Polaris 2009 Phoenix 200 Owner'S Manual Download

Page: 79 / 109

MAINTENANCE

Battery

Battery Removal

1. Remove the seat.
2. Disconnect the battery

hold-down strap.

3. On conventional batteries,

remove the battery vent

tube.

4. Disconnect the black

(negative) battery cable

first.

5. Disconnect the red

(positive) battery cable

last.

6. Lift the battery out of the battery compartment. Be careful not to tip

a conventional battery sideways, which could spill electrolyte.

NOTICE:

If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the

vehicle.

Summary of Contents for 2009 Phoenix 200

Page 1: ......

Page 2: ...For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921841 Rev 01 Printed in USA...

Page 3: ...r s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to...

Page 4: ...safe and 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 abou...

Page 5: ...and quality 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 publicatio...

Page 6: ...Introduction 4 Safety 7 Features and Controls 24 Operation 32 Emission Control Systems 51 Maintenance 52 Adjustments 87 Troubleshooting 91 Specifications 94 Polaris Products 96 Warranty 97 Maintenanc...

Page 7: ...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 8: ...ty warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers of a new...

Page 9: ...ated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ____________...

Page 10: ...ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris A...

Page 11: ...eds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE m...

Page 12: ...protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a Polaris A...

Page 13: ...properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never...

Page 14: ...e off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run...

Page 15: ...ts properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perce...

Page 16: ...sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road...

Page 17: ...ng improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Ne...

Page 18: ...a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hil...

Page 19: ...and remount following the procedure described in the owner s manual See page 44 If the ATV begins rolling downhill Keep body weight uphill Apply the front brakes gradually Never apply the rear brake...

Page 20: ...verturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating Improperly in Reverse Improperly operating in reverse could re...

Page 21: ...rating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating the ATV through deep or fast flowing w...

Page 22: ...tly and replace burned out headlamps promptly Operating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entir...

Page 23: ...the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WIT...

Page 24: ...r than 25 degrees 25 To pre vent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To...

Page 25: ...DEATH 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 4 0 psi...

Page 26: ...VER operate this ATV if you are under age 16 7175374 Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not...

Page 27: ...the engine press the lower end of the switch down to the OFF position The engine will not start or run when the switch is off Main Key Switch Turn the main key switch clockwise to the ON position befo...

Page 28: ...ident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Modifications to the electro...

Page 29: ...not aggressively apply the rear brakes when going forward The rear wheels may skid and slide sideways causing loss of control which may result in serious injury or death Front Brakes Right Lever Squee...

Page 30: ...Foot Brake The foot brake is a mechanical rear wheel brake Using the foot brake is the same as using the left brake lever Only the rear brake is applied The foot brake is located on the inside of the...

Page 31: ...position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake ma...

Page 32: ...the recommended level The master cylinder is located on the left handlebar Maintain the fluid level 1 4 6 3 mm below the top edge of the master cylinder Do not overfill 1 Position the vehicle on a le...

Page 33: ...inimum 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 vehicle storage and when transpor...

Page 34: ...r Kick Start Lever If the battery is 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 Lock the parking...

Page 35: ...during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drive...

Page 36: ...s fre quently and replace burned out headlamps promptly 7 Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or othe...

Page 37: ...icle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and alwa...

Page 38: ...ndition and pressure 66 Wheels fasteners Inspect ensure fastener tightness 66 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 30 57 Coolant level if applicable En...

Page 39: ...o the left until it stops Tip The choke is fully on when the lever is com pletely to the left The choke is off when the lever is completely to the right The choke can be adjusted gradually depending o...

Page 40: ...to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up 13 When the engine idles smoothly move the choke lever completely to the right Cold Weather Operation I...

Page 41: ...the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the left brake lever and slowly depre...

Page 42: ...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 43: ...on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Ne...

Page 44: ...s check the terrain carefully before ascending any hill 4 Never climb hills with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill 7 Proceed at a stea...

Page 45: ...ssing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Shift body weight uphill 4...

Page 46: ...maximum 2 Shift body weight uphill 3 Drive straight downhill 4 Slow down Excessive speed when traveling downhill can cause loss of control 5 Squeeze the rear left brake lever gradually Applying the b...

Page 47: ...t if the vehi cle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the rear left brake lever release the parking brake lock and slowly allow th...

Page 48: ...oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to...

Page 49: ...ing in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfami...

Page 50: ...6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly in...

Page 51: ...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 52: ...cities specified for your ATV on warning labels and in the specifications section of this manual Always read and understand the load distribution warnings listed on the rack and hitch warning labels N...

Page 53: ...oid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the dow...

Page 54: ...cess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases ex...

Page 55: ...and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approx...

Page 56: ...ous injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use E Emission related...

Page 57: ...Air filter 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 replacin...

Page 58: ...for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years X Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect Q E Spark plu...

Page 59: ...at the General Lubrication interval Item Lube Method Engine Oil PS 4 PLUS Performance Synthetic 2W 50 See page 57 Brake Fluid DOT 4 Only See page 29 Transmission Oil Polaris AGL Synthetic Gearcase Lub...

Page 60: ...nds 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 such...

Page 61: ...oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption 2 Position the vehicle on a level surface 3 Clean the area around the drain plug on the bot...

Page 62: ...re the gasket is in good con dition 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 ad...

Page 63: ...s 3 Remove the fill plug and add the recommended oil as needed 4 Reinstall the fill plug Oil Change The transmission drain plug is located on the bottom of the vehicle near the center 1 Remove the fil...

Page 64: ...evel 3 Remove the fill plug Add the rec ommended oil as needed 4 Reinstall the fill plug Torque to specification 5 Reinstall the check plug Torque to specification 6 Check for leaks Oil Change 1 Remov...

Page 65: ...e brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 29 2 Check the brake system for fl...

Page 66: ...Block the front wheels 3 Place the transmission in neutral 4 Using suitable stands elevate the rear of the vehicle so the rear wheels are slightly off the ground 5 Slowly tighten the hand brake wing n...

Page 67: ...nd secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both ma...

Page 68: ...ically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Remove the three fasteners sec...

Page 69: ...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 94 for recom mended tire type size and p...

Page 70: ...tion 1 Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 2 Install the wheel nuts finger tight 3 Lower the ve...

Page 71: ...x cover 6 Loosen the clamp and remove the air filter 7 Remove the pre filter from the main filter 8 Wash the pre filter in soapy water then rinse and let dry 9 Reinstall the pre filter over the main f...

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: ...end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 71 CAUTION A hot exhaust system and engin...

Page 74: ...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 75: ...off 3 Check the air box and dry any water 4 Remove the spark plug 5 Loosen the carburetor drain screw and drain the carburetor 6 Turn the engine over several times using the electric start 7 Dry the s...

Page 76: ...he spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically remove accumulated carbon from the arrestor screen 1 Remov...

Page 77: ...rocedures 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 secu...

Page 78: ...duce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV m...

Page 79: ...e black negative battery cable first 5 Disconnect the red positive battery cable last 6 Lift the battery out of the battery compartment Be careful not to tip a conventional battery sideways which coul...

Page 80: ...securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an expl...

Page 81: ...a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point...

Page 82: ...the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing...

Page 83: ...dard 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 months...

Page 84: ...to contact the vehicle The best 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 fi...

Page 85: ...ler to purchase a 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 wat...

Page 86: ...Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodical...

Page 87: ...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 88: ...ly Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 52 Battery Storage See pages 78 79 for storage and...

Page 89: ...transmission 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 ATV to...

Page 90: ...aster are non adjustable 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 a...

Page 91: ...he 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 the desired height 4 Be sure the handleb...

Page 92: ...your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause p...

Page 93: ...sen the adjuster locknut 2 Turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth several ti...

Page 94: ...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 95: ...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...

Page 96: ...replace spark plug s 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 ti...

Page 97: ...kg Overall Length 65 in 165 cm Overall Width 42 in 106 7 cm Overall Height 42 in 106 7 cm Wheelbase 45 in 114 3 cm Ground Clearance 5 7 in 14 5 cm Minimum Turning Radius 65 in 165 1 cm unloaded Engin...

Page 98: ...Foot Mechanical Drum Rear Brake 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 DC Plug In rear Acc...

Page 99: ...remium ATV Angle Drive Fluid 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cart...

Page 100: ...IES The 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...

Page 101: ...your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any add...

Page 102: ...ling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Co...

Page 103: ...ed outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Ve...

Page 104: ...replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL...

Page 105: ...section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECH...

Page 106: ...103 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 107: ...sion 74 Consumer Product Safety 7 Corrosion Removal Chrome 83 Crankcase Emission Control System 51 CVT Drying 74 CVT System 74 D Drivetrain Break In 32 Driving Downhill 43 Driving in Reverse 47 Drivin...

Page 108: ...Checklist 35 R Reverse Operation 47 Riding Area 34 Riding Gear 8 9 S Safe Operation Practices 33 Safety Labels 20 23 No Passenger Warning 22 Age 16 Warning 23 Clutch Cover Warning 23 Discretionary Wa...

Page 109: ...ng the Vehicle 86 Tread Lightly 34 Turning Around on a Hill 44 Turning the Vehicle 39 V Vehicle Identification Numbers 6 Vehicle Immersion 72 W Warning Symbols 4 Washing the Vehicle 81 82 Wheel Hub Ti...

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Polaris 2009 Phoenix 200, Owner'S Manual

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Summary of Contents for 2009 Phoenix 200

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