Phoenix 200 Owner's Manual for Maintenance and Safety Read this manual 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.
WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance. For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
Dear Parents: We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We’ve provided this owner's manual to assist you and your children in learning about safe operation and care of your new ATV. A POLARIS ATV is not a toy and can be hazardous to operate. Make sure any child who will operate the ATV takes a training course before operating the ATV.
Dear Children: Before you ride your new Polaris ATV, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you’re riding. Your parents and Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the information in your owner’s manual. You must also take an ATV training course before you begin riding.
WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
POLARIS® a trademark of POLARIS Industries Inc. Copyright 2014 POLARIS Industries 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 24 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Emission Control Systems . . . . . . . . . . . . . . . 51 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 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. DANGER A DANGER indicates a hazardous situation that, if not avoided, will 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. 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. • Read this owner’s manual.
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. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
SAFETY Safety Training ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course. If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCoursesm that is available to you and your eligible family members. This training is included in the purchase price of your ATV.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Eye Protection Long Sleeves Helmet Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, 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.
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 Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or rollover, 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. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident.
SAFETY Safety Warnings 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 Safety Warnings Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident. Always 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. Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.
SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or rollover. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it’s unavoidable, travel slowly and avoid sudden turns or stops.
SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator’s foot is not firmly planted on the footrest, it could also contact the rear wheels. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover. • 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 43. • Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. • Always check the terrain carefully before descending a hill.
SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. • Always maintain a steady speed when climbing a hill. If all forward speed is lost: • Keep body weight uphill. • Apply the front brakes (right lever). • When fully stopped, apply the rear brake as well, and then lock the parking brake. • Lock the parking brake when fully stopped.
SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.
SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 46. Skidding or Sliding Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly).
SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. • Never exceed the stated load capacity for this ATV. • Cargo should be properly distributed and securely attached. • Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. • Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer.
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 Discretionary Warning + General Warning 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. • REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.
SAFETY Safety Labels and Locations “No Passenger” Warning Tire Pressure/Load Warning Age Warning Clutch Cover Warning “No Passenger” Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 4.0 psi (27.6 kPa) Rear: 4.0 psi (27.
SAFETY Safety Labels and Locations Age Warning WARNING Operation of this ATV 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 Cover Warning WARNING • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch.
FEATURES AND CONTROLS Switches Override Switch Light Switch ON OFF Main Key Switch Start Button Engine Stop Switch Light Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position to operate the headlights. Engine Stop Switch Before starting the engine, press the upper end of the switch down to the ON position. To stop the engine, press the lower end of the switch down to the OFF position.
FEATURES AND CONTROLS Switches Override Switch (Reverse Speed Limiter) This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch. WARNING! Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override button.
FEATURES AND CONTROLS 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. Always contact your dealer for service before operating the vehicle. WARNING Aggressively 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.
FEATURES AND CONTROLS Brakes Rear Brakes (Left Lever) Rear Brakes Squeeze the left brake lever toward the handlebar to apply the mechanical rear wheel brakes. This lever does not apply the front brakes. Rear Brakes (Foot Brake) The foot brake operates the rear brakes. The foot brake is located on the inside of the right footrest. Operate this brake with your right foot. The foot brake is a mechanical rear wheel brake.
FEATURES AND CONTROLS Brakes Parking Brake 1. Place the transmission in gear. 2. Squeeze and release the left brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock down 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. WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire.
FEATURES AND CONTROLS Brakes Brake Fluid 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. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 36 for correct choke and throttle settings during starting. Fuel Tank Cap Fuel Tank Cap Always refuel with the engine Fuel Valve stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See page 98 for the part numbers of POLARIS products.
FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. Gear Selector 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 ATV properly can result in a collision, loss of control, accident or rollover, 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 ATV 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 14 years of age to operate this vehicle. Adult supervision is required for children under age 16. Do not allow anyone with cognitive or physical disabilities to operate this vehicle. 3. Never carry a passenger on this ATV. 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Operate this vehicle off-road only.
OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
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 wellventilated area. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Turn the fuel valve on. 5. Sit on the vehicle. Tip: Do not use the choke if starting a warm engine. Excessive use of the choke can cause the spark plug to become wet fouled. 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.
OPERATION Starting the Engine 10. Activate the starter for a maximum of five seconds, releasing the button 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. 11. If the engine does not start, release the start button, wait five seconds, then attempt to start again. Repeat this procedure until the engine starts. 12.
OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your path of travel. 6. Release the left brake lever and slowly depress the throttle with your right thumb to begin driving. 7. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
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 rollover. 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 when entering 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.
OPERATION Driving Uphill 25° Maximum Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or rollover. 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. Never climb hills with excessively slippery or loose surfaces. 5. Keep both feet on the 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 rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Avoid crossing the side of a steep hill. 3. Shift body weight uphill. 4. Keep your feet on the footrests. 5.
OPERATION Driving Downhill 25° Maximum When driving downhill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Shift body weight uphill. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Squeeze the rear (left) brake lever gradually. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control.
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. 8 ft. (2.4 m) 1. 1. 2. 3. 4. 5. 6. 7. 8. 44 Squeeze the front (right) brake lever to stop the vehicle. Lock the parking brake while keeping body weight uphill. 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. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible. 4. Never attempt to operate over large obstacles, such as rocks or fallen trees.
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. 7. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased.
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 Maximum 70 lbs. (31.7 kg) Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Always read and understand the load distribution warnings listed on the accessory rack and hitch warning labels. Never carry cargo on the front of the vehicle. If the accessory rear rack is installed, cargo should be evenly distributed and mounted as low as possible on the rack. Always attach a towed load to the hitch point.
OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. 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 U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c.
MAINTENANCE 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. Record maintenance and service in the Maintenance Log beginning on page 106.
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Symbol Description Ź Perform these operations more often for vehicles subjected to severe use. E Emission-related service (failure to conduct this maintenance will not void the emissions warranty but may affect emissions) D Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death.
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Steering - - Front suspension - - Rear suspension - - Tires - Brake fluid level - Brake lever travel - Brake system - - Wheels/fasteners - - Pre-Ride - Inspect and make adjustments as needed. See Pre-Ride Checklist on page 35.
MAINTENANCE Periodic Maintenance Chart Item Carburetor float bowl D Throttle Cable/ E Throttle Release Switch D Choke cable E E Carburetor air intake ducts/flange Drive belt Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) 50 H 6M 500 (800) Remarks Drain bowl periodically and prior to storage Inspect; adjust; lubricate; replace if necessary 50 H 6M 500 (800) 50 H 6M 500 (800) 50 H 6M 50 H 6M Ź Engine oil change 100 H 6M Ź Oil filter change Ź Front gearcase oil (if equ
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 Extreme Duty 10W-50 4-Cycle Oil See page 57. Brake Fluid DOT 4 Brake Fluid See page 29. Transmission Oil AGL Gearcase Lubricant & Transmission Fluid See page 60. Rear Gearcase ATV Angle Drive Fluid See page 61.
MAINTENANCE Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. POLARIS recommends the use of POLARIS PS-4 Extreme Duty 10W-50 4-cycle engine oil for this vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage.
MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter whenever changing oil. NOTICE: 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.
MAINTENANCE Oil and Filter Change 8. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 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. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn. 12.
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Maintain the oil level between 1/4 and 3/4 on the sight glass. See page 98 for the part numbers of POLARIS products. Transmission Oil Recommendations Gearcase Lubricant Capacity Drain Plug Torque Transmission AGL Gearcase Lubricant & Transmission Fluid 18.6 oz. (550 ml) 18 ft. lbs. (24 Nm) Oil Check 1. Position the vehicle on a level surface. 2.
MAINTENANCE Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. 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 components. See page 98 for the part numbers of POLARIS products.
MAINTENANCE Brakes Front Brake Inspections The front (right lever) brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. This brake system is selfadjusting. The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate level. See page 29. 2. Check the brake system for fluid leaks. 3.
MAINTENANCE Brakes Rear Brake Adjustments The rear (left lever) brakes 2 1/2" (65 mm) are mechanical brakes, activated by moving the brake lever toward the handlebar. The foot brake is also a mechanical rear brake. Adjust the rear brakes when brake lever travel reaches 2 1/2" (65 mm). Always adjust the brakes when there is no longer sufficient stopping ability at the specified lever travel setting. 1. Position the vehicle on a level surface. 2. Block the front wheels. 3. Place the transmission in neutral.
MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 to 1/4 inch (3-6 mm) toe out. 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. 1. Position the vehicle on a level surface. 2. Set the handlebars in a straight-ahead position and secure them in this position. 3.
MAINTENANCE 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. Side Panel Removal 1. Remove the seat. 2. Remove the three fasteners securing the side panel to the vehicle. 3. Pull the side panel away from the vehicle.
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 96 for recommended tire type, size and pressure.
MAINTENANCE Tires Wheel Removal 1. 2. 3. 4. Position the vehicle on a level surface. Place the transmission in gear. Stop the engine. Lock the parking brake. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 5. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. 6. Remove the wheel nuts. Remove the wheel. Wheel Installation 1.
MAINTENANCE Air Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the seat. 5. Release the air box cover clips, and remove the air box cover. 6. Loosen the clamp and remove the air filter. 7. Remove the pre-filter from the main filter. 8. Wash the pre-filter in soapy water, then rinse and let dry. 9. Reinstall the pre-filter over the main filter. Replace the main filter if needed. 10. Reinstall the air filter into the air box.
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 Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 96 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 9-11 ft. lbs. (12-15 Nm) Previously Installed Spark Plug 17-20 ft. lbs.
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 Vehicle Immersion 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. Turn the fuel valve off. 3. Check the air box and dry any water. 4. Remove the spark plug. 5.
MAINTENANCE Spark Arrester WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrester while the system is hot.
MAINTENANCE 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 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. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the battery compartment. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 79 before 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 vent tube).
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 Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 76. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 77. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various 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 and could remove paint and decals.
MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" 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 exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
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 81. 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 52. • Rear gearcase • Transmission • Brake fluid (change every two years and any time the fluid looks dark or contaminated) Fog the Engine Use POLARIS Engine Fogging Oil. Follow label directions carefully.
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 ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front bumper, racks or handlebars.
ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Accessory springs are available through your POLARIS dealer.
ADJUSTMENTS 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. Cover 2. Loosen (do not remove) the four handlebar clamp bolts. 3.
ADJUSTMENTS Carburetor Your POLARIS ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 8,000 feet (2400 m) and temperatures above 15° F (-9° C). Refer to the specifications section beginning on page 96 for carburetor and jetting specifications. Any jetting changes must be made only by an authorized POLARIS dealer. Always see your dealer if jetting changes are needed.
ADJUSTMENTS Speed Control System This vehicle is delivered in a limited mode to have a maximum speed at or below 20 MPH (32 km/h). The vehicle contains a means for limiting the maximum speed to 20 MPH (32 km/h) and 30 MPH (48 km/h) or less. The maximum unrestricted speed capability is 38 MPH (61 km/h) or less. The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the consumer's request, remove or adjust any speed limiting devices.
ADJUSTMENTS Speed Control System Throttle Stop Speed Control System 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 throttle opens. To remove the speed limiting entirely and allow operation up to the maximum vehicle speed of 38 MPH (61 km/h), the speed limit bracket can be removed. 1. To adjust the speed limit screw, loosen the jam nut. 2.
ADJUSTMENTS 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 1/16" to 1/8" (1.5-3 mm) of freeplay is achieved at the thumb lever. While adjusting freeplay, be sure to flip the throttle lever back and forth several times. 3. Tighten the lock nut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster.
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 Throttle release switch malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to ON position three times for 5 sec
SPECIFICATIONS Phoenix 200 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 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 Spark Plug / Gap Driving
SPECIFICATIONS Phoenix 200 Shock Adjustment Brakes, Front Brakes, Rear Brake, Foot Brake, Parking Headlight Taillight Brake Light Battery Electric Start DC Plug-In (rear) Windshield Neutral Indicator Reverse Indicator Tool Kit CAM Hydraulic Disc Mechanical Drum Mechanical Drum, Rear Brake Mechanical, Rear Front Cover, Hi/Lo 35W Halogen 12V 5W 12V 21W 12V 12 AH Standard Accessory Accessory Standard Standard Standard Jetting Chart Carburetor Jetting *Shaded cells indicate factory settings.
POLARIS PRODUCTS Part Description Number 2870791 2878920 2878919 2878068 2878069 2870465 2871312 2871322 2871423 2876160 2872276 2871460 2871515 2871551 2871329 2871326 2870652 2872189 2871956 2859044 98 Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l) Gearcase / Transmission Lubricants AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./ .
WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • • • • • • • •
WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered 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.
WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations.
WARRANTY U.S.A.
WARRANTY U.S.A. EPA Emissions Limited Warranty Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 107
INDEX A D Air Filter . . . . . . . . . . . . . . . . . . . . . 68 Drivetrain Break-In . . . . . . . . . . . . . . 32 Driving Downhill. . . . . . . . . . . . . . . . 43 Driving in Reverse. . . . . . . . . . . . . . . 47 Driving on a Sidehill . . . . . . . . . . . . . 42 Driving on Slippery Surfaces . . . . . . 40 Driving Over Obstacles . . . . . . . . . . . 46 Driving Procedures . . . . . . . . . . . . . . 38 Driving Through Water . . . . . . . . . . . 45 Driving Uphill . . . . . . . . . . . . . . . . . .
INDEX J-K-L-M-N S Jetting Chart . . . . . . . . . . . . . . . . . . . 97 Key Switch . . . . . . . . . . . . . . . . . . . . 24 Kick-Start Lever . . . . . . . . . . . . . . . . 31 K-Turn . . . . . . . . . . . . . . . . . . . . . . . 44 Lights . . . . . . . . . . . . . . . . . . . . . . . . 69 Headlamp Replacement . . . . . . 69 Taillight/Brakelight. . . . . . . . . . 69 Lubrication Guide . . . . . . . . . . . . . . . 56 Maintenance Chart . . . . . . . . . . . 52-55 Modifications . . . . . . . . . . . . . .
WARNING Improper vehicle 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: • without proper training or instruction. • at speeds too fast for your skills or the conditions. • on public roads - a collision can occur with another vehicle. • with a passenger - passengers affect balance and steering and increase risk of losing control.
