (Nyogelt) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid Engine Degreaser 2872893 2871956 LOCTITE 565 Thread Sealant POLARIS PRODUCTS... -
Page 101: Troubleshooting
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start... -
Page 102: Engine Backfires
TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer... - Page 103 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...
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Page 104: Warranty
WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. -
Page 105: Engine Oil
HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re- pair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). - Page 106 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
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Page 107: Maintenance Record
MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS... - Page 108 MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS...
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Page 109: Index
INDEX Adjustments ....Age Restrictions ....Air Filter ..... Battery . - Page 110 Parking on an Incline ... Periodic Maintenance Chart POLARIS PRODUCTS ..Pre Ride Inspection ... . .