Pantone 426 C For your nearest Polaris dealer, visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A. Part No.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles Always follow the instructions and recommendations in this manual.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2008 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emission Control Systems . . . . . . . . . . . . . . . 47 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 82 Troubleshooting . .
INTRODUCTION The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. This vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions. • Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle. • Never operate this vehicle without proper instruction.
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. The ignition switch must be replaced if all keys are lost.
SAFETY Safety Training When you purchased your new Polaris vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis. If you purchased your vehicle from a party other than a Polaris dealer, please request free safety training from any authorized Polaris dealer.
SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. Helmet Eye Protection Long Sleeves Gloves Long Pants Boots Helmet Always wear a helmet that meets or exceeds 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.
SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
SAFETY Operator Safety WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating this vehicle.
SAFETY Operator Safety Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. Do not fill the tank neck.
SAFETY Operator Safety Never consume alcohol or drugs before or while operating this vehicle. Keep both hands on the handlebars. Keep both feet on the footrests. Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers.
SAFETY Operator Safety Never carry a passenger on the rear rack. Ejection from the vehicle or contact with moving components can result in serious injury or death. Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control, accident and/or injury. Avoid sudden turns or swift movement of the handlebars. Never operate at excessive speeds.
SAFETY Operator Safety Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn. See page 35. Never attempt jumps or other stunts. Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 41.
SAFETY Operator Safety Always follow the procedures outlined in this manual for driving on hills. See page 37. Never operate on hills too steep for this vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°. Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 39.
SAFETY Operator Safety Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure. Always travel slowly when operating on unfamiliar terrain. Use extra caution. Always follow the procedures outlined in this manual for driving in reverse. See page 43. Use caution when operating on rough, slippery or loose terrain. Always follow the procedures outlined in this manual for operating over obstacles. See page 42.
SAFETY Operator Safety Never operate this vehicle on a frozen body of water. Never modify a Quadricycle through improper installation or use of accessories. Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your 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. Replacement safety labels are provided by Polaris at no charge.
SAFETY Safety Labels and Locations General Warning <1166 Clutch Cover Warning 7173027 Age Warning 19
SAFETY Safety Labels and Locations Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually. > 7173026 Rack Warning DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death.
SAFETY Safety Labels and Locations “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure/Load 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 (27.6 kPa) Rear: 4.0 psi (27.6 kPa) • Maximum weight capacity: 285 lbs. (129 kg) Improper tire pressure or overloading can cause loss of control.
FEATURES AND CONTROLS Switches and Levers Start Switch Light Switch Main Key Switch Turn Signal Switch Horn Switch Choke Lever Hazard Warning Switch Main Key Switch Turn the main switch to the OFF position to stop the engine and end all electrical power to the vehicle. The main key switch must be in the ON position before starting the engine. The headlights are not on in this position. Move the key switch to the LIGHTS ON position to turn the headlight on.
FEATURES AND CONTROLS Switches and Levers Light Switch Use the headlight switch to change the lights from high beam to low beam. Move the main key switch to the LIGHTS ON position to turn the headlight on. Choke Lever The choke assists in starting a cold engine. See page 32. Horn Switch Press the horn button to alert others of your presence. Hazard Warning Switch Push the hazard warning switch to cause all turn indicators to flash simultaneously.
FEATURES AND CONTROLS Switches and Levers Throttle Lever Press the throttle lever to increase engine speed and vehicle movement. Release the lever to reduce engine speed and vehicle movement. WARNING! Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.
FEATURES AND CONTROLS Foot Brake The all-wheel foot brake is located on the right footrest. Press the brake pedal forward with your foot to engage all four brakes, providing maximum stopping power. Inspect and maintain the brake fluid level as outlined in this manual. See page 58. Parking Brake Foot Brake 1. Squeeze the brake lever. 2. Push the parking brake lock down to engage the lock. 3. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever.
FEATURES AND CONTROLS Indicator Lights View vehicle functions on the instrument panel. Each light illuminates when the feature is activated. High Beam Indicator Hazard Warning Indicator Neutral Gear Indicator Turn Signal Indicator Reverse Gear Indicator Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Quadricycle.
FEATURES AND CONTROLS Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel to the fuel tank. The gauge in the cap shows the approximate amount of fuel remaining. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. Fuel Tank Cap Fuel Valve Fuel Valve The fuel valve is located on the left side of the vehicle. ON: For normal operation.
FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. R: Reverse N: Neutral F: Forward Gear To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. Gear Selector R N F NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for your new Polaris Quadricycle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle. 3. Never carry a passenger on this vehicle. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Avoid sudden turns or swift movement of the handlebars when operating on pavement. 6.
OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Sit on the vehicle. 3. Turn the fuel valve on. 4. Turn the main key switch on. 5. Squeeze the brake lever. Tip: Do not use the choke if starting a warm engine. 6. If the engine is cold, move the choke lever to the left until it stops. Tip: The choke is fully on when the lever is completely to the left. The choke is off when the lever is completely to the right.
OPERATION Starting the Engine 9. Activate the starter for a maximum of five seconds. Release the start switch when the engine starts. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle. 10. If the engine does not start, release the start switch, wait five seconds, then attempt to start again. Repeat this procedure until the engine starts. 11.
OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever. 4. Start the engine and allow it to warm up. 5. Shift the transmission into gear. 6. Check your surroundings and determine your path of travel. 7. Release the brake lever. 8. Slowly squeeze the throttle lever toward the handlebar to begin driving. Squeeze the throttle lever further to increase speed. 9. Drive slowly.
OPERATION Turning the Vehicle To 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. The same leaning technique should be used for turning in reverse. Practice making turns at slow speeds before attempting to turn at faster speeds. WARNING! Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.
OPERATION Driving on Slippery Surfaces Sideways skid Turn in direction of skid Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down before driving onto slippery surfaces. 3. Be alert. Watch the trail. Avoid quick, sharp turns. 4. Never apply the brakes during a skid.
OPERATION Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25° maximum). 3. Always check the terrain carefully before ascending any hill. 4. Avoid hills with excessively slippery or loose surfaces. 5. Keep both feet on the 25° Maximum footrests. 6. Shift body weight uphill. 7.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Avoid hills with excessively slippery or loose surfaces. 3. Avoid crossing the side of a steep hill. 4. Shift body weight uphill. 5. Keep your feet on the footrests. 6.
OPERATION Driving Downhill 25° Maximum When driving downhill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Avoid hills with excessively slippery or loose surfaces. 3. Shift body weight uphill. 4. Drive straight downhill. 5. Slow down. Never go down a hill at high speed. 6. Avoid going down a hill at an angle, which can cause the vehicle to pitch sharply to one side. 7. Apply the brakes slightly to aid in slowing.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 2.4 m 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 40 Apply the all-wheel foot brake to stop the vehicle. Keep your weight uphill. Squeeze and hold the brake lever while completing steps 4-6. Leave the transmission in forward and shut off the engine. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gradual inclines. 3. Avoid operating through deep or fastflowing water. Maximum Depth NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water.
OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly.
OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
OPERATION Hauling Cargo 31.7 kg Load Distribution Read and understand the load distribution warnings listed on the vehicle warning labels. Never exceed the specified weights. Your Quadricycle may carry a maximum of 31.7 kg of cargo on the rear rack. It may tow a maximum of 136 kg with a maximum tongue weight of 13.6 kg. Load cargo as low as possible. Never carry cargo on the front of the vehicle.
OPERATION Parking on an Incline Avoid parking on an incline. 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 downhill side. 5. Turn the fuel valve off.
EMISSION CONTROL SYSTEMS This vehicle complies with the requirements of European directive 97/ 24/EC. Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements. Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition.
MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Record maintenance and service in the Maintenance Log beginning on page 90.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Hours Calendar Kilometers Q Steering - Pre-Ride - X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride - - Pre-Ride - X Brake fluid level - Pre-Ride - X Brake lever travel - Pre-Ride - Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - Tires Frame fasteners Remarks Make adjustments as need ed.
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Q Choke cable 50 6M 500 Inspect; adjust; lubricate; replace if necessary E Carburetor air intake ducts/flange 50 6M 500 Inspect duct for proper sealing/air leaks Drive belt 50 6M 500 Inspect; adjust; replace as needed Shift linkage Inspect; lubricate; adjust E 50 6M 500 Q Steering 50 6M 500 Lubricate X Front suspension 50 6M 500 Lubricate X Rear susp
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Engine Oil Lube Method PS-4 PLUS Performance Synthetic 2W-50 See page 52. Brake Fluid DOT 4 Only See page 58. Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 55. Rear Gearcase Premium Angle Drive Fluid See page 56.
MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.
MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Always change the oil filter whenever changing oil. Change the oil more often if the vehicle is routinely subjected to: • operation in dusty or wet conditions. • operation when air temperature is below -12° C. • short trips at -12° to -1° C. (engine fails to reach operating temperature).
MAINTENANCE Oil and Filter Change 7. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 8. Clean the filter sealing surface on the crankcase. 9. Lubricate the filter o-ring. 10. Install the new oil filter. After the filter contacts the engine surface, turn it 1/2 turn by hand. 11. Remove the oil fill plug. Add 850 ml of the recommended oil (see page 52). 12. Reinstall the fill plug. 13. Start the engine. Allow it to idle for two minutes.
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Transmission Oil Recommendations Gearcase Lubricant Capacity Drain Plug Torque Transmission Premium AGL Synthetic Gearcase Lubricant 550 ml 24 Nm Oil Check 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. View the oil level through the sight glass. The oil level should be between 1/4 and 3/4.
MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. Rear Gearcase Oil Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain/Check Plug Torque Rear Gearcase Premium ATV Angle Drive Fluid 120 ml 34 Nm 24 Nm Oil Check 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Remove the check plug. View the oil level.
MAINTENANCE Brakes WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Once open, a bottle of brake fluid absorbs moisture from the air, which causes the boiling temperature of the brake fluid to drop. This can lead to early brake fade and the possibility of accident. Do not store opened brake fluid. Properly discard any unused portion.
MAINTENANCE Brakes Brake Check Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily during normal operation. 1. Always keep foot brake fluid at an adequate level. Check the foot brake system regularly for fluid leaks. 2. Check the brakes for excessive travel or spongy feel. 3. Check the brake pads for wear, dam1 mm age or looseness. Replace pads when they are worn to 1 mm. 4.
MAINTENANCE Brakes Brake Lever Travel Service the brakes when brake lever travel reaches 65 mm. Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting. 65 mm Brake Freeplay Periodically measure the freeplay of the rear brakes. Acceptable freeplay range is 10-20 mm. To adjust rear brake freeplay, turn the adjuster nut at the rear brake drum.
MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Set the handlebars in a straight-ahead position and secure them in this position. 3. Place a chalk mark on the 2 center line of the front tires approximately 25 cm from the floor, or as 1 close to the hub/axle center line as possible. Make sure both marks are the same distance from the floor. 4.
MAINTENANCE Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Accessory springs are available through your Polaris dealer. Adjuster Side Panel Removal 1. Remove the seat. 2.
MAINTENANCE Handlebars 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 serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference. 1. Remove the handlebar cover. 2. Loosen (do not remove) the four handlebar clamp bolts. 3.
MAINTENANCE Carburetor Your Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. or higher. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation. Although this power cannot be regained, adjustments to the carburetor and drive system can be made to allow more efficient operation.
MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Slide the boots off the inline cable adjuster sleeve. Loosen the adjuster locknut. 2. Turn the adjuster until 1.6-3 mm of freeplay exists at the lever. Move the throttle lever back and forth several times while adjusting. 3. Tighten the lock nut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster. 1.
MAINTENANCE Tires 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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Refer to the specifications section beginning on page 86 for recommended tire type, size and pressure.
MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Safely place jackstands under the vehicle. 4. Remove the wheel nuts. Remove the wheel. Wheel Installation 1. 2. 3. 4. 66 Place the wheel on the wheel hub. Install the wheel nuts finger tight. Carefully remove the jackstands. Torque the wheel nuts to 37 Nm.
MAINTENANCE Air Filter 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake. 2. Remove the seat. 3. Release the air box cover clips. Remove the air box cover. 4. Loosen the hose clamp and remove the filter. 5. Remove the pre-filter from the main filter. 6. Wash the pre-filter in soapy water. Rinse and air dry. 7. Reinstall the pre-filter over the main filter. Replace the main filter if needed. 8. Reverse the steps to reinstall all components.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 86 for the recommended spark plug type and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs.
MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments. Wet Fouled Spark Plug The wet fouled insulator tip is black.
MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlamp Replacement To access the assembly from the front, remove the front cover and unplug the wiring harness. Remove the headlight assembly from the vehicle.
MAINTENANCE Vehicle Immersion If the vehicle stops while fully submerged, 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 vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle out of the water. 2. Turn the fuel valve off. 3. Check the air box and dry any water. 4. Remove the spark plug. 5. Drain any water found in the air box. 6.
MAINTENANCE Constant Variable Transmission (CVT) System WARNING 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. The CVT system rotates at high speeds, creating large amounts of force on clutch components.
MAINTENANCE 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. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
MAINTENANCE Battery 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 last. 5. Lift the battery out of the battery compartment. Battery Installation 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Connect and tighten the red (positive) cable first. 4. Connect and tighten the black (negative) cable last. 5.
MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of an activated, sealed battery. Read all instructions before proceeding with the installation of this battery. A sealed battery is already filled with electrolyte. It has been sealed and is fully charged at the factory. Always keep a sealed battery fully charged. • DO NOT pry the sealing strip off. • DO NOT add any other fluid to this battery. • A fully charged battery will register 12.
MAINTENANCE Battery 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. Polaris recommends maintaining battery charge by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping the vehicle clean will extend the life of components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components. Avoid directing the water stream at the following items: • Wheel bearings • Transmission seals • Brakes • Cab and body panels • Labels and decals • Electrical components • Switches and controls If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: 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. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 77. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 48. • Rear gearcase • Transmission • Brake fluid Fog the Engine Use Polaris Engine Fogging Oil. Follow label directions carefully. Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 48.
MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop 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 the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front bumper, racks or handlebars.
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2870465 2871653 2872276 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 82 Description Engine Lubricant Fogging Oil (355 ml Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (.95 l) Premium AGL Synthetic Gearcase Lube (3.8 l) Pump for 3.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Solution Reset the breaker Recharge the battery to 12.
TROUBLESHOOTING Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Idle set too low Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Adjust idle speed Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Overuse of choke Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Turn fuel valve to reserve, refuel Inspect and rep
SPECIFICATIONS Phoenix 200 Quadricycle Maximum Weight Capacity Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Rear Rack Capacity Hitch Tongue Weight Capacity Hitch Towing Weight Capacity Overall Length Overall Width Overall Height Seat Height Wheelbase Ground Clearance Minimum Turning Radius Engine Type Lubrication Engine Cooling Displacement Bore x Stroke Alternator Output Compression Ratio Carburetor Pilot Jet Main Jet Air Screw Jet Needle Ignition System Ignition Timing S
SPECIFICATIONS Phoenix 200 Quadricycle Drive Ratio, Front Tires, Front Tires, Rear Front Suspension Rear Suspension Shock Adjustment Brakes, Rear (Handlebar) Brake, Foot Brake, Parking Headlight Taillight Brake Light Battery Electric Start Speedometer Neutral Indicator Reverse Indicator Tool Kit DC Plug-In (rear) Windshield N/A 21x7-10 / 27.6 kPa 20x10-9 / 27.6 kPa Dual A-Arm w/17.8 cm travel Mono-Shock Swing Arm w/16.
WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship. 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. This warranty is transferable to another consumer during the warranty period through a Polaris dealer.
WARRANTY 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 TWO YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
MAINTENANCE LOG DATE 90 MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 91
INDEX A D Air Filter . . . . . . . . . . . . . . . . . . . . . 67 Driving Procedures . . . . . . . . . . . . . . 34 Driving Properly . . . . . . . . . . . . . . . . 34 Driving Through Water . . . . . . . . . . . 41 Driving Uphill . . . . . . . . . . . . . . . . . . 37 B Battery . . . . . . . . . . . . . . . . . . . . 73-76 Charging . . . . . . . . . . . . . . . . . 75 Installation . . . . . . . . . . . . . . . . 74 Removal. . . . . . . . . . . . . . . . . . 74 Storage . . . . . . . . . . . . . . . . . .
INDEX L S Levers . . . . . . . . . . . . . . . . . . . . . 22-24 Light Switch . . . . . . . . . . . . . . . . . . . 23 Lights Headlamp Replacement . . . . . . 70 Indicator Lights. . . . . . . . . . . . . 26 Taillight/Brake Light . . . . . . . . 70 Load Distribution . . . . . . . . . . . . . . . 45 Lubrication Guide . . . . . . . . . . . . . . . 51 Safe Operation Practices. . . . . . . . . . 30 Safety Labels . . . . . . . . . . . . . . . 18-21 Age Warning. . . . . . . . . . . . . . .
INDEX T Transporting the Vehicle . . . . . . . . . Turn Signal Switch . . . . . . . . . . . . . Turning Around on a Hill . . . . . . . . Turning the Vehicle . . . . . . . . . . . . . W 81 23 40 35 V Vehicle Identification Numbers. . . . . 6 Vehicle Immersion. . . . . . . . . . . . . . 71 94 Warning Symbols . . . . . . . . . . . . . . . . 4 Washing the Vehicle . . . . . . . . . . 77-78 Wheel and Hub Tightening . . . . . . . . 65 Wheel Installation . . . . . . . . . . . . . . . 66 Wheel Removal . . . . .
