Polaris 2005 Phoenix 200 Owner'S Manual Download

Page: 83 / 111

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.

Brake Lever Travel (Rear)

Service the brakes when

brake lever travel reaches

2 1/2

″

(65 mm). Always

service the brakes when there

is no longer sufficient stopping

ability at the specified lever

travel setting.

.40

″

-.80

″

(10-20 mm)

2 1/2

″

(65 mm)

Summary of Contents for 2005 Phoenix 200

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Page 3: ...e minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No li...

Page 4: ...d enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major...

Page 5: ...4...

Page 6: ...E IDENTIFICATION NUMBERS 6 SAFETY 7 FEATURES AND CONTROLS 33 OPERATION 42 EMISSION CONTROL SYSTEMS 60 MAINTENANCE AND LUBRICATION 61 SPECIFICATIONS 96 POLARIS PRODUCTS 99 TROUBLESHOOTING 100 WARRANTY...

Page 7: ...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...

Page 8: ...ead and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your de...

Page 9: ...your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safe...

Page 10: ...ncluding a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacke...

Page 11: ...attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use prope...

Page 12: ...use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concer...

Page 13: ...e and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 WARNING POTENTIAL HAZAR...

Page 14: ...D Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Carryin...

Page 15: ...loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING POTENTIAL HAZARD Operating...

Page 16: ...ID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNING POTENTIAL HAZARD Oper...

Page 17: ...ccident 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 WARNING POTENTIAL HAZARD Attempting wheelies jum...

Page 18: ...ance procedures and schedules described in the owner s manual WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one...

Page 19: ...ert to changing terrain conditions WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough sl...

Page 20: ...at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for y...

Page 21: ...the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your...

Page 22: ...down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 52 Always check the terrain carefully before descending a hill Shift y...

Page 23: ...t to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 54 Use extra caution when turning on any hill Avoid crossin...

Page 24: ...ake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 54 If the ATV begins ro...

Page 25: ...OTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery s...

Page 26: ...nts and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after le...

Page 27: ...TV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo...

Page 28: ...serious injury or death Always remove the ignition key when the vehicle is not in use WARNING After any overturn or accident have a qualified service dealer inspect the entire vehicle for possible da...

Page 29: ...fully If any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact...

Page 30: ...ARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 4 27 6 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weigh...

Page 31: ...ER USE WITH DRUGS OR ALCOHOL NEVER operate ALWAYS 7172560 WARNING MANUFACTURED IN TAIWAN DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN...

Page 32: ...stitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protecti...

Page 33: ...o not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run i...

Page 34: ...on 3 Main Key Switch Turn the main key switch clockwise to the ON position before starting the engine Turn the main switch off to stop the engine and end all electrical power to the vehicle 4 Start Bu...

Page 35: ...nt and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check...

Page 36: ...ervoir is level 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...

Page 37: ...r can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always test front brake lever travel and master cylinder fluid level before riding...

Page 38: ...TE If the rear wheels slide while using the foot brake reduce brake pedal pressure to brake the rear wheels without skidding WARNING Aggressively applying the rear brake when backing down a hill may c...

Page 39: ...rake lever 1 2 Push the park brake lock 2 down This will prevent the lever from returning to the released position 3 To release the parking brake lock squeeze and release the brake lever The parking b...

Page 40: ...he main fuel supply is exhausted Refuel as soon as possible Reserve fuel range is about 7 10 miles 11 16 km NOTE Return the valve to the ON position after refueling Fuel Tank The fuel tank filler cap...

Page 41: ...Gear N Neutral R Reverse Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehi...

Page 42: ...ake sure the stop switch and main key switch are on 3 Place your foot on the kick start Thrust your heel downward to crank the engine NOTE If the engine is cold use the choke as outlined on page 44 4...

Page 43: ...ing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another 0W 40 API certified SH oil Never substitute or mix oil bran...

Page 44: ...Tires Inspect condition and pressure 29 90 Wheels fasteners Inspect ensure fastener tightness 89 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 67 Coolant level...

Page 45: ...st contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface 2 Turn t...

Page 46: ...starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts 9 If the engine slows or stops position the choke lever half way...

Page 47: ...gine and allow it to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Slowly squeeze the throttle lever toward the handlebar to begin driving...

Page 48: ...e supporting your weight on the outer footrest Use the same leaning technique for turning in reverse 2 Practice turning at slow speeds before attempting to turn at faster speeds WARNING Turning at sha...

Page 49: ...ack capacity is 70 lbs 31 7 kg of cargo Always read and understand the load distribution warnings listed on the rack and hitch warning labels Never exceed the specified weights Never carry cargo on th...

Page 50: ...ads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle S HEAVY LOADS CAN CAUSE BRAKING AND CONTRO...

Page 51: ...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 WARNING Failure to exercise care when operating...

Page 52: ...egins rolling downhill never apply engine power Never apply the rear brakes while rolling backwards 2 Gradually squeeze the right hand brake lever to engage the front brakes When fully stopped apply t...

Page 53: ...rear brake lever slightly to aid in slowing Do not apply the front brakes 6 Avoid hills with excessively slippery or loose surfaces 7 Avoid going down a hill at an angle which can cause the vehicle t...

Page 54: ...in the owner s manual Avoid crossing the side of a hill sidehilling if possible If sidehilling is necessary follow these precautions 1 Avoid hills with excessively slippery or loose surfaces 2 Avoid c...

Page 55: ...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...

Page 56: ...uphill 6 Staying uphill of the vehicle turn the handlebars full left 7 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it...

Page 57: ...pply them lightly several times to allow friction to dry out the pads After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 61 The followin...

Page 58: ...e 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...

Page 59: ...erse always come to a complete stop and check for obstacles or people behind the vehicle When it s safe to proceed back slowly Avoid backing on inclines Avoid turning at sharp angles Do not use the ov...

Page 60: ...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 th...

Page 61: ...olaris specifications to achieve optimal performance Adjustment to engine idle is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an autho...

Page 62: ...ce intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and ser...

Page 63: ...ily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housi...

Page 64: ...asonally pressure test system yearly E Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at one month E Oil filter change 100 H 6 M 1000 1600 Replace with oil change J E Valve cleara...

Page 65: ...Inspect clean replace worn parts J Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Cle...

Page 66: ...he chart should be lubricated at the General Lubrication interval Item Lube Method Engine Oil Premium 4 Synthetic 0W40 See page 67 Brakes DOT 3 fluid only See page 35 Transmission Premium AGL Syntheti...

Page 67: ...breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris...

Page 68: ...Position the vehicle on a level surface 2 View the oil level through the sight glass 1 on the right side of the vehicle NOTE A rising oil level between checks in cool weather driving can indicate con...

Page 69: ...r change can be completed without interruption 2 Position the vehicle on a level surface 3 Clean the area around the drain plug on the bottom of the engine crankcase 4 Run the engine for two to three...

Page 70: ...e the gasket is in good condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Remove the oil fill plug and add...

Page 71: ...e 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 vehi...

Page 72: ...vehicle on a level surface 2 Remove the check plug 1 and view the oil level 3 Remove the fill plug 2 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification 5 Reinstall th...

Page 73: ...ps until they ve cooled sufficiently Headlight Lamp Replacement To access the assembly from the front remove the front cover and unplug the wiring harness Remove the headlight assembly from the vehicl...

Page 74: ...t 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 Apply dielectric grease to the so...

Page 75: ...ht brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A w...

Page 76: ...irbox for any water and dry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw 1 6 Turn the engine over several times using the electric start...

Page 77: ...eed these warnings could result in serious injury or death Periodically clean the spark arrestor to remove accumulated carbon 1 Remove the three screws 1 and remove the arrestor from the end of the mu...

Page 78: ...system remains safe 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 i...

Page 79: ...tery cable next 5 Lift the battery out of the battery compartment Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has...

Page 80: ...ready filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintain...

Page 81: ...tandard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 mont...

Page 82: ...over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill 1 Always keep brake fluid at...

Page 83: ...o adjust rear brake freeplay turn the adjuster nuts 1 at the rear brake drum Brake Lever Travel Rear Service the brakes when brake lever travel reaches 2 1 2 65 mm Always service the brakes when there...

Page 84: ...n be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear ti...

Page 85: ...d bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by...

Page 86: ...edures exactly or see your Polaris dealer for service Handlebars The handlebars can be adjusted for rider preference 1 Remove the handlebar cover 2 Loosen do not remove the four handlebar bolts 3 Adju...

Page 87: ...ailable from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when require...

Page 88: ...ster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth several times 3 Tighten the locknut and slide the boots o...

Page 89: ...r ATV and in the specifications section of the owner s manual beginning on page 96 Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always r...

Page 90: ...sition the vehicle on a level surface 2 Lock the parking brake 3 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotatio...

Page 91: ...rating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 mm...

Page 92: ...n 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 5 Reinstall the pre filter over the main filter Replace the...

Page 93: ...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 i...

Page 94: ...ast seals Fuel Stabilizer Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and p...

Page 95: ...riod Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricat...

Page 96: ...uring transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly and securely 4 Always tie the frame of the ATV to the transporting unit securely using suit...

Page 97: ...Radius 65 in 165 1 cm unloaded Ground Clearance 5 7 in 14 5 cm Length 65 in 165 1 cm Width 42 in 106 7 cm Height 42 in 106 7 cm Seat Height 32 in 81 3 cm Wheel Base 45 in 114 3 cm Engine Cooling Engi...

Page 98: ...in 17 8 cm travel Rear Suspension Mono Shock Swing Arm w 6 5 in 16 5 cm travel Shock Adjustment CAM Front Brake Hydraulic Disc Rear Brake Mechanical Drum Foot Brake Mechanical Drum Rear Brake Park Br...

Page 99: ...EMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above Meters Feet 0 1800 0 6000 108 TBD 1800 3700 6000 12000 TBD TBD Clutching Chart Altitude Roller Weight Grams Each Driven Clutch Spring Meter...

Page 100: ...d 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz...

Page 101: ...in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if n...

Page 102: ...o specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fue...

Page 103: ...s See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to...

Page 104: ...ANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not...

Page 105: ...u must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling de...

Page 106: ...ized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer wi...

Page 107: ...106 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 108: ...107 MAINTENANCE RECORD DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 109: ...ownhill 52 Driving in Reverse 58 Driving on Slippery Surfaces 50 Driving Over Obstacles 57 Driving Procedures 46 Driving Safely 46 59 Driving Through Water 56 Driving Uphill 51 E Electrical Switches 3...

Page 110: ...evere Use 61 Side Panel Removal 87 Sidehilling 53 Spark Arrestor 60 S Spark Arrestor Clean Out 76 Spark Plug Removal and Replacement 74 Spark Plugs 74 SPECIFICATIONS 96 98 Start Button 33 Starting the...

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