Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational and Utility Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S Victory motorcycles S RANGER utility vehicles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
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TABLE OF CONTENTS WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . 6 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FEATURES AND CONTROLS . . . . . . . . . . . . . . . 33 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . 60 MAINTENANCE AND LUBRICATION . . . . . . . . . 61 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers in the spaces provided. Remove the spare key and store it in a safe place. If both keys are lost, the ignition switch must be replaced.
Operator Safety SAFETY WARNING Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Operator Safety SAFETY WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Beginners should receive training from a certified instructor.
SAFETY Operator Safety S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills. S Always follow proper procedures for climbing hills. Check the terrain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
Operator Safety SAFETY S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operating in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles. S Always use the size and type of tires specified for your ATV, and always maintain tire pressure as recommended.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger. 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.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience. WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions. WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner’s manual. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 52. Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at high speed.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 54. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill. Gradually apply the front brakes (right lever). When fully stopped, apply the rear brakes and lock the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight uphill.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual. WARNING POTENTIAL HAZARD Skidding or sliding.
Operator Safety SAFETY WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc.
Operator Safety SAFETY WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death.
SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals and other warnings on the ATV carefully. 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 your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. WARNING 7172566 Location D NEVER operate this ATV if you are under age 16. 7172559 Location B WARNING S S Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch.
SAFETY Safety Decals and Locations 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 WITH DRUGS OR ALCOHOL NEVER operate: ALWAYS: 7172560 Location G MANUFACTURED IN TAIWAN DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.
SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.
SAFETY Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck.
FEATURES AND CONTROLS Electrical Switches 1 2 5 4 3 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main key switch is on. 2 2. Engine Stop Switch - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency. To stop the engine, press the lower end of the rocker switch down to the OFF position.
FEATURES AND CONTROLS Throttle Lever Press the throttle lever (1) toward the handlebar to increase engine speed and vehicle movement. Engine speed returns to idle when the lever is released. 1 This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.
Brakes FEATURES AND CONTROLS Master Cylinder Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (1) is located on the right handlebar. View the fluid level through the indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. NOTE: 2 1 When checking the fluid level, position the ATV on level ground with the handlebars turned so the top of the reservoir is level.
FEATURES AND CONTROLS Brakes WARNING Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time. 1 Brake Lever (Right) Squeeze the right brake lever (1) toward the handlebar to apply the hydraulic front wheel brakes. THIS LEVER DOES NOT APPLY THE REAR BRAKES. WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever.
Brakes FEATURES AND CONTROLS Foot Brake The foot brake (1) is a mechanical rear wheel brake. The foot brake is located on the inside of the right footrest. Apply the brake with your right foot. This is identical to squeezing the left brake lever on the handlebar. NOTE: 1 If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the rear wheels without skidding.
FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Squeeze the left brake 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.
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. See page 44 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle. 1 OFF Turn the valve off before storage and when transporting. 2 ON Turn the valve on for normal operation. RES Turn the valve to the reserve setting if the main fuel supply is exhausted. Refuel as soon as possible. Reserve fuel range is about 7-10 miles (11-16 km).
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake. F N R CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.
FEATURES AND CONTROLS Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Lock the parking brake. 3. Place the transmission in neutral. 1. Fold out the kick-start lever on the left side of the ATV. 2. Make 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.
OPERATION Break-In Period The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.
OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition.
OPERATION Cold Weather Operation for 4-Cycle Engines Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the crankcase, which can lead to engine damage. Any condensation must be drained. If the oil level rises to the top of the sight glass, change the oil immediately.
Starting the Engine OPERATION 6. Squeeze the left brake lever. NOTE: The starter will not engage unless the rear brake is applied. Always squeeze and hold the left brake lever before attempting to start the engine. 7. Press the start button. 8. Activate the starter for a maximum of five seconds, releasing the button when the engine starts. If it doesn’t start, release the starter, wait five seconds, then activate for another five seconds. Repeat until the engine starts. 9.
OPERATION Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4. Slowly squeeze the throttle lever toward the handlebar to begin driving. Squeeze the throttle lever further to increase speed. 5. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
Driving Safely OPERATION Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse. 2. Practice turning at slow speeds before attempting to turn at faster speeds. WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.
OPERATION Driving Safely Hauling Cargo and Towing 70 lbs. (31.7 kg) If the Polaris accessory rear rack or hitch are installed on your ATV, the ATV may carry or tow a maximum of 300 lbs. (136 kg) with a maximum tongue weight of 30 lbs. (13 kg). Maximum rear rack capacity is 70 lbs. (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 the front of the ATV.
Driving Safely OPERATION Hauling Cargo and Towing WARNING S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. S When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. S CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. S SECURE ALL LOADS BEFORE OPERATING.
OPERATION Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Use extra caution. 3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward.
Driving Safely OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25_ maximum). 3. Avoid hills with excessively slippery or loose surfaces. 4. Keep your feet on the footrests. 5. Shift your weight uphill. 6. Drive at a steady rate of speed to avoid stalling. 7. Be alert. Be prepared to take emergency action. 25_ This may include dismounting quickly. 8. Never go over the top of a hill at high speed. If all forward speed is lost: 1.
OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive straight downhill. 2. Shift your weight rearward. 3. Slow down. 4. Never go down a hill at high speed. 5. Squeeze the (left--hand) rear brake lever slightly to aid in slowing. Do not apply the front brakes. 6. Avoid hills with excessively slippery or loose surfaces. 7. Avoid going down a hill at an angle, which can cause the vehicle to pitch sharply to one side.
Driving Safely OPERATION Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions: 1. Avoid hills with excessively slippery or loose surfaces. 2. Avoid crossing the sides of steep hills.
OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. If the vehicle stalls while climbing a hill, never back down the hill! Use the K-turn to turn around. 8 ft. (2.
Driving Safely OPERATION K-Turn/Turning Around on a Hill 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Squeeze the front (right) brake lever to stop the vehicle. Keep your weight uphill. Lock the parking brake. Leave the transmission in forward gear and shut off the engine. Dismount on the uphill side of the vehicle, or on either side if the vehicle is pointing straight uphill. Staying uphill of the vehicle, turn the handlebars full left.
OPERATION Driving Safely Driving Through Water Follow these procedures when operating through water: 1. Check water depths and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests (1). If it’s unavoidable, travel 1 slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes. 3. Choose a crossing where both banks have gradual inclines. 4. Drive slowly.
Driving Safely OPERATION Driving Over Obstacles 1. 2. 3. 4. Always check for obstacles before operating in a new area. Be alert. Watch the terrain. Use extra caution. Never operate over large obstacles. Avoid hazards such as logs, rocks and low branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never apply the throttle suddenly. WARNING Failure to use caution when operating in reverse can result in serious injury or death.
Driving Safely OPERATION Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear and lock the parking brake. 2. Always block the rear wheels on the downhill side. 3. Turn the fuel valve off.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. 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. The system does not allow the blow-by gases to enter the atmosphere.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) J Steering -- Pre-Ride -- " Front suspension -- Pre-Ride -- " Rear suspension -- Pre-Ride -- Tires Remarks Make adjustments j as needed See Pre ed. Pre-Ride Ride Checklist on page 43.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item " General Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) 50 H 3M 500 (800) Lubricate all fittings, pivots, cables, etc.
MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks " Wiring 100 H 12 M 1000 (1600) J Clutches (drive 100 H 12 M 1000 (1600) J Front wheel 100 H 12 M 1000 (1600) Inspect; replace as needed J Brake fluid 200 H 24 M 2000 (3200) Change every two years 300 H 36 M 3000 (4800) Clean out and driven) bearings Spark arrestor Inspect for wear, routing, security; apply dielectric grease to connectors subj
MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil Premium 4 Synthetic 0W40 See page 67. Brakes DOT 3 fluid only See page 35. Transmission Premium AGL Synthetic Gearcase Lube See page 70. Rear Gearcase Premium ATV Angle Drive Fluid See page 71.
MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. NOTE: See page 99 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
MAINTENANCE AND LUBRICATION Engine Oil Check Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Maintain the oil level at the center of the sight glass. Do not overfill. 1. Position the vehicle on a level 2 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 contaminants such as gas or moisture collecting in the crankcase.
MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil. Do not allow the vehicle to be without oil overnight. 1. Obtain the correct 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.
MAINTENANCE AND LUBRICATION Oil and Filter Change 7. Reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove. 9. Using a clean, dry cloth, clean the filter sealing surface on the crankcase. 10. Lubricate the gasket on the new filter with a film of engine oil. Check to make sure the gasket is in good condition. 11.
MAINTENANCE AND LUBRICATION Gearcase Specification Chart Gearcase Lubricant Capacity Drain/Check Plug Torque Fill Plug Torque Transmission Premium AGL Synthetic Gearcase Lubricant 18.6 oz. (550 ml) 18 ft. lbs. (24 Nm) N/A Rear Gearcase Premium ATV Angle Drive Fluid 4 oz. (120 ml) 18 ft. lbs. (24 Nm) 25 ft. lbs. (34 Nm) Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61.
MAINTENANCE AND LUBRICATION Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 61. Maintain the oil level at the bottom of the check plug hole. We recommend the use of Polaris Premium ATV Angle Drive Fluid. Refer to the gearcase specifications chart on page 70. See page 99 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface. 2.
MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled sufficiently. Headlight Lamp Replacement To access the assembly from the front, remove the front cover and unplug the wiring harness.
Lights MAINTENANCE AND LUBRICATION Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws (1). 2 1 2. Remove the lens cover and set aside for reassembly. 3. Remove the lamp (2). 4. Apply dielectric grease to the socket and install a new lamp. 5. Test the taillight/brakelight for proper operation. 6. Reinstall the lens cover.
MAINTENANCE AND LUBRICATION Spark Plugs Refer to the specifications section beginning on page 96 for spark plug and gap specifications. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the airbox for any water and dry it if water is present. 3. Turn the fuel valve off. 4.
MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out WARNING Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Wear eye protection and gloves. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas. Failure to heed these warnings could result in serious injury or death. Periodically clean the spark arrestor to remove accumulated carbon. 1.
MAINTENANCE AND LUBRICATION Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Battery Removal 1. Remove the seat. 2. Disconnect the battery hold-down strap. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5.
Battery MAINTENANCE AND LUBRICATION Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge.
MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage 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% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify state of charge 0%-25% 11.
MAINTENANCE AND LUBRICATION Adjustments Brakes (Front) The front brakes are hydraulic disc brakes. These brakes are self-adjusting. The following checks are recommended to keep the hydraulic brake system in good operating condition. Check more often if brakes are used heavily under normal operation. WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
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. .40″-.80″ (10-20 mm) 1 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.
MAINTENANCE AND LUBRICATION Adjustments WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8″ - 1/4″ (3-6 mm) toe out. 1. Set the handlebars in a straight-ahead position.
MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension.
MAINTENANCE AND LUBRICATION Adjustments WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference. 1. Remove the handlebar cover. 2.
MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay The throttle cable adjuster is located at the right handlebar. 1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever. NOTE: While adjusting freeplay, be sure to flip the throttle lever back and forth several times. 3.
MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner’s manual beginning on page 96. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly.
MAINTENANCE AND LUBRICATION Adjustments WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. Position the vehicle on a level surface. 2. Lock the parking brake. 3.
MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (3 mm) or less. See illustration. 1/8I (3 mm) WARNING Operating the vehicle with worn tires will increase the possibility of skidding, which could lead to loss of control and serious injury or death.
MAINTENANCE AND LUBRICATION Adjustments Air Filter Service 1. Remove the seat. 2. Release the clips and remove the air box cover (1). 3. Loosen the clamp and remove the filter. 4. Remove the pre-filter (2) from the main filter (3). Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.) 6. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.
MAINTENANCE AND LUBRICATION Cleaning and Storage See page 99 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 99 for the part numbers of Polaris products. CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or high pressure washers.
MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 99 for the part numbers of Polaris products. Fluid Levels Inspect fluid levels and change fluids if necessary. S Transmission S Brake Fluid Engine Fogging Use Polaris Engine Fogging Oil. Follow label directions carefully. CAUTION Starting the engine during the storage period will disturb the protective oil film, which can lead to engine damage. Never start the engine during the storage period.
MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly and securely. 4. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting the unit. 5.
SPECIFICATIONS 2005 Phoenix 200 Capacities Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Length Width Height Seat Height Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement Compression Ratio Engine Cooling Alternator Output (watts) Carburetion Main Jet Pilot Jet Jet Needle Air Screw Ignition Timing Spark Plug Type / Gap 96 720 lbs. (326 kg) 395 lbs. (179.
2005 Phoenix 200 Drive System Type Shift Type Front Drive (ratio) Front Tires Rear Tires Front Suspension Rear Suspension Shock Adjustment Front Brake Rear Brake Foot Brake Park Brake Headlight Taillight Brake Light Battery DC Plug-In (Rear) Electric Start Windshield Neutral Indicator Reverse Indicator Tool Kit SPECIFICATIONS Drive System Constant Variable Transmission (CVT) Side Lever F/N/R N/A 21 x 7-10 (4 psi) 20 x 10-9 (4 psi) Suspension and Brakes Dual A-Arm w/7 in. (17.
SPECIFICATIONS 2005 Phoenix 200 Jetting Chart Altitude AMBIENT TEMPERATURE 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 Meters (Feet) 98 Roller Weight Grams Each Driven Clutch Spring 0-1800 (0-6000) 6 @ 14.
POLARIS PRODUCTS Part No. Description 2870791 2871281 2871844 Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) 2873602 2873603 2871653 2872276 2870465 Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lube (qt.) Premium AGL Synthetic Gearcase Lube (gal.) Premium ATV Angle Drive Fluid (8 oz.) Premium ATV Angle Drive Fluid (2.5 gal.
TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.
Engine Backfires TROUBLESHOOTING Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition con
LIMITED WARRANTY WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
MAINTENANCE RECORD DATE 106 MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE RECORD DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS 107
INDEX A Adjustments . . . . . . . . . . . . . . . . 81-91 Age Restrictions . . . . . . . . . . . . . . . . 7 Air Filter . . . . . . . . . . . . . . . . . . . . . 91 B Battery . . . . . . . . . . . . . . . . . . . . 78-80 Battery Charging . . . . . . . . . . . . . 79-80 Battery Installation . . . . . . . . . . . . . 78 Battery Removal . . . . . . . . . . . . . . . 78 Battery Storage . . . . . . . . . . . . . . . . 79 Brake (Foot-Operated) . . . . . . . . . . 37 Brake Lever (Left) . . . . . . . . . . . . .
INDEX M S Main Switch . . . . . . . . . . . . . . . . . . 33 MAINTENANCE AND LUBRICATION . . . . . . . . . 61-95 MAINTENANCE RECORD . 106-107 Making Turns . . . . . . . . . . . . . . . . . 47 Master Cylinder . . . . . . . . . . . . . . . 35 Spark Arrestor Clean-Out . . . . . . . . 76 Spark Plug Removal and Replacement . . . 74 Spark Plugs . . . . . . . . . . . . . . . . . . . 74 SPECIFICATIONS . . . . . . . . . . . 96-98 Start Button . . . . . . . . . . . . . . . . . . . 33 Starting the Engine . . . . .
