Polaris Phoenix 200 Quadricycle User's Manual

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. 9922082 Rev 01
Printed in USA
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.
The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.
For more information about Polaris, visit us online at www.polarisindustries.com.
1
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. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in USA
2009 Phoenix 200 Quadricycle Owner’s Manual
P/N 9922082
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Emission Control Systems . . . . . . . . . . . . . . . 47
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 82
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 83
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 90
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3
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.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, may result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that may result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
4
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. Take a training course.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a
Quadricycle/trailer combination on public roads is prohibited.
5
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.
Engine Serial Number
VIN
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
6
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.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equipment has been added, or if any modifications have been made, that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling.
Use only Polaris-approved accessories. Know their function and effect
on the vehicle.
7
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. The ECE mark consists
E4
of a circle surrounding the letter E, followed by the
051039
distinguishing number of the country which has
0006.31
granted approval. The approval number and serial
number will also be displayed on the label.
8
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.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
9
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.
Never operate this vehicle without proper
instruction. Take a training course. Beginners
should receive training from a certified instructor.
Contact an authorized Polaris dealer or visit the
Polaris web site at www.polarisindustries.com.
Never permit others to operate this vehicle unless
they have read and understand this manual and all
product labels, and have completed a certified
safety training course.
Never allow anyone under 16 years of age to
operate this vehicle.
10
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.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Turn the fuel valve off whenever the vehicle is stored or parked.
Never start the engine or let it run in an enclosed area. Operate this vehicle only
outdoors or in well-ventilated areas.
Always inspect your vehicle before each use to
verify that it's in safe operating condition. Follow
the inspection and maintenance procedures
outlined in this manual. See page 31.
Always wear an approved helmet that fits
properly. Wear eye protection (goggles or
face shield), gloves, boots, long sleeves and
long pants.
11
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.
12
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. Travel
and turn at speeds appropriate for the
terrain, visibility, operating conditions and
your experience.
13
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.
14
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.
Always follow the procedures outlined in this
manual for braking if you stall or roll backwards
while climbing a hill. Never back down a hill. See
page 40.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See page
38. Never attempt to turn this vehicle around on
any hill until you've mastered (on level ground)
the turning technique outlined in this manual.
15
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.
Always follow the procedures outlined in this manual for operating on slippery or
loose surfaces. Use extra caution. Always avoid skidding or sliding. See page
36.
16
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.
If this vehicle has been involved in an accident, always have an authorized
Polaris dealer inspect the entire vehicle for possible damage, including (but not
limited to) brake, throttle and steering systems.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use or accidental starting.
For more information about Quadricycle safety, contact
an authorized Polaris Quadricycle dealer or visit the
Polaris web site at www.polarisindustries.com.
17
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. The part number is printed
on the label.
Rack Warning
Age Warning
No Passenger
Warning
Discretionary
Warning
Tire Pressure/Load
Warning
+
+
++
+
+
+
Clutch Cover
Warning
General
Warning
18
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. Tow only from tow
hooks or hitch. Max. Rack 70
lbs. (31.7 kg)
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or
tipover may result causing severe injury or death. Tow only from tow
hooks or hitch. Max. Rack 70 lbs. (31.7 kg)
7173312
Hitch Warning
Exceeding vehicle towing
limit could lead to an
accident. Reduce speed
Exceeding vehicle towing limit could lead to an accident.
Reduce speed when towing a trailer. Read owner's manual
when towing a trailer. Read
for details. Trailer Tongue Weight should be about 10% of the
owner's manual for details.
Gross Trailer Weight, and should not exceed 13.6 kg (30 lbs).
MAXIMUM TOWING CAPACITY: 136 KG (300 lbs)
Trailer Tongue Weight should
7173312
be about 10% of the Gross
Trailer Weight, and should
not exceed 13.6 kg (30 lbs).
MAXIMUM TOWING CAPACITY: 136 KG (300 lbs)
20
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.
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)
7175749
21
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.
WARNING! Do not attach a large key fob or key ring to the main switch. It may
contact the gas tank cap when turning, causing an interruption to the electrical
system and an unexpected engine shut-down during operation.
Start Switch
Press the start switch toward the handlebar to engage the starter.
Tip: The starter will not engage unless the rear brakes are applied. See page 32
for engine starting procedures.
22
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. Use this feature to alert others of an emergency or other situation requiring caution.
Turn Signal Switch
Move the switch either left or right to activate the corresponding
turn signal. Return the switch to the center position to end the signal.
23
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.
ETC
Throttle Lever
Do not start or operate a Quadricycle with sticking or improperly operating throttle controls.
Contact your dealer for repair if throttle problems arise.
The Electronic Throttle Control (ETC) stops the engine in the event of a
throttle system malfunction. Do not modify the ETC system or replace it
with other throttle mechanisms.
Rear Brake Lever
Rear Brake Lever
The brake lever operates the rear
brakes only. Squeeze the brake lever
toward the handlebar to apply the
rear brakes.
Since the brake lever operates the
rear brakes only, it is not as effective
as the all-wheel foot brake.
If the rear wheels begin to skid or slide while using this brake, reduce
lever pressure.
WARNING! Aggressively applying the rear brake when backing down a hill may
cause rear tipover. Aggressively applying the rear brake while moving forward
may cause the rear wheels to skid and result in loss of control.
24
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. The parking brake
will release automatically.
WARNING! Operating the vehicle while the parking brake is engaged could
result in an accident or fire. Always check to be sure the parking brake is
disengaged before operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Never depend on the parking brake
alone if the vehicle is parked on a hill. Always block the wheels to prevent rolling.
25
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.
Mirrors
26
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.
OFF: For vehicle storage
and when transporting.
RES: Turn the valve to the
OFF
ON
RES
reserve setting if the main
fuel supply is exhausted.
Refuel as soon as possible. Return the valve to the ON position after
refueling.
Reserve fuel range is about 7-10 miles (11-16 km).
27
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.
Whenever the vehicle is left unattended, always place the transmission
in gear and lock the parking brake.
Kick-Start Lever
If the battery is too weak to start the engine, use the kick-start lever to
start the engine until the battery is serviced.
1. Position the vehicle on a level surface.
2. Lock the parking brake.
3. Place the transmission in neutral.
4. Fold out the kick-start lever on the left side of the vehicle.
5. Make sure the main key switch is on.
6. Place your foot on the kick-start lever. Thrust your heel downward
to crank the engine.
7. If the engine is cold, use the choke as outlined on page 32.
8. After the engine has started, fold the kick-start lever back into place.
Tip: A 10/12 mm wrench is provided in the tool kit for removing or installing the
lever. If not installed, make sure the rubber cap is installed on the kick-start
shaft to protect the rider. The storage area for the kick-start lever is on the
left side of the frame above the rear swing arm pivot.
28
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. No single action on your part is as important as following the
procedures for a proper break-in. Careful treatment of a new engine and
drive components will result in more efficient performance and longer
life for these components.
NOTICE: Do not operate at full throttle or high speeds during the first three
hours of use.
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 27. Always exercise
extreme caution whenever handling gasoline.
2. Check the oil level. See page 52. Add oil as needed to maintain the
level in the proper range.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 31.
6. Pull only light loads (if equipped with a hitch).
7. Change both the oil and the filter at 20 hours or one month, whichever comes first.
29
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. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
8. Never consume alcohol or drugs before or while operating this vehicle.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged Quadricycle. After any overturn or accident, have a qualified service dealer inspect the entire machine for
possible damage.
11. Never operate the vehicle on a frozen body of water.
12. Familiarize yourself with all laws and regulations concerning the
operation of this vehicle in your area.
13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
14. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
30
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.
Item
Remarks
Page
Brake system/lever travel
Ensure proper operation
58
59
Brake fluid
Ensure proper level
58
Foot brake
Ensure proper operation
25
Front suspension
Inspect, lubricate if necessary
51
Rear suspension
Inspect, lubricate if necessary
51
Steering
Ensure free operation
Tires
Inspect condition and pressure
65
Wheels/fasteners
Inspect, ensure fastener tightness
65
Frame nuts, bolts, fasteners
Inspect, ensure tightness
Fuel and oil
Ensure proper levels
27
52
Throttle
Ensure proper operation
24
64
Indicator lights/switches
Ensure operation
22
Air filter, pre-filter
Inspect, clean
67
-
-
Air box sediment tube
Drain deposits whenever visible
Headlamp
Check operation, apply Polaris dielectric grease when lamp is replaced
23
70
-
Brake light/tail lamp
Check operation, apply Polaris dielectric grease when lamp is replaced
70
Riding gear
Wear approved helmet, goggles, and
protective clothing
8
31
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. The choke can
be adjusted gradually, depending on how much
choke is needed for starting.
7. Press the start switch.
8. Do not press the throttle while starting the
engine.
32
Choke
Lever
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. If the engine slows or stops, move the choke lever half way to the
right to allow proper engine warm-up. Vary the engine RPM
slightly with the throttle to aid in warm-up.
12. When the engine idles smoothly, move the choke lever completely
to the right.
Cold Weather Operation
If the vehicle is used year-round, check the oil level frequently. A rising
oil level could indicate condensation in the bottom of the crankcase,
which can lead to engine damage. Any condensation must be drained.
Tip: Internal engine condensation increases as outside temperature decreases.
If the oil level rises to the top of the sight glass, change the oil immediately. Always operate the engine long enough to reach operating temperature, which reduces condensation.
33
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. Practice maneuvering and using the throttle and
brakes on level surfaces.
34
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.
35
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. To correct a rear wheel skid,
turn the handlebars in the same direction as the skid and shift body
weight forward.
36
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. Drive at a steady rate of speed to avoid stalling.
8. Never open the throttle suddenly or make sudden gear changes.
9. Never go over the top of a hill at high speed.
10. Be alert. Be prepared to take emergency action. This may include
dismounting quickly.
If all forward speed is lost:
Keep your weight uphill.
If the vehicle begins rolling downhill, never apply engine power. Never
apply the rear brakes while rolling backwards.
Apply the foot brake gradually. When fully stopped, squeeze the brake
lever as well.
Dismount on the uphill side, or to either side if the vehicle is pointed
straight uphill. Turn the vehicle around and remount, following the procedure described on page 40.
37
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. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
38
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.
39
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.
Staying uphill of the vehicle, turn the handlebars full left.
Slowly release the brake lever and allow the vehicle to roll around
to your right until it's pointing across the hill or slightly downward.
Squeeze the brake lever. Remount from the uphill side. Keep your
weight uphill.
With the transmission still in forward, start the engine
Release the brake lever and drive slowly downhill. Control speed
with the brake lever until the vehicle is on level ground.
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. If the vehicle tips or overturns in
water, or if the engine stops during or after operating in water,
restarting can result in serious engine damage. Transport the vehicle
to your dealer for service before restarting the engine. If this is not
possible, follow the vehicle immersion inspection and drying
procedures outlined on page 71, then see your dealer for service at
the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops.
Do not make sudden throttle changes.
41
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.
42
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.
43
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. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.
When operating over rough or hilly terrain, reduce speed and cargo to maintain
stable driving conditions.
CARRY LOAD AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on
the rack raises the center of gravity of the vehicle and creates a less stable
operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.
NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level surface.
Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough
terrain, while cornering, or while ascending or descending a hill.
44
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. When operating over rough or hilly terrain, reduce cargo and
drive slowly to maintain stable driving conditions.
Slow down. Operate with extreme caution when hauling cargo or towing loads. Balance, handling and control may be affected.
Towing
Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer
combination on public roads is prohibited. Do not exceed the maximum
capacities when towing. Do not tow any trailer on a grade steeper than
15°.
Phoenix 200
Quadricycle
Maximum Towed Load
(Level Ground)
136 kg
Maximum Vertical Hitch
Weight
13.6 kg
45
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.
46
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. The engine and
related components must be maintained at Polaris specifications to
achieve optimal performance.
Engine idle speed is the only adjustment Polaris recommends that the
operator perform. Any other adjustments should be performed by an
authorized Polaris dealer.
47
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.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
WARNING
Improperly performing the procedures marked with a „ could result in
component failure and cause an accident, which may result in serious injury or
death. Always have an authorized Polaris dealer perform these services.
Maintenance Chart Key
X
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.)
Q Have an authorized Polaris dealer perform these services.
48
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. See Pre-Ride Checklist
on page 31.
-
Pre-Ride
-
X Engine oil level
-
Pre-Ride
-
X Air filter, pre-filter
E
-
Daily
-
Inspect; clean often; replace
as needed
X Air box sediment
tube
-
Daily
-
Drain deposits when visible
Headlamp/tail
lamp
-
Daily
-
Check operation; apply
dielectric grease if replacing
X Air filter,
E main element
-
Weekly
-
Inspect; replace as needed
10
Monthly
100
Inspect periodically
X Brake pad wear
Q
20
Monthly
200
Check terminals; clean; test
X Front gearcase oil
(if equipped)
Battery
25
Monthly
250
Inspect level; change yearly
X Transmission oil
25
Monthly
250
Inspect level; change yearly
X Engine breather
E filter (if equipped)
25
Monthly
250
Inspect; clean if needed
X Engine oil change
E (break-in)
25
1M
250
Perform a break-in oil change
X General
lubrication
50
3M
500
Lubricate all fittings, pivots,
cables, etc.
50
6M
500
Drain bowl periodically and
prior to storage
50
6M
500
Inspect; adjust; lubricate;
replace if necessary
Carburetor float
bowl
Q Throttle Cable/
E ETC Switch
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
49
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 suspension
50
6M
500
Lubricate
X Engine oil change
E
100
6M
1000
Perform a break-in oil change
at 20 hours
X Oil filter change
E
100
6M
1000
Replace with oil change
Q Valve clearance
100
12 M
1000
Inspect; adjust
Q Fuel system/filter
100
12 M
1000
Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
X Engine mounts
100
12 M
1000
Inspect
100
12 M
1000
Inspect
Q Spark plug
100
12 M
1000
Inspect; replace as needed
Q Ignition Timing
100
12 M
1000
Inspect
X Wiring
100
12 M
1000
Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Q Clutches (drive
100
12 M
1000
Inspect; clean; replace worn
parts
Q Front wheel
100
12 M
1000
Inspect; replace as needed
Q Brake fluid
200
24 M
2000
Change every two years
E
E
Exhaust muffler/
pipe
E
E
and driven)
bearings
E Idle speed
-
Adjust as needed
Q Toe adjustment
-
Inspect periodically; adjust
when parts are replaced
-
Adjust as needed
Headlight aim
50
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.
Front A-Arms
Polaris Premium U-Joint
Lube
Inspect; tighten fasteners; grease
(also after washing vehicle or
driving in water)
Front A-Arms
51
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.
Oil Specifications
Lubricant
Capacity
Drain Plug Torque
PS-4 PLUS Performance
Synthetic 2W-50 4-Cycle Oil
1200 ml
15 Nm
Oil Level
Maintain the oil level at the center of the sight glass. Do not overfill.
NOTICE: A rising oil level between checks in cool weather driving can indicate
contaminants such as gas or moisture collecting in the crankcase. If
the oil level rises to the top of the sight glass, change the oil
immediately.
1. Position the vehicle on a level
surface.
2. Start the engine. Allow it to idle
for 30 seconds. Stop the engine.
3. View the oil level through the
sight glass.
4. Remove the fill plug. Add the
recommended oil as needed.
5. Reinstall the fill plug securely.
52
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).
NOTICE: If the vehicle 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.
2.
3.
4.
Use Polaris-recommended products.
Position the vehicle on a level surface.
Start the engine. Allow it to idle for two minutes. Stop the engine.
Place a drain pan beneath the engine crankcase. Remove the drain
plug. Allow the oil to drain completely.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
5. Reinstall the drain plug with a new sealing washer.
6. Reinstall the drain plug. Torque to specification (see page 52).
53
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. Stop the
engine.
14. Check for oil leaks.
15. Check the oil level. Add oil as
needed.
16. Discard used oil and filter
properly.
54
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.
3. Remove the fill plug. Add the
recommended oil as needed.
4. Reinstall the fill plug.
3/4
1/4
Oil Change
1. Position the vehicle on a level surface. Place the transmission in
gear. Lock the parking brake.
2. Remove the fill plug.
3. Remove the transmission drain plug.
4. Drain the fluid into a drain pan.
5. Clean and reinstall the drain plug. Torque to specification.
6. Add 550 ml of the recommended fluid.
7. Reinstall the fill plug.
8. Check for leaks. Discard used oil properly.
55
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. The oil level should be
at the bottom of the plug hole.
3. Remove the fill plug. Add the
recommended fluid as needed.
4. Reinstall the fill plug. Torque to
specification.
5. Reinstall the check plug. Torque
to specification.
Fill Plug
Check Plug
Oil Change
1. Remove the skid plate.
2. Remove the drain plug. Drain the fluid into a drain pan.
3. Clean and reinstall the drain plug with a new sealing washer. Torque
to specification.
4. Remove the fill plug. Add 120 ml of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the skid plate. Discard used oil properly.
56
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.
Under normal operation, a diaphragm extends into the reservoir as fluid
level drops. If the fluid level is low and the diaphragm is not extended, a
leak is likely. The brake system should be inspected by your dealer. Fill
the reservoir as needed whenever the cover is loosened or removed to
ensure proper diaphragm operation. Use Polaris DOT 4 brake fluid. Do
not overfill.
Reservoir levels will decrease as brake pads become worn. When checking the fluid level, the vehicle must be on level ground with the handlebars straight. If the fluid level is low, check brake pad thickness before
adding brake fluid. Do not overfill.
57
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. Check the security and surface condition of the brake discs.
Brake Fluid (Foot Brake)
Check brake fluid level before each use of the vehicle.
The brakes should feel firm when they're applied. Spongy or weak
brakes may indicate a fluid leak or low fluid level. A low fluid level
may also mean that brake pads are worn and need to be replaced. Do not
operate the vehicle with spongy or weak brakes. See your dealer for service.
1. Locate the foot brake master cylinFull
der under the right rear fender.
2. View the fluid level through the resAdd
ervoir body.
3. Fluid level is full at the MAX mark.
Add brake fluid if the level reaches
the MIN mark.
58
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.
10-20 mm
Adjuster Nut
59
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. Measure the distance between the marks and record the
measurement (1).
5. Move the vehicle until the chalk marks are at the rear of the tires,
even with the hub/axle center line.
6. Measure the distance between the marks and record the
measurement (2).
7. Subtract measurement 2 from measurement 1. The difference is the
vehicle toe-out alignment.
8. If you discover improper alignment, see your Polaris dealer for service.
60
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. Remove the three fasteners
securing the side panel to
the vehicle.
3. Pull the side panel away
from the vehicle.
Fasteners
61
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. Adjust the handlebar to the desired height.
4. Be sure the handlebars do not contact the gas tank or any other part
of the machine when turned fully to the left or right.
5. Tighten the front handlebar clamp bolts first, then tighten the rear
bolts. Torque to 34 Nm.
Tip: A gap of up to 3 mm should remain at the rear bolts.
62
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. Optional jets and clutch components,
available from your Polaris dealer, are required for operation above
1800 meters. Jetting is required only when operating below 4 degrees C.
at 1800 meters and lower.
Tip: Continuous operation of the engine without proper jetting when required
can cause poor performance, overheating or engine damage. See your
Polaris dealer for more information about jetting.
Carburetor/Engine Idle RPM Adjustment
If necessary, the carburetor can be adjusted.
1. Position the vehicle on a level surface. Place the transmission in gear.
Lock the parking brake.
2. Start the engine. Allow it to idle for
approximately five minutes. Stop
the engine.
3. Turn the carburetor idle screw in
(clockwise) to raise RPM. Turn the
screw out (counterclockwise) to
lower RPM.
Adjuster
63
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.
1.6-3 mm
Tip: Engine RPM should not increase when steering is turned full left or right.
Readjust cable freeplay if this occurs.
Boot
Boot
Sleeve
Lock Nut
64
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.
Wheel and Hub Tightening
Wheel hub and bearing tightness and spindle nut retention are critical
items. These services must be performed by an authorized dealer.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 3 mm or less.
3 mm
65
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.
67
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.
Plug Condition
Torque Specification
New Spark Plug
12-15 Nm
Previously Installed Spark Plug
23-27 Nm
Spark Plug Inspection
Check the spark plug firing end condition after the engine has been
warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 69.
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate
the spark plug counterclockwise to remove it.
3. Inspect the electrodes for wear
and carbon buildup. Replace
worn or fouled plugs. Verify
that the gap is at specification
before installation.
4. Reverse the procedure for
spark plug installation. Torque
to specification.
68
Spark Plug Cap
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. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil, improper use of the choke, or incorrect throttle body/carburetor adjustments.
69
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.
To access the headlight assembly without removing the front cover,
reach up under the front cab.
1. Remove the rubber cover
Rubber
from the back of the headCover
light.
2. Rotate the socket counterclockwise and pull it away
from the headlight assembly.
3. Remove the headlamp and
install the new headlamp.
Socket
4. Reinstall all components.
Taillight/Brake Light Lamp Replacement
1.
2.
3.
4.
5.
6.
70
Remove the taillight lens cover mounting screws.
Remove the lens cover.
Remove the lamp.
Apply dielectric grease to the socket and install a new lamp.
Test the light for proper operation.
Reinstall the lens cover.
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. Loosen the carburetor drain screw and
drain the carburetor.
7. Turn the engine over several times using
the electric start.
8. Dry the spark plug. Reinstall the plug or
install a new plug.
9. Tighten the carburetor drain screw.
Drain
Screw
10. Turn the fuel valve on.
11. Attempt to start the engine. If necessary,
repeat the drying procedure.
12. Have the vehicle serviced by your dealer
promptly, whether you succeed in starting it or not.
13. If water has been ingested into the transmission, follow the procedure on page 72 for drying.
71
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. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. See your dealer as
outlined in the owner's manual.
• This CVT system is intended for use on Polaris products only. Do not install it
in any other product.
• Always make sure the CVT housing is securely in place during operation.
CVT Drying
If water is ingested into the CVT system, dry it before operating the
vehicle.
1. Position the vehicle on a level surface.
2. Place the transmission in neutral.
3. Lock the parking brake.
4. Remove the CVT drain plug from the bottom of the CVT cover.
Drain the water. Reinstall the drain plug. Torque to 24 Nm.
5. Start the engine. Place the transmission in neutral.
6. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open.
7. Allow the engine RPM to settle to idle speed, then shift the transmission into forward gear.
8. Test for belt slippage. If the belt slips, repeat the process.
9. Take the vehicle to your dealer for service promptly.
72
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.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,
beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space. Always shield eyes
when working near batteries. KEEP OUT OF REACH OF CHILDREN.
73
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. Attach the hold-down strap
6. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
7. Reinstall the seat.
74
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 12.8 V or higher.
1. Check battery voltage with a
voltmeter or multimeter.
2. If voltage is low, recharge the
battery at 1.2 amps or less until
the voltage is 12.8 or greater.
Tip: When using an automatic charger,
refer to the charger manufacturer's
instructions for recharging. When
using a constant current charger,
follow the guidelines below.
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. from date of
manufacture
May need slight
charge, if no
charge given,
check in 3 months
Needs charge
Needs charge
0%-25%
11.5 volts or less
Needs charge with
desulfating charger
3-6 hours
5-11 hours
At least 13 hours,
verify state of charge
At least 20 hours
75
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. Battery Tender can be left connected during the
storage period, and will automatically charge the battery if the voltage
drops below a pre-determined point. See page 82 for the part numbers of
Polaris products.
76
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.
The best and safest way to clean your Polaris vehicle is with a garden
hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
77
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. Replacement safety
labels are provided by Polaris at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
Polaris recommends the use of common household aerosol furniture
polish for polishing the finish on your Polaris vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
78
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. Carbon Clean removes water from fuel systems, stabilizes
fuel and removes carbon deposits from pistons, rings, valves and
exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the fuel in the tank and carburetor.
4. Stop the engine.
5. Turn the fuel valve off.
6. Drain the carburetor bowl.
Oil and Filter
Change the oil and filter. See page 53.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter.
2. Clean the air box.
3. Drain the sediment tube.
79
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.
Battery Storage
See page 75-76 for storage and charging procedures.
Storage Area/Covers
1. Make sure tire pressure is at specification.
2. Using suitable supports under the frame, raise the vehicle slightly so
that the tires are not touching the ground.
3. Be sure the storage area is well ventilated.
4. Cover the machine with an appropriate cover. Do not use plastic or
coated materials, as they do not allow proper ventilation to prevent
condensation, corrosion and oxidation.
80
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.
81
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 3.8 Liter Jug
Premium ATV Angle Drive Fluid (237 ml)
Premium ATV Angle Drive Fluid (9.5 l)
Grease / Specialized Lubricants
Grease Gun Kit, Premium All Season
Premium All Season Grease (89 ml cartridge)
Premium All Season Grease (414 ml cartridge)
Starter Drive Grease
Premium U-Joint Lube (89 ml)
Premium U-Joint Lube (414 ml)
Dielectric Grease (NyogelTM)
Additives / Miscellaneous
Carbon Clean Plus (355 ml)
Fuel Stabilizer (473 ml)
DOT4 Brake Fluid
LoctiteTM 565 Thread Sealant
Polaris Battery TenderTM Charger
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 12.8 VDC
Check all connections and tighten
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Clogged fuel valve or filter
Water is present in fuel
Fuel valve is turned off
Old or non-recommended fuel
Fouled or defective spark plug(s)
No spark to spark plug
Overuse of choke
Water or fuel in crankcase
Low battery voltage
Mechanical failure
Solution
Turn fuel valve to reserve, refuel
Inspect and clean or replace
Drain the fuel system and refuel
Turn the fuel valve on
Replace with fresh recommended fuel
Inspect plugs and replace if necessary
Inspect plugs, verify stop switch is on
Inspect, clean and/or replace spark plugs
Immediately see your Polaris dealer
Recharge the battery to 12.8 VDC
See your dealer
Engine Backfires
Possible Cause
Weak spark from spark plug
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Mechanical failure
Solution
Inspect, clean and/or replace spark plugs
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
See your dealer
83
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
Kinked or plugged fuel tank vent line
Incorrect fuel
Clogged air filter
Reverse speed limiter malfunction
Electronic throttle control malfunction
Other mechanical failure
Possible Lean Fuel Cause
Low or contaminated fuel
Low octane fuel
Clogged fuel filter
Incorrect jetting
Possible Rich Fuel Cause
Overuse of choke
Fuel is very high octane
Incorrect jetting
84
Solution
Inspect, clean and/or replace spark plugs
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
See your dealer
Solution
Add or change fuel, clean the fuel system
Replace with recommended fuel
Replace filter
See your dealer
Solution
Inspect, clean and/or replace spark plugs
Replace with lower octane fuel
See your dealer
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 replace
Replace with new fuel
Inspect, clean and/or replace spark plugs
Inspect, clean and/or replace spark plugs
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
See your dealer
See your dealer
See your dealer
Clean engine exterior; see your Polaris
dealer
85
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
Spark Plug / Gap
Driving System Type
Shift Type
86
129 kg
179 kg
9.5 liters
1200 ml
550 ml
120 m
31.7 kg
13.6 kg (rear rack weight and tongue weight not
to exceed 13.6 kg)
136 kg
165 cm
106.7 cm
106.7 cm
81.3 cm
114.3 cm
14.5 cm
165 cm unloaded
4-Cycle, Single Cylinder
Wet sump
Air
196 cc
65 x 59
210w @5000 rpm
9.2:1 Full Stroke
1 / 22 mm (VM Type)
38
100
1 Turn Out
2MKNN-4 clip
DC CDI
32° +/- 2° @ 3000 RPM
NGK CR7HSA / 0.6-0.7 mm
Constant Variable Transmission (CVT)
Side Lever (F/N/R)
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/16.5 cm travel
CAM
Mechanical Drum
Hydraulic, All Wheel
Mechanical, Rear
Front Cover, Hi/Lo 35W Halogen
12V 5W
12V 21W
12V 12 AH
Standard
Standard
Standard
Standard
Standard
Accessory
Accessory
Jetting Chart
ALTITUDE
(Meters)
0-1800
1800-3700
AMBIENT TEMPERATURE
Below 5° C
5°C and above
102
100
96
92
Clutching Chart
Altitude
(Meters)
0-1800
1800-3700
Roller Weight
Grams Each
6 @ 14.7 grams
6 @ 9.5 grams
87
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.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will
record the registration for warranty. THE PURCHASER MUST COMPLETE A
QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN
ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification
of registration will be sent to the purchaser as the copy of the Warranty Registration
Form will be the warranty entitlement. If you have not signed the original registration
and received the "customer copy", please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS
REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect in
material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any Quadricycle
that has been altered structurally, modified, neglected, improperly maintained, used for
racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the vehicle due to fire, explosions or any other cause beyond
Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the Quadricycle. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY
ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF
THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON
FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR
OTHERWISE. Some states do not permit the exclusion or limitation of incidental or
consequential damages or implied warranties, so the above limitations or exclusions
may not apply to you if inconsistent with controlling state law.
88
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.
HOW TO OBTAIN WARRANTY SERVICE
If your Quadricycle requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris Quadricycles. 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.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate personnel at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
89
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 . . . . . . . . . . . . . . . . . . . 76
Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake
All-Wheel Brake . . . . . . . . . . . 25
Foot Brake . . . . . . . . . . . . . . . . 25
Parking Brake . . . . . . . . . . . . . 25
Rear Brake Lever. . . . . . . . . . . 24
Brake Check. . . . . . . . . . . . . . . . . . . 58
Brake Fluid . . . . . . . . . . . . . . . . . . . 57
Brake Fluid (Foot Brake). . . . . . . . . 58
Brake Freeplay. . . . . . . . . . . . . . . . . 59
Brake Lever Travel . . . . . . . . . . . . . 59
Brake Light . . . . . . . . . . . . . . . . . . . 70
Brake Maintenance . . . . . . . . . . . 57-59
Break-In Period . . . . . . . . . . . . . . . . 29
C
Carburetor . . . . . . . . . . . . . . . . . . . . 63
Carburetor Adjustment . . . . . . . . . . 63
Cargo . . . . . . . . . . . . . . . . . . . . . . 44-45
Choke Lever. . . . . . . . . . . . . . . . . . . 23
Cleaning and Storage. . . . . . . . . . 77-80
Clothing . . . . . . . . . . . . . . . . . . . . . . . 9
Clutching Chart . . . . . . . . . . . . . . . . 87
Cold Weather Operation . . . . . . . . . 33
Constant Variable Transmission . . . 72
CVT Drying . . . . . . . . . . . . . . . . . . . 72
CVT System. . . . . . . . . . . . . . . . . . . 72
D
Drivetrain Break-In . . . . . . . . . . . . .
Driving Downhill. . . . . . . . . . . . . . .
Driving in Reverse. . . . . . . . . . . . . .
Driving on a Sidehill . . . . . . . . . . . .
Driving on Slippery Surfaces. . . . . .
Driving Over Obstacles . . . . . . . . . .
92
29
39
43
38
36
42
E
Engine Break-In. . . . . . . . . . . . . . . . . 29
Engine Fogging . . . . . . . . . . . . . . . . . 80
Engine Idle RPM Adjustment . . . . . . 63
Engine Oil . . . . . . . . . . . . . . . . . . . . . 52
Equipment Modifications . . . . . . . . . . 7
Exhaust Emission Control System . . 47
Eye Protection . . . . . . . . . . . . . . . . . . . 9
F
Fuel Safety. . . . . . . . . . . . . . . . . . . . . 11
Fuel Tank Cap . . . . . . . . . . . . . . . . . . 27
Fuel Valve . . . . . . . . . . . . . . . . . . . . . 27
G
Gasoline Handling . . . . . . . . . . . . . . . 11
Gear Selector . . . . . . . . . . . . . . . . . . . 28
Gearcase Oil . . . . . . . . . . . . . . . . . . . 56
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
H
Handlebar Adjustment. . . . . . . . . . . . 62
Hauling Cargo . . . . . . . . . . . . . . . 44-45
Hazard Warning Switch. . . . . . . . . . . 23
Headlamp Replacement. . . . . . . . . . . 70
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8
Horn Switch. . . . . . . . . . . . . . . . . . . . 23
I
Idle RPM Adjustment . . . . . . . . . . . . 63
Immersion . . . . . . . . . . . . . . . . . . . . . 71
Indicator Lights . . . . . . . . . . . . . . . . . 26
J
Jetting Chart. . . . . . . . . . . . . . . . . . . . 87
K
Key Switch . . . . . . . . . . . . . . . . . . . . 22
Kick-Start Lever . . . . . . . . . . . . . . . . 28
K-Turn . . . . . . . . . . . . . . . . . . . . . . . . 40
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. . . . . . . . . . . . . . . 19
Clutch Cover Warning . . . . . . . 19
Discretionary Warning . . . . . . . 20
General Warning. . . . . . . . . . . . 19
Hitch Warning . . . . . . . . . . . . . 20
No Passenger Warning . . . . . . . 21
Rack Warning . . . . . . . . . . . . . . 20
Tire Pressure/Load Warning. . . 21
Safety Training . . . . . . . . . . . . . . . . . . 7
Severe Use . . . . . . . . . . . . . . . . . . . . 48
Shifter . . . . . . . . . . . . . . . . . . . . . . . . 28
Side Panel Removal . . . . . . . . . . . . . 61
Sidehilling. . . . . . . . . . . . . . . . . . . . . 38
Signal Words . . . . . . . . . . . . . . . . . . . 4
Spark Plugs . . . . . . . . . . . . . . . . . 68-69
Spring Adjustments, Rear . . . . . . . . . 61
Start Switch. . . . . . . . . . . . . . . . . . . . 22
Starting the Engine . . . . . . . . . . . 32-33
Starting, Kick-Start Lever. . . . . . . . . 28
Steering Assembly . . . . . . . . . . . . . . 61
Storage . . . . . . . . . . . . . . . . . . . . 77-80
Switches . . . . . . . . . . . . . . . . . . . 22-24
Hazard Warning Switch . . . . . . 23
Horn Switch . . . . . . . . . . . . . . . 23
Light Switch . . . . . . . . . . . . . . . 23
Main Key Switch . . . . . . . . . . . 22
Start Switch. . . . . . . . . . . . . . . . 22
Turn Signal Switch . . . . . . . . . . 23
M
Maintenance Chart . . . . . . . . . . . 48-50
Maintenance Chart Key . . . . . . . . . . 48
Mirrors . . . . . . . . . . . . . . . . . . . . . . . 26
Modifications . . . . . . . . . . . . . . . . . . . 7
N
Noise Emission Control System . . . . 47
O
Oil
Engine . . . . . . . . . . . . . . . . . . . . 52
Rear Gearcase . . . . . . . . . . . . . . 56
Transmission . . . . . . . . . . . . . . . 55
Oil and Filter Change . . . . . . . . . 53-54
Oil Level, Engine . . . . . . . . . . . . . . . 52
Oil Level, Rising. . . . . . . . . . . . . . . . 33
Oil Recommendations
Engine . . . . . . . . . . . . . . . . . . . . 52
Rear Gearcase . . . . . . . . . . . . . . 56
Transmission . . . . . . . . . . . . . . . 55
Oil Specifications, Engine . . . . . . . . 52
Operator Safety . . . . . . . . . . . . . . 10-17
P
Panel Removal . . . . . . . . . . . . . . . . . 61
Parking Brake . . . . . . . . . . . . . . . . . . 25
Parking on an Incline . . . . . . . . . . . . 46
Periodic Maintenance Chart . . . . 48-50
Polaris Product List. . . . . . . . . . . . . . 82
Polishing the Vehicle . . . . . . . . . . . . 78
Pre-Ride Checklist . . . . . . . . . . . . . . 31
R
Reverse Operation. . . . . . . . . . . . . . . 43
Riding Gear. . . . . . . . . . . . . . . . . . . 8, 9
T
Taillight. . . . . . . . . . . . . . . . . . . . . . . 70
Throttle Cable Freeplay . . . . . . . . . . 64
Throttle Lever . . . . . . . . . . . . . . . . . . 24
Tires . . . . . . . . . . . . . . . . . . . . . . 65-66
Tread Depth . . . . . . . . . . . . . . . 65
Wheel and Hub Tightening. . . . 65
Wheel Installation . . . . . . . . . . . 66
Wheel Removal . . . . . . . . . . . . 66
Toe Alignment . . . . . . . . . . . . . . . . . 60
Towing . . . . . . . . . . . . . . . . . . . . . . . 45
Training. . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission Oil. . . . . . . . . . . . . . . . 55
Transmission System (CVT) . . . . . . 72
93
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 . . . . . . . . . . . . . . . . . 66