Polaris 2009 Phoenix 200 Quadricycle Owner'S Manual Download

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INDEX

Air Filter . . . . . . . . . . . . . . . . . . . . . 67

Battery . . . . . . . . . . . . . . . . . . . . 73-76

Charging . . . . . . . . . . . . . . . . . 75

Installation . . . . . . . . . . . . . . . . 74

Removal. . . . . . . . . . . . . . . . . . 74

Storage . . . . . . . . . . . . . . . . . . . 76

Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake

All-Wheel Brake . . . . . . . . . . . 25

Foot Brake . . . . . . . . . . . . . . . . 25

Parking Brake . . . . . . . . . . . . . 25

Rear Brake Lever. . . . . . . . . . . 24

Brake Check. . . . . . . . . . . . . . . . . . . 58

Brake Fluid . . . . . . . . . . . . . . . . . . . 57

Brake Fluid (Foot Brake). . . . . . . . . 58

Brake Freeplay. . . . . . . . . . . . . . . . . 59

Brake Lever Travel . . . . . . . . . . . . . 59

Brake Light . . . . . . . . . . . . . . . . . . . 70

Brake Maintenance . . . . . . . . . . . 57-59

Break-In Period . . . . . . . . . . . . . . . . 29

Carburetor . . . . . . . . . . . . . . . . . . . . 63

Carburetor Adjustment . . . . . . . . . . 63

Cargo . . . . . . . . . . . . . . . . . . . . . . 44-45

Choke Lever. . . . . . . . . . . . . . . . . . . 23

Cleaning and Storage. . . . . . . . . . 77-80

Clothing . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching Chart . . . . . . . . . . . . . . . . 87

Cold Weather Operation . . . . . . . . . 33

Constant Variable Transmission . . . 72

CVT Drying . . . . . . . . . . . . . . . . . . . 72

CVT System. . . . . . . . . . . . . . . . . . . 72

Drivetrain Break-In . . . . . . . . . . . . . 29

Driving Downhill. . . . . . . . . . . . . . . 39

Driving in Reverse. . . . . . . . . . . . . . 43

Driving on a Sidehill . . . . . . . . . . . . 38

Driving on Slippery Surfaces. . . . . . 36

Driving Over Obstacles . . . . . . . . . . 42

Driving Procedures . . . . . . . . . . . . . . 34

Driving Properly . . . . . . . . . . . . . . . . 34

Driving Through Water . . . . . . . . . . . 41

Driving Uphill . . . . . . . . . . . . . . . . . . 37

Engine Break-In. . . . . . . . . . . . . . . . . 29

Engine Fogging . . . . . . . . . . . . . . . . . 80

Engine Idle RPM Adjustment . . . . . . 63

Engine Oil . . . . . . . . . . . . . . . . . . . . . 52

Equipment Modifications . . . . . . . . . . 7

Exhaust Emission Control System . . 47

Eye Protection . . . . . . . . . . . . . . . . . . . 9

Fuel Safety. . . . . . . . . . . . . . . . . . . . . 11

Fuel Tank Cap . . . . . . . . . . . . . . . . . . 27

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 27

Gasoline Handling . . . . . . . . . . . . . . . 11

Gear Selector . . . . . . . . . . . . . . . . . . . 28

Gearcase Oil . . . . . . . . . . . . . . . . . . . 56

Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9

Handlebar Adjustment. . . . . . . . . . . . 62

Hauling Cargo . . . . . . . . . . . . . . . 44-45

Hazard Warning Switch. . . . . . . . . . . 23

Headlamp Replacement. . . . . . . . . . . 70

Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8

Horn Switch. . . . . . . . . . . . . . . . . . . . 23

Idle RPM Adjustment . . . . . . . . . . . . 63

Immersion . . . . . . . . . . . . . . . . . . . . . 71

Indicator Lights . . . . . . . . . . . . . . . . . 26

Jetting Chart. . . . . . . . . . . . . . . . . . . . 87

Key Switch . . . . . . . . . . . . . . . . . . . . 22

Kick-Start Lever . . . . . . . . . . . . . . . . 28

K-Turn . . . . . . . . . . . . . . . . . . . . . . . . 40

Summary of Contents for 2009 Phoenix 200 Quadricycle

Page 1: ......

Page 2: ...Pantone 426 C For your nearest Polaris dealer visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 U S A Part No 9922082 Rev 01 Printed in USA...

Page 3: ...s Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manua...

Page 4: ...uality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are...

Page 5: ...CONTENTS Introduction 4 Safety 7 Features and Controls 22 Operation 29 Emission Control Systems 47 Maintenance 48 Polaris Products 82 Troubleshooting 83 Specifications 86 Warranty 88 Maintenance Log 9...

Page 6: ...l injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may...

Page 7: ...you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Never operate this vehicle without proper...

Page 8: ...spare key and store it in a safe place The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN ___________________...

Page 9: ...er than a Polaris dealer please request free safety training from any authorized Polaris dealer Equipment Modifications The warranty on your Polaris vehicle may be terminated if any equip ment has bee...

Page 10: ...bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distin...

Page 11: ...sonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and p...

Page 12: ...perating procedures in this manual and on the safety labels before operating this vehicle Never operate this vehicle without proper instruction Take a training course Beginners should receive training...

Page 13: ...tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the vehicle is stored or parked Never start the e...

Page 14: ...or while operating this vehicle Keep both hands on the handlebars Keep both feet on the footrests Never carry a passenger The purpose of the long seat is to allow the operator to shift position as nee...

Page 15: ...or death Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control accident and or injury Avoid sudden turns or swift movement of...

Page 16: ...ual for turning Never turn sharply at excessive speeds which can lead to vehicle overturn See page 35 Never attempt jumps or other stunts Always follow the procedures outlined in this manual for drivi...

Page 17: ...low the procedures outlined in this manual for driving downhill and for braking on hills See page 39 Always follow the procedures outlined in this manual for braking if you stall or roll backwards whi...

Page 18: ...lways follow the procedures outlined in this manual for driving in reverse See page 43 Use caution when operating on rough slippery or loose terrain Always follow the procedures outlined in this manua...

Page 19: ...has been involved in an accident always have an authorized Polaris dealer inspect the entire vehicle for possible damage including but not limited to brake throttle and steering systems Hot component...

Page 20: ...vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement...

Page 21: ...19 SAFETY Safety Labels and Locations 16 1 16 6 6 6 6 6 6 6 1 1 1 1 1 1 1 16 6 6 6 6 6 6 6 7173027 General Warning Clutch Cover Warning Age Warning...

Page 22: ...Tongue Weight should be about 10 of the Gross Trailer Weight and should not exceed 13 6 kg 30 lbs MAXIMUM TOWING CAPACITY 136 KG 300 lbs Never operate this ATV on HILLS steeper than 25 degrees 25 To p...

Page 23: ...overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 4 0 psi 27 6 kPa Rear 4 0 psi 27 6 kPa Maximum weight capacity 285 lbs 129 kg Improp...

Page 24: ...urn the headlight on WARNING Do not attach a large key fob or key ring to the main switch It may contact the gas tank cap when turning causing an interruption to the electrical system and an unexpecte...

Page 25: ...ng a cold engine See page 32 Horn Switch Press the horn button to alert others of your presence Hazard Warning Switch Push the hazard warning switch to cause all turn indicators to flash simultaneousl...

Page 26: ...throttle problems arise The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Do not modify the ETC system or replace it with other throttle mechanisms Rea...

Page 27: ...the lock 3 Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever The parking brake will release automatically WARNING Operating the vehicle while the parking...

Page 28: ...h light illuminates when the feature is activated Mirrors Use the mirrors to assist in traffic maneuvers Always check and adjust the mirrors before driving the Quadricycle Reverse Gear Indicator Turn...

Page 29: ...aded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the left side of the vehicle ON For normal operation OFF For...

Page 30: ...t 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 4 Fold out the kick start lever on the left side of th...

Page 31: ...nce and longer life for these components NOTICE Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See...

Page 32: ...ur skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both fee...

Page 33: ...ricate if necessary 51 Steering Ensure free operation Tires Inspect condition and pressure 65 Wheels fasteners Inspect ensure fastener tightness 65 Frame nuts bolts fasteners Inspect ensure tightness...

Page 34: ...not use the choke if starting a warm engine 6 If the engine is cold move the choke lever to the left until it stops Tip The choke is fully on when the lever is com pletely to the left The choke is of...

Page 35: ...lever half way to the right to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up 12 When the engine idles smoothly move the choke lever completely to the ri...

Page 36: ...er 4 Start the engine and allow it to warm up 5 Shift the transmission into gear 6 Check your surroundings and determine your path of travel 7 Release the brake lever 8 Slowly squeeze the throttle lev...

Page 37: ...urn while supporting your weight on the outer footrest The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds...

Page 38: ...ions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before driving onto slippery surfaces 3 Be alert Watch the trail Avoid quick sharp turns 4 Never apply the brakes durin...

Page 39: ...teady rate of speed to avoid stalling 8 Never open the throttle suddenly or make sudden gear changes 9 Never go over the top of a hill at high speed 10 Be alert Be prepared to take emergency action Th...

Page 40: ...less absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid hills with excessively slippery or loose surfaces 3 Avoid crossing the side of a steep hill...

Page 41: ...Avoid hills with excessively slippery or loose surfaces 3 Shift body weight uphill 4 Drive straight downhill 5 Slow down Never go down a hill at high speed 6 Avoid going down a hill at an angle which...

Page 42: ...the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill 6 Staying uphill of the vehicle turn the handlebars full left 7 Slowly release the brake lever and allow the...

Page 43: ...ps during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the ve...

Page 44: ...these precautions when operating 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...

Page 45: ...ecautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at s...

Page 46: ...ss stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE A...

Page 47: ...nt of the vehicle When operating over rough or hilly terrain reduce cargo and drive slowly to maintain stable driving conditions Slow down Operate with extreme caution when hauling cargo or tow ing lo...

Page 48: ...ine Avoid parking on an incline If it s unavoidable follow these precau tions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill...

Page 49: ...vel requirements Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related...

Page 50: ...Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation Improperly performing the...

Page 51: ...pre filter Daily Inspect clean often replace as needed X Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric grease if replacing X E Air f...

Page 52: ...e with oil change Q E Valve clearance 100 12 M 1000 Inspect adjust Q E Fuel system filter 100 12 M 1000 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two year...

Page 53: ...at the General Lubrication interval Item Lube Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 See page 52 Brake Fluid DOT 4 Only See page 58 Transmission Oil Polaris AGL Synthetic Gearcase Lub...

Page 54: ...brands Oil Specifications Oil Level Maintain the oil level at the center of the sight glass Do not overfill NOTICE A rising oil level between checks in cool weather driving can indicate contaminants...

Page 55: ...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 Do not allow the vehicle...

Page 56: ...ubricate the filter o ring 10 Install the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand 11 Remove the oil fill plug Add 850 ml of the recommended oil see page 52...

Page 57: ...d 3 4 3 Remove the fill plug Add the recommended oil as needed 4 Reinstall the fill plug Oil Change 1 Position the vehicle on a level surface Place the transmission in gear Lock the parking brake 2 Re...

Page 58: ...ended fluid as needed 4 Reinstall the fill plug Torque to specification 5 Reinstall the check plug Torque to specification Oil Change 1 Remove the skid plate 2 Remove the drain plug Drain the fluid in...

Page 59: ...used portion Under normal operation a diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely The brake system should be...

Page 60: ...Check the security and surface condition of the brake discs Brake Fluid Foot Brake Check brake fluid level before each use of the vehicle The brakes should feel firm when they re applied Spongy or we...

Page 61: ...the brakes when there is no longer sufficient stopping ability at the specified lever travel setting Brake Freeplay Periodically measure the freeplay of the rear brakes Acceptable free play range is...

Page 62: ...5 cm from the floor or as close to the hub axle cen ter line as possible Make sure both marks are the same distance from the floor 4 Measure the distance between the marks and record the measurement 1...

Page 63: ...ng the vehicle Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension Accessory springs are availab...

Page 64: ...r see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Remove the handlebar cover 2 Loosen do not remove the four handlebar clamp bolts 3 Adjust the handlebar to t...

Page 65: ...from your Polaris dealer are required for operation above 1800 meters Jetting is required only when operating below 4 degrees C at 1800 meters and lower Tip Continuous operation of the engine without...

Page 66: ...er until 1 6 3 mm of freeplay exists at the lever Move the throttle lever back and forth several times while adjusting 3 Tighten the lock nut and slide the boots over the cable adjuster until they tou...

Page 67: ...outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 86 for recom mended tire...

Page 68: ...ear Lock the parking brake 2 Loosen the wheel nuts slightly 3 Safely place jackstands under the vehicle 4 Remove the wheel nuts Remove the wheel Wheel Installation 1 Place the wheel on the wheel hub 2...

Page 69: ...at 3 Release the air box cover clips Remove the air box cover 4 Loosen the hose clamp and remove the filter 5 Remove the pre filter from the main filter 6 Wash the pre filter in soapy water Rinse and...

Page 70: ...medi ately check the spark plug for correct color See page 69 A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the spark plug c...

Page 71: ...hould not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator ti...

Page 72: ...mbly from the vehicle To access the headlight assembly without removing the front cover reach up under the front cab 1 Remove the rubber cover from the back of the head light 2 Rotate the socket count...

Page 73: ...dry any water 4 Remove the spark plug 5 Drain any water found in the air box 6 Loosen the carburetor drain screw and drain the carburetor 7 Turn the engine over several times using the electric start...

Page 74: ...e 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 CVT Drying I...

Page 75: ...ulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten eg...

Page 76: ...attery out of the battery compartment Battery Installation 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 Connect and tighten the red posi tive cable first 4 Co...

Page 77: ...ttery at 1 2 amps or less until the voltage is 12 8 or greater Tip When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger...

Page 78: ...e each month during storage and recharge as needed to maintain a full charge Polaris recommends maintaining battery charge by using a Polaris Bat tery Tender charger or by charging about once a month...

Page 79: ...and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Ri...

Page 80: ...replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have...

Page 81: ...r Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons ring...

Page 82: ...s of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 48 Battery Storage See page 75 76 for storage and charging procedures Storage Area Covers 1 Make sure tire pressure...

Page 83: ...ansmission in gear 3 Lock the parking brake 4 Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the vehicle...

Page 84: ...g 2871653 Premium ATV Angle Drive Fluid 237 ml 2872276 Premium ATV Angle Drive Fluid 9 5 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 89...

Page 85: ...Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Ov...

Page 86: ...tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended f...

Page 87: ...Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery vol...

Page 88: ...7 cm Overall Height 106 7 cm Seat Height 81 3 cm Wheelbase 114 3 cm Ground Clearance 14 5 cm Minimum Turning Radius 165 cm unloaded Engine Type 4 Cycle Single Cylinder Lubrication Wet sump Engine Cool...

Page 89: ...al Drum Brake Foot Hydraulic All Wheel Brake Parking Mechanical Rear Headlight Front Cover Hi Lo 35W Halogen Taillight 12V 5W Brake Light 12V 21W Battery 12V 12 AH Electric Start Standard Speedometer...

Page 90: ...he Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handl...

Page 91: ...it to a Polaris dealer autho rized to repair Polaris Quadricycles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANS PORTATIO...

Page 92: ...90 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 93: ...91 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 94: ...vetrain Break In 29 Driving Downhill 39 Driving in Reverse 43 Driving on a Sidehill 38 Driving on Slippery Surfaces 36 Driving Over Obstacles 42 D Driving Procedures 34 Driving Properly 34 Driving Thr...

Page 95: ...Reverse Operation 43 Riding Gear 8 9 S Safe Operation Practices 30 Safety Labels 18 21 Age Warning 19 Clutch Cover Warning 19 Discretionary Warning 20 General Warning 19 Hitch Warning 20 No Passenger...

Page 96: ...urn Signal Switch 23 Turning Around on a Hill 40 Turning the Vehicle 35 V Vehicle Identification Numbers 6 Vehicle Immersion 71 W Warning Symbols 4 Washing the Vehicle 77 78 Wheel and Hub Tightening 6...

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