Polaris PHOENIX 200 User Manual

9SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further d

99POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

100TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Turn OverPos

101TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

102TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

103WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITEDWARRANTY on all components of the Polaris A

104WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARR

105WARRANTYExported Veh iclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, T HERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS S

106MAINTENANCE RECORDDATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS

107MAINTENANCE RECORDDATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS

108INDEXAAdjustments 81-91...Age Restrictions 7...Air Filter 91...BBattery 78-80...Batter

10SAFETYOperator SafetyS Always have the ATV inspected by an authorized Polaris dealer ifit’s been involved in an accident.S Never operate on hills to

109INDEXMMain Switch 33...MAINTENANCE ANDLUBRICATION 61-95...MAINTENANCE RECORD 106-107.Making Turns 47...Master Cy

11SAFETYOperator SafetyS Wet brakes may have reduced stopping ability. Test your brakes afterleaving water. If necessary, apply them lightly several t

12SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CANHAPPENThe risk of an accident is greatly increased

13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on anATV.WHAT CANHAPPENCarrying a passengergreatly reduces theoperator’s ability to

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating an ATVon pavedsurfaces, includingsidewalks, paths,parking lots, anddriveways.WHAT CANHAPPENATV

15SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV withoutwearing an approvedhelmet, eye protection andprotective clothing.WHAT CANHAPPE

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV at excessivespeeds.WHAT CANHAPPENExcessive speed increases theoperator’s chance of los

17SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CANHAPPENPoor main

18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extracaution when operatingthe ATV on unfamiliarterrain.WHAT CANHAPPENUnfamiliar terrain

19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT urning improperly.WHAT CANHAPPENImproper turns could cause loss of control and lead to a collisionor o

20SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDClimbing hills improperly.WHAT CANHAPPENImproper hill climbing couldcause loss of control oroverturn.HOW

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT raveling downhillimproperly.WHAT CANHAPPENImproperly descending a hillcould cause loss of controlor ov

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills andturning on hills.WHAT CANHAPPENImproperly crossing or turning ashills could

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwardsor improperly dismountingwhile climbing a hill.WHAT CANHAPPENThe vehicle coul

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles could cause loss of control o

25SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATVthrough deep orfast-flowing water.WHAT CANHAPPENT ires may float, causingloss of tracti

26SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV with improper modifications.WHAT CANHAPPENImproper installation of accessories or modi

27SAFETYOperator SafetyWARNINGOperating the ATV on streets or roads, especially in darkness,could result in an accident and serious injury or death.Yo

28SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals and o

2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

29SAFETYSafety Decals and LocationsLocation BLocation CLocation DOperating this ATV if you are underthe age of 16 increases your chanceof severe injur

30SAFETYSafety Decals and LocationsLocation GImproper A T V use can result in SEVERE INJUR Y or DEAT HALWAYS USEAN APPROVEDHELMET ANDPROTECTIVEGEARNEV

31SAFETYSafe Riding GearAlways wear clothing suited t o the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce t

32SAFETYFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasol

33FEATURES AND CONTRO LSElectrical Switches1. Light Switch/Hi-Lo Beam Control - The lights won’t turn onunless the main key switch is on.2. Engine Sto

34FEATURES AND CONTRO LSThrottle LeverPress the throttle lever (1) towardthe handlebar to increase enginespeed and vehicle movement.Engine speed retur

35FEATURES AND CONTRO LSBrakesMaster CylinderCheck the brake fluid level inthe master cylinder before eachuse of the ATV. The mastercylinder (1) is lo

36FEATURES AND CONTRO LSBrakesWARNINGApplying only one brake could cause loss of control and result inserious injury or death. Always apply both brake

37FEATURES AND CONTRO LSBrakesFoot BrakeThe foot brake (1) is amechanical rear wheel brake.The foot brake is located onthe i nside of the rightfootres

1238FEATURES AND CONTRO LSParking BrakeWARNINGOperating the ATV while the parking brake is engaged couldresult in an accident and serious injury or de

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

2139FEATURES AND CONTRO LSChokeThe choke assists in starting a cold engine. See page 44 for correctchoke and throttle settings during starting.Fuel Va

40FEATURES AND CONTRO LSAutomatic Transmission Gear SelectorThe transmission gear selector (1)is located on the right side ofthe vehicle.F: Forward Ge

41FEATURES AND CONTRO LSKick-Start LeverIf the battery becomes too weak to start the engine, use the kick-startlever to start the engine until the bat

42OPERATIONBreak-In PeriodThe break-in period for your new Polaris 4-cycle ATV is defined as thefirst ten hours of operation, or the time it takes to

43OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

44OPERATIONCold Weather Operation for 4-Cycle EnginesInternal engine condensation increases as outside temperaturesdecrease. If the vehicle is used ye

45OPERATIONStarting the Engine6. Squeeze the left brake lever.NOTE: The starter will not engage unless the rear brake is applied.Always squeeze and ho

46OPERATIONDriving SafelyDriving Procedures1. Sit upright. Keep your feet on the footrests. Keep both hands on thehandlebars.2. Start t he engine and

47OPERATIONDriving SafelyMaking Turns1. To make a turn, steer in the direction of the turn, leaning yourupper body to the inside of the turn while sup

48OPERATIONDriving SafelyHauling Cargo an d TowingIf the Polaris accessory rear rack or hitch are installed on your ATV, theATV m ay carry or tow a ma

4

49OPERATIONDriving SafelyHauling Cargo an d TowingWARNINGS REDUCE SPEED AND ALLOW GREATER DISTANCES FORBRAKING WHEN HAULING CARGO OR TOWING.S When ope

50OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever driving on slippery or loose surfaces such as wet trails,gravel, snow or ice, follow the

25_51OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow theseprecautions:1. Drive straight uphill.2. Avoid steep hills (25_ maximu

52OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Drive straight downhill.2. Shift your weight rearward

53OPERATIONDriving SafelySidehillingWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting i

8 ft. (2.4 m)54OPERATIONDriving SafelyTurning Around on a HillWARNINGImproper hill climbing procedures could cause loss of control oroverturn and resu

55OPERATIONDriving SafelyK -Turn/Turning Around on a Hill1. Squeeze the front (right) brake lever to stop the vehicle.2. Keep your weight uphill.3. Lo

56OPERATIONDriving SafelyDriving Through WaterFollow these procedureswhen operating throughwater:1. Check water depthsand current beforecrossing.2. Av

57OPERATIONDriving SafelyDriving Over Obstacles1. Always check for obstacles before operating in a new area.2. Be alert. Watch the terrain. Use extra

58OPERATIONDriving SafelyDriving in ReverseFollow these precautionswhen operating in reverse:1. Avoid backingdownhill.2. Always check forobstacles or

5TABLE OF CONTENTSWELCOME 3...VEHICLE IDENTIFICATION NUMBERS 6...SAFETY 7...FEATURE

59OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline. If it’s unavoidable, follow theseprecautions:1. Turn the engine off.1. Place t

60EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with s

61MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition.

62MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interv

63MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Generallub

64MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Wiring 100

65MAINTENANCE AND LUBRICATIONLubrication GuideCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart beginning

66MAINTENANCE AND LUBRICATIONPremium 4 Synthetic LubricantPolaris P remium 4 All Season synthetic engine oil has been speciallyformulated for use in P

67MAINTENANCE AND LUBRICATIONEngine Oil CheckAlways check and change the oil at the intervals outlined in thePeriodic Maintenance C hart beginning on

68MAINTENANCE AND LUBRICATIONOil and Filter ChangeCAUTIONIf the ATV is left without oil in the system for extended periods,the oil pump may lose its p

6VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers in the spaces provided.Remove the spare key and store it in a safe place. If b

69MAINTENANCE AND LUBRICATIONOil and Filter Change7. Reinstall t he drain plug.Torque to 11 ft. lbs. (15 Nm).8. Place shop towels beneaththe oil filte

1270MAINTENANCE AND LUBRICATIONGearcase Specification ChartGearcase Lubricant Capacity Drain/CheckPlug TorqueFill PlugTorqueTransmission Premium AGL S

71MAINTENANCE AND LUBRICATIONRear Gearcase OilAlways check and change the rear gearcase oil at the intervals outlinedin the Periodic Maintenance Chart

1272MAINTENANCE AND LUBRICATIONLightsWARNINGPoor lighting while driving can result in severe injury or death.Headlight and taillight lenses become dir

73MAINTENANCE AND LUBRICATIONLightsTaillight/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp may need to bereplaced.1. R

174MAINTENANCE AND LUBRICATIONSpark PlugsRefer to the specifications section beginning on page 96 for spark plugand gap specifications.CAUTIONUsing no

75MAINTENANCE AND LUBRICATIONVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the machine is not thoroughly

76MAINTENANCE AND LUBRICATIONSpark Arrestor Clean- OutWARNINGDo not perform clean-out immediately after the engine has beenrun, as the exhaust system

77MAINTENANCE AND LUBRICATIONConstant Variable Transmission (CVT) SystemWARNINGFailure to comply with the instructions in this warning can result inse

78MAINTENANCE AND LUBRICATIONBatteryWARNINGImproperly connecting or disconnecting battery cables can resultin an explosion and cause serious injury or

7SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy a

79MAINTENANCE AND LUBRICATIONBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more,remove the battery from the v

80MAINTENANCE AND LUBRICATIONBatteryBattery ChargingNOTE: Always verify battery condition before and 1-2 hours after theend of charging.State ofCharge

81MAINTENANCE AND LUBRICATIONAdjustmentsBrakes (Front)The front brakes are hydraulic disc brakes. These brakes areself-adjusting.The following checks

82MAINTENANCE AND LUBRICATIONAdjustmentsBrakes (Rear)Periodically measure the freeplay of the rear brakes. To adjust rearbrake freeplay, turn the adju

83MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGSevere injury or death can result from improper toe alignment andadjustment. Do not attempt to adjust t

84MAINTENANCE AND LUBRICATIONAdjustmentsSteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If l

85MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGImproper adjustment of the handlebars or incorrect torquing ofthe adjuster block tightening bolts can c

86MAINTENANCE AND LUBRICATIONAdjustmentsCarburetorIMPORTANT: Your Polaris ATV is calibrated at the factory foroptimal performance at altitudes ranging

87MAINTENANCE AND LUBRICATIONAdjustmentsThrottle Cable FreeplayThe throttle cable adjuster is located at the right handlebar.1. Slide the boots (1) of

88MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGOperating your ATV with worn tires, improperly inflated tires,non-standard tires or improperly installe

8SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your ATV. Your safety is involved when these wordsand

89MAINTENANCE AND LUBRICATIONAdjustmentsWARNINGImproperly installed wheels can adversely affect tire wear andvehicle handling, which can result in ser

90MAINTENANCE AND LUBRICATIONAdjustmentsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent operat

13291MAINTENANCE AND LUBRICATIONAdjustmentsAir Filter Service1. Remove the seat.2. Release the clips and remove the airbox cover (1).3. Loosen the cla

92MAINTENANCE AND LUBRICATIONCleaning and StorageSee page 99 for the part numbers of Polaris products.Cleaning th e ATVKeeping your ATV clean will not

93MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 99 for the part numbers of Polaris products.CAUTIONStarting the engine during th

94MAINTENANCE AND LUBRICATIONCleaning and StorageStorage TipsSee page 99 for the part numbers of Polaris products.Fluid LevelsInspect fluid levels and

95MAINTENANCE AND LUBRICATIONCleaning and StorageTransporting an ATVFollow these procedures whentransporting an ATV.1. Turn off the engine andremove t

96SPECIFICATIONS2005 Phoenix 200CapacitiesGross Vehicle Weight 720 lbs. (326 kg)Dry Weight 395 lbs. (179.2 kg)Fuel Capacity 2.5 gal. (9.5 l)Engine Oil

97SPECIFICATIONS2005 Phoenix 200Drive SystemDrive System Type Constant Variable Transmission (CVT)Shift Type Side Lever F/N/RFront Drive (ratio) N/AFr

98SPECIFICATIONS2005 Phoenix 200Jetting ChartAltitude AMBIENTTEMPERATUREBelow 40° F(Below 5° C)+40°F and above(+5°C and above)Meters(Feet)0-1800(0-600