Polaris Phoenix 200 Owner'S Manual Download Page 55

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LUBRICATION RECOMMENDATIONS

ITEM

LUBE

METHOD

Engine Oil

PS-4 Extreme Duty
10W-50 4-Cycle Oil

See page 54

Brake Fluid

DOT 4 Brake Fluid

See page 29

Transmission Oil

AGL Gearcase Lubricant &
Transmission Fluid

See page 57

Rear Gearcase

ATV Angle Drive Fluid

Seepage 58

Front A-Arms

U-Joint Grease

Inspect; tighten fasteners; grease
(also after washing ATV or driving
in water).

▶

Perform these procedures more often for vehicles subjected to severe use.

Grease Points

MAINTENANCE

Summary of Contents for Phoenix 200

Page 1: ...carefully It contains important safety information Adult supervision is required for children under 16 years of age Operation is prohibited for children under 14 years of age OWNER S MANUAL For Maint...

Page 2: ...e except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passeng...

Page 3: ...ant Safety Video regarding your Polaris vehicle This safety video can also be found at http www polaris com en us rider support safety If you are on the homepage of the Polaris website click on the Ri...

Page 4: ...n 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 vehic...

Page 5: ...duction 5 Safety 9 Features and Controls 27 Operation 35 Emission Control Systems 47 Maintenance 49 Adjustments 83 Specifications 89 Polaris Products 93 Troubleshooting 95 Warranty 99 Maintenance Log...

Page 6: ...4...

Page 7: ...h and operate all ATV controls including handlebars brake levers throttle lever and engine stop switch The preventive maintenance program outlined in this manual is designed to ensure that all critica...

Page 8: ...NING indicates a hazardous situation which if not avoided COULD result in death or serious injury CAUTION CAUTION indicates a hazardous situation which if not avoided COULD result in minor to moderate...

Page 9: ...ing or driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS...

Page 10: ...DECLARATION OF CONFORMITY This document is setting out the contents of the EC Declaration of Conformity The particulars of machinery may differ for specific model 8 INTRODUCTION...

Page 11: ...800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training FOR...

Page 12: ...shield roof and or cab systems may contribute to this condition by restricting airflow Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying...

Page 13: ...yeglasses or sunglasses for eye protection Whenever riding this POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal P...

Page 14: ...for proper operating procedures FOR MORE INFORMATION ABOUT SAFETYcall POLARIS at 1 800 342 3764 OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an...

Page 15: ...wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants HANDLING GASOLINE Gasoline is highly flammable...

Page 16: ...le before each use to make sure it s in safe operating condition See page 36 Always follow the inspection and maintenance procedures and schedules described in this owner s manual See page 49 CARRYING...

Page 17: ...URNING IMPROPERLY Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in this owner s manual Never turn abrupt...

Page 18: ...control or overturn NOTE A special technique is required when braking while traveling downhill See page 42 Always follow proper procedures for traveling down hills as described in the owner s manual A...

Page 19: ...cause an overturn Always maintain a steady speed when climbing a hill If you lose all forward speed Keep body weight uphill Apply the front brakes right lever When fully stopped apply the rear brake...

Page 20: ...on with an obstacle or person Always follow proper operating procedures as outlined in this manual Before shifting into reverse gear always check for obstacles or people behind the vehicle When it s s...

Page 21: ...ough deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see the Driving Through Water section for details Travel slowly Balance your weight carefu...

Page 22: ...F THE ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use PHYSI...

Page 23: ...vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement R...

Page 24: ...e proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOL...

Page 25: ...TV by children under the age of 14 increases the risk of severe injury or death Adult supervision is required for children under age 16 NEVER permit children under age 14 to operate this ATV CLUTCH CO...

Page 26: ...Never carry passengers Never use with drugs or alcohol Never operate this ATV on HILLS steeper than 15 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight u...

Page 27: ...this ATV NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH Improper tire pressure or overloading can cause loss of control Loss of control can result...

Page 28: ...26...

Page 29: ...e 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 START BUTTON To start the engine make sure the stop s...

Page 30: ...V with a sticking or improperly operating throttle Always contact your dealer or other qualified person for service if throttle problems arise Failure to check or maintain proper operation of the thro...

Page 31: ...y applying the rear brakes when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill Use caution when applying the rear brakes Do not aggress...

Page 32: ...to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position The CVTsystem is always in forward gear Usi...

Page 33: ...e 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 level...

Page 34: ...se fuel with ethanol content greater than 10 percent such as E 85 fuel FUEL VALVE The fuel valve w is located on the left side of the ATV It has three settings OFF For vehicle storage and when transpo...

Page 35: ...the kick start lever q on the left side of the vehicle 5 Make sure the engine stop switch and main key switch are in the ON position 6 Place your foot on the kick start Thrust your heel downward to c...

Page 36: ...34...

Page 37: ...close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Mixing brands or using a non recommended oil may cause serious engine...

Page 38: ...essary page 53 Rear suspension Inspect lubricate if necessary page 53 Steering Ensure free operation lubricate if necessary Tires Inspect condition and pressure page Wheels fasteners Inspect ensure fa...

Page 39: ...xhaust fumes are poisonous Never start the engine or let it run in an enclosed area Never allow a child to handle gasoline 5 Operate this vehicle off road only Never operate the vehicle on pavement or...

Page 40: ...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 always stay on the designated trails TRAIL ETIQUETTE...

Page 41: ...e Squeeze the left brake lever TIP 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 9 Press the start but...

Page 42: ...Always operate the engine long enough to reach operating temperature which reduces condensation DRIVING PROCEDURE 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Shift...

Page 43: ...slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Never apply the brakes during a skid Correct a skid by turning the handleba...

Page 44: ...body weight uphill while keeping your feet on the footrests 3 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately DRIVING...

Page 45: ...ll side keeping body weight uphill 8 Start the engine with the transmission still in forward 9 Release the parking brake and proceed slowly Control speed with the rear brake until the vehicle is on mo...

Page 46: ...driving through water dry the brakes by applying light pressure to the levers while moving until braking action is normal If you do not perform this procedure your brakes may be ineffective NOTICE Ser...

Page 47: ...eed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 45 OPERA...

Page 48: ...46...

Page 49: ...urrent title 43 subtitle B chapter I part 420 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 in...

Page 50: ...tandards and directives that apply to this vehicle EUROPEAN VIBRATION AND NOISE The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per EN 15997 NOISE...

Page 51: ...r your vehicle POLARIS also recommends POLARIS parts for emissions related service however equivalent parts can be used It is a potential violation of the Clean Air Act if a part supplied by an afterm...

Page 52: ...erform these procedures more often for vehicles subjected to severe use D Have an authorized Polaris dealer or other qualified person perform these services WARNING Improperly performing the procedure...

Page 53: ...in oil and filter change Front Gearcase Oil if equipped 25 1 M 250 400 Break in oil level check Transmission oil 25 1 M 250 400 Break in oil level check Fuel System 25 Monthly 250 400 Turn the fuel v...

Page 54: ...ffler pipe 100 12 M 1000 1600 Inspect D Spark Plug 100 12 M 1000 1600 Inspect replace as needed D Ignition Timing 100 12 M 1000 1600 Inspect Wiring 100 12 M 1000 1600 Inspect for wear routing security...

Page 55: ...ee page 29 Transmission Oil AGL Gearcase Lubricant Transmission Fluid See page 57 Rear Gearcase ATV Angle Drive Fluid Seepage 58 Front A Arms U Joint Grease Inspect tighten fasteners grease also after...

Page 56: ...rious engine damage Always use the recommended oil Never substitute or mix oil brands OIL SPECIFICATIONS Lubricant Capacity Drain Plug Torque PS 4 Extreme Duty 10W 50 4 Cycle Oil 41 oz 1200 ml 11 ft l...

Page 57: ...engine damage Always replace the oil and filter within a few hours of draining the oil Do not allow the vehicle to be without oil overnight 1 Obtain the correct oil filter and an adequate supply of oi...

Page 58: ...condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 3 4 turn 12 Remove the oil fill plug and add the recommended oil Do...

Page 59: ...oducts TRANSMISSION OIL RECOMMENDATIONS Gearcase Lubricant Capacity Drain Plug Torque Transmission AGL Gearcase Lubricant Transmission Fluid 18 6 oz 550 ml 18 ft lbs 25 Nm TRANSMISSION OIL CHECK 1 Pos...

Page 60: ...ance Chart beginning on page 49 Maintain the oil level at the bottom of the check plug hole We recommend the use of POLARIS ATV Angle Drive Fluid Use of other oils may result in improper operation of...

Page 61: ...priate container Discard used oil properly 3 Clean and reinstall the drain plug with a new sealing washer Torque to specification 4 Remove the fill plug and add the recommended gearcase oil 5 Reinstal...

Page 62: ...eck the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace brake pads when they are worn to 03 0 762 mm 5 Check the security and surface conditi...

Page 63: ...face 2 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...

Page 64: ...is position 3 Place a chalk mark on the center line of both front tires w approximately 10 inches 25 4 cm from the floor or as close to the hub axle center line q as possible Make sure both marks are...

Page 65: ...nd bolts If loose nuts and bolts are found see your POLARIS dealer or other qualified service facility before operating the vehicle SIDE PANEL REMOVAL 1 Remove the seat 2 Remove the three fasteners q...

Page 66: ...al and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section for recommended tire type size and pressure TIRE TREAD DEPTH Al...

Page 67: ...the ground 4 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or rollover Always ensure that all nuts are tor...

Page 68: ...amage could occur 11 Reinstall the air box cover and the seat LIGHTS Poor lighting can result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Cle...

Page 69: ...emove the headlamp and install the new headlamp 4 Reinstall all components TAILLIGHT BRAKELIGHT LAMP REPLACEMENT 1 Remove the taillight lens cover mounting screws 2 Remove the lens cover 3 Remove the...

Page 70: ...s 23 27 Nm SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at...

Page 71: ...r service before starting the engine Your POLARIS dealer can provide this service If it s impossible to take your vehicle to a dealer before starting it follow the steps outlined below This procedure...

Page 72: ...ark arrester while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically remove accumulated carbon from the arrester screen 1 Remove the...

Page 73: ...e some instances when water is accidently ingested into the CVT system Use the following instructions to dry it out before operating The drain plug is located on the bottom of the CVTcover 1 Remove th...

Page 74: ...g or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV may have either a sealed battery which requires little maintenance or a convention...

Page 75: ...e installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed batteries do not have a...

Page 76: ...mmends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the stora...

Page 77: ...aining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheat...

Page 78: ...ACTION CHARGE TIME 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 3 6 hours 50 75 12...

Page 79: ...quently 3 Dry surfaces with a chamois to prevent water spots If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could rem...

Page 80: ...appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exp...

Page 81: ...atments or stabilizers 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 rings v...

Page 82: ...ct all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 49 BATTERY STORAGE See page 74 for storage and charging procedures STORAGE AREA...

Page 83: ...the engine 2 Place the 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...

Page 84: ...82...

Page 85: ...er for service The handlebars can be adjusted for rider preference 1 Remove the handlebar cover q 2 Loosen do not remove the four handlebar clamp bolts w 3 Adjust the handlebar to the desired height 4...

Page 86: ...aler THROTTLE CABLE FREEPLAY Adjust throttle cable freeplay at the handlebar 1 Slide the boots q off the inline cable adjuster sleeve w Loosen the adjuster locknut e 2 Turn the adjuster until 1 16 to...

Page 87: ...jetting when required can cause poor performance overheating or engine damage See your POLARIS dealer or other qualified personnel for more information about jetting for conditions in your area CARBUR...

Page 88: ...TEM The speed control system has two options for limiting speed Adjusting the speed limit screw allows you to control vehicle speed between 0 and 30 MPH 48 km h This adjustment controls how far the th...

Page 89: ...Adjusted at Maximum Bracket Removed 87 ADJUSTMENTS...

Page 90: ...88...

Page 91: ...kg Rear rack weight and tongue weight not to exceed 30 lbs 13 6 kg Hitch Towing Weight Capacity 300 lbs 136 kg Overall Length 65 in 165 cm Overall Width 42 in 106 7 cm Overall Height 42 in 106 7 cm W...

Page 92: ...9 4 psi 27 6 kPa Front Suspension Dual A Arm w 7 in 17 8 cm travel Rear Suspension Mono Shock Swing Arm w 6 5 in 16 5 cm travel Shock Adjustment CAM Brakes Front Hydraulic Disc Brakes Rear Mechanical...

Page 93: ...5 4 4 4 4 1200 1800 4000 6000 Main Jet 96 96 96 96 96 96 96 96 Pilot Jet 40 40 40 40 40 40 40 40 Clip Position 5 5 5 5 4 4 4 4 1800 2400 6000 8000 Main Jet 96 96 96 96 96 96 96 96 Pilot Jet 40 40 40 4...

Page 94: ...0 1800 0 6000 6 14 7 grams 1800 3700 6000 12000 6 9 5 grams 92 SPECIFICATIONS...

Page 95: ...2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid gal 3 8 l 2870465 Pump for gallon jug GREASE SPECIALIZED LUBRICANTS PART NUMBER DESCRIPTION 2871312 Grease Gun Kit All Season Grease 28...

Page 96: ...VES MISCELLANEOUS PART NUMBER DESCRIPTION 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger 94 POLARIS PR...

Page 97: ...recommended fuel Replace with new fuel Incorrectly installed spark plug wires Your POLARIS dealer can assist Incorrect ignition timing Your POLARIS dealer can assist Mechanical failure Your POLARIS d...

Page 98: ...LARLY STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug s Inspect clean and or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer can assist Incorrect s...

Page 99: ...uel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective sp...

Page 100: ...UTION Throttle release switch malfunction Your POLARIS dealer can assist Other mechanical failure Your POLARIS dealer can assist Overheated engine Clean engine exterior Your POLARIS dealer can assist...

Page 101: ...uch transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the...

Page 102: ...ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs o...

Page 103: ...Y POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE O...

Page 104: ...aler s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure t...

Page 105: ...istered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dea...

Page 106: ...date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emis...

Page 107: ...OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDE...

Page 108: ...manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law CALIFORNIA RESIDENTS Certain POLARIS Off Road Vehicles are avail...

Page 109: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 107 MAINTENANCE LOG...

Page 110: ...108...

Page 111: ...nary Warning 22 Driving Downhill 42 Driving on a Sidehill Sidehilling 42 Driving on Slippery Surfaces 41 Driving Over Obstacles 43 Driving Procedure 40 Driving Through Water 44 Driving Uphill 41 E Ele...

Page 112: ...nd Young Operators 5 N No Passenger Warning 22 Noise Decibel Levels 48 Noise Emission Control System 47 North American Safety Labels Tire Pressure Warning 23 Notice 103 O Oil and Filter Change 55 Oil...

Page 113: ...k Plug Recommendations 68 Speed Control System 86 Stalling While Climbing a Hill 17 Start Button 27 Starting the Engine 38 Steering Assembly 63 Storage Tips 79 Switches Buttons 27 T Taillight Brakelig...

Page 114: ......

Page 115: ...ntrol Always use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control SCAN CODE FOR PRDUC...

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