2
Copyright 2004 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or
reuse of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
Printed in USA
2005 Phoenix 200 Owner’s Manual P/N 9919964
3
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
Polaris Recreational and Utility Vehicles
S Snowmobiles
S All-terrain vehicles (ATVs)
S Watercraft
S Victory motorcycles
S RANGER utility vehicles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
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.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
POLARIS and POLARIS THE WAY OUT are registered trademarks of
Polaris Industries Inc.
4
5
TABLE OF CONTENTS
WELCOME 3.................................
VEHICLE IDENTIFICATION NUMBERS 6........
SAFETY 7...................................
FEATURES AND CONTROLS 33...............
OPERATION 42..............................
EMISSION CONTROL SYSTEMS 60............
MAINTENANCE AND LUBRICATION 61.........
SPECIFICATIONS 96.........................
POLARIS P RODUCTS 99......................
TROUBLESHOOTING 100.....................
WARRANTY 103..............................
MAINTENANCE RECORD 106.................
INDEX 108...................................
6
VEHICLE IDENTIFICATION NUMBERS
Record your ATV’s identification numbers in the spaces provided.
Remove the spare key and store it in a safe place. If both keys are lost,
the ignition switch must be replaced.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
1
2
7
SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result
in serious injury or death.
A Polaris ATV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris ATV.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
Safety Training
When you purchased your new ATV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You were
also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
8
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your ATV. Your safety is involved when these words
and symbols are used. Become familiar with their meanings before
reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts
you to the potential for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor personal injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
9
SAFETY
Operator Safety
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.
S Read this manual and all labels carefully, and follow the operating
procedures described.
S Never operate an ATV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris ATV dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
S Never allow anyone under 16 years of age to operate this ATV.
S Never permit a guest to operate the ATV unless the guest has read
this manual and all product l abels and has completed a certified safe-
ty training course.
S Always avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
S Never operate an ATV on a public street, road or highway, including
a dirt or gravel road.
S Never operate an ATV without wearing an approved helmet that fits
properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
S Never consume alcohol or drugs before or while operating an ATV.
S Never operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
S Never attempt wheelies, jumps or other stunts.
S Always inspect your ATV before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
S Always keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.
S Always travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
S Never operate on excessively rough, slippery, or loose terrain.
S Always follow proper turning procedures as described in this manu-
al. Practice t urning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
10
SAFETY
Operator Safety
S Always have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
S Never operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
S Always follow proper procedures for climbing hills. Check the ter-
rain carefully before ascend a hill. Never climb hills with excessive-
ly slippery or loose surfaces. Shift your weight forward. Never open
the t hrottle suddenly or make sudden gear changes. Never go over
the top of a hill at high speed.
S Always follow proper procedures for going downhill and for braking
on hills. C heck the t errain carefully before you start down a hill.
Shift your weight backward. Never go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle
to lean sharply to one side. Travel straight down the hill when pos-
sible.
S Always follow proper procedures for crossing the side of a hill.
Avoid hills with excessively slippery or loose surfaces. Shift your
weight to the uphill side of the ATV. Never attempt t o turn the ATV
around on any hill until you’ve mastered (on level ground) the turn-
ing technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.
S Always use proper procedures if you stall or roll backwards while
climbing a hill. To avoid stalling, maintain a steady speed when
climbing a hill. If you stall or roll backwards, follow the special pro-
cedure for braking described in this manual. Always dismount on the
uphill side, or to either side if the ATV is pointed straight uphill.
Turn the ATV around and remount following the procedure de-
scribed in t his manual.
S Always check for obstacles before operating in a new area. Never
attempt to operate over large obstacles, s uch as rocks or fallen trees.
Always follow proper procedures when operating over obstacles as
described in this manual.
S Always be careful of skidding or sliding. On slippery surfaces like
ice, travel slowly and use extra caution to reduce the chance of skid-
ding or sliding out of control.
S Avoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud-
den m ovements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
11
SAFETY
Operator Safety
S Wet brakes may have reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them lightly several times to allow
friction to dry out the pads.
S Always check for obstacles or people behind the ATV before operat-
ing in reverse. When it’s safe to proceed in reverse, move slowly and
avoid turning at sharp angles.
S Always use t he size and type of tires specified for your ATV, and
always maintain tire pressure as recommended.
S Never modify an ATV through improper installation or use of acces-
sories.
S Never exceed the stated load capacity for your ATV. 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.
S Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-
sumer Product Safety Commission at 1-800-638-2772, or call
Polaris at 1-800-342-3764.
Equipment Modifications
We are concerned for the s afety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris ATV any equipment that may increase the speed or
power of the vehicle, or make any other m odifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may
change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with
their function and effect on the vehicle.
12
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN
HAPPEN
The risk of an accident is greatly increased if the operator does
not know how to operate the ATV properly in different situations
and on different types of terrain.
HOW TO AVOID THE
HAZARD
Beginning and inexperienced operators should complete the
certified training course offered by Polaris. Operators should
regularly practice the skills learned in the course and the
operating techniques described in the owner’s manual.
For more information about the training course, contact an
authorized ATV dealer or call Polaris at 1-800-342-3764.
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN
HAPPEN
Severe injury and/or death could occur if a child under the
minimum age recommendation operates an ATV.
Even though a child may be within the recommended age group
for operating some ATVs, he/she may not have the skills,
abilities, or judgment needed to operate an ATV safely and could
be susceptible to accident or injury.
HOW TO AVOID THE
HAZARD
No one under the age of 16 should operate a Polaris ATV.
13
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Carrying a passenger on an
ATV.
WHAT CAN
HAPPEN
Carrying a passenger
greatly reduces the
operator’s ability to balance
and control the ATV, which
could cause an accident
and injury to the
operator and/or passenger.
HOW TO AVOID THE
HAZARD
Never carry a passenger. The purpose of the long seat is to
allow the operator to shift position as needed during operation. It
is not intended for carrying passengers.
WARNING
POTENTIAL HAZARD
Carrying a passenger on the
rear rack.
WHAT CAN
HAPPEN
A passenger riding on the rear
rack could be ejected from the
vehicle unexpectedly or may
contact moving components,
both of which can result in
severe injury or death.
HOW TO AVOID THE
HAZARD
Never allow passengers to ride on the rear rack.
14
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating an ATV
on paved
surfaces, including
sidewalks, paths,
parking lots, and
driveways.
WHAT CAN
HAPPEN
ATV tires are designed for
off-road use. Operating on
paved surfaces may
seriously affect the handling and
control of the ATV and could result in loss of control, accident,
and/or injury.
HOW TO AVOID THE
HAZARD
Avoid operating the ATV on pavement. If it’s unavoidable, travel
slowly and avoid sudden turns or stops.
WARNING
POTENTIAL HAZARD
Operating this ATV on
public streets, roads or
highways.
WHAT CAN
HAPPEN
The ATV could collide
with another vehicle.
HOW TO AVOID THE
HAZARD
Never operate the ATV on any
public street, road or highway,
including dirt and gravel roads. In many states
it’s illegal to operate ATVs on public streets, roads and highways.
15
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without
wearing an approved
helmet, eye protection and
protective clothing.
WHAT CAN
HAPPEN
Operating an ATV without
an approved helmet
increases the risk of a
severe head injury or
death in the event of an
accident.
Operating without eye protection could result in an accident and
could increase the chance of a severe injury in the event of an
accident.
HOW TO AVOID THE
HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield), gloves,
boots, long-sleeved shirt or jacket, and long pants.
WARNING
POTENTIAL HAZARD
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN
HAPPEN
Consumption of alcohol and/or drugs
could seriously affect operator
judgment. Reaction time may be slower
and operator balance and perception
could be affected.
Consuming alcohol and/or drugs before
or while operating an ATV could result in
an accident causing severe injury or death.
HOW TO AVOID THE
HAZARD
Never consume alcohol or drugs before or while operating an
ATV.
16
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV at excessive
speeds.
WHAT CAN
HAPPEN
Excessive speed increases the
operator’s chance of losing control of
the ATV, which can result in an
accident.
HOW TO AVOID THE
HAZARD
Always operate the ATV at a speed
that’s proper for the terrain, visibility and
operating conditions, and your
experience.
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps
and other stunts.
WHAT CAN
HAPPEN
Attempting stunts increases
the chance of an accident,
including an overturn.
HOW TO AVOID
THE
HAZARD
Never attempt wheelies,
jumps, or other stunts. Avoid
exhibition driving.
17
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN
HAPPEN
Poor maintenance increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE
HAZARD
Always inspect your ATV before each use to make sure it’s in
safe operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the owner’ s manual.
WARNING
POTENTIAL HAZARD
Removing hands from the
handlebars or feet from the
footrests during operation.
WHAT CAN
HAPPEN
Removing even one hand or
foot can reduce ability to
control the vehicle or could
cause loss of balance and
ejection from the ATV.
If the operator’s foot is not firmly planted on the footrest, it could
come into contact with the rear wheels and lead to accident or
injury.
HOW TO AVOID THE
HAZARD
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.
18
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating
the ATV on unfamiliar
terrain.
WHAT CAN
HAPPEN
Unfamiliar terrain may
contain hidden rocks,
bumps, or holes that
could cause loss of
control or overturn.
HOW TO AVOID THE
HAZARD
T ravel slowly and use extra caution when operating on unfamiliar
terrain. Always be alert to changing terrain conditions.
WARNING
POTENTIAL HAZARD
Failure to use extra
caution when operating on
excessively rough,
slippery or loose terrain.
WHAT CAN
HAPPEN
Operating on excessively
rough, slippery or loose
terrain could cause loss of
traction or loss of control,
which could result in an
accident or overturn.
HOW TO AVOID THE
HAZARD
Do not operate on excessively rough, slippery or loose terrain
until you’ve learned and practiced the skills necessary to control
the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
19
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
T urning improperly.
WHAT CAN
HAPPEN
Improper turns could cause loss of control and lead to a collision
or overturn.
HOW TO AVOID THE
HAZARD
Always follow proper procedures for turning as described in the
owner’s manual.
Practice turning at slow speeds before attempting to turn at faster
speeds.
Never turn at excessive speed.
WARNING
POTENTIAL HAZARD
Operating on excessively steep hills.
WHAT CAN
HAPPEN
The vehicle may overturn.
HOW TO AVOID THE
HAZARD
Never operate on hills too steep for the ATV or for your abilities.
Never operate the ATV on hills steeper than 25_.
Practice on smaller hills before attempting large hills.
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN
HAPPEN
Severe injury or death can result if the ATV and/or the operator
fall through the ice.
HOW TO AVOID THE
HAZARD
Never operate the ATV on a frozen body of water.
20
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN
HAPPEN
Improper hill climbing could
cause loss of control or
overturn.
HOW TO AVOID
THE
HAZARD
Always follow proper
procedures for climbing
hills as described in the
owner’s manual.
Always check the terrain
carefully before ascending
any hill.
Never operate the ATV on hills steeper than 25_.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly while traveling uphill. The ATV
could flip over backwards.
Never go over the top of any hill at high speed. An obstacle, a
sharp drop, or another vehicle or person could be on the other
side of the hill.
21
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
T raveling downhill
improperly.
WHAT CAN
HAPPEN
Improperly descending a hill
could cause loss of control
or overturn.
HOW TO AVOID
THE
HAZARD
Always follow proper
procedures for traveling
down hills as described in
the owner’s manual.
NOTE: A special technique
is required when braking
while traveling downhill. See
page 52.
Always check the terrain carefully before descending a hill.
Shift your weight backward.
Never travel down a hill at high speed.
Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight down the hill
when possible. Never travel backwards down a hill.
22
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly crossing hills and
turning on hills.
WHAT CAN
HAPPEN
Improperly crossing or turning as
hills could cause loss of control
or overturn.
HOW TO AVOID THE
HAZARD
NeverattempttoturntheATV
around on any hill until you’ve
mastered the turning technique
(on level ground) as described in
the owner’s manual. See page
54. Use extra caution when
turning on any hill.
Avoid crossing the side of a steep hill.
When crossing the side of a
hill:
Always follow proper procedures as described in the owner’s
manual.
Avoid hills with excessively slippery or loose surfaces.
Shift your weight to the uphill side of the ATV.
23
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards
or improperly dismounting
while climbing a hill.
WHAT CAN
HAPPEN
The vehicle could overturn.
HOW TO AVOID
THE
HAZARD
Maintain steady speed
when climbing a hill.
If all forward speed is
lost:
Keep your weight uphill.
Gradually apply the front brakes (right
lever).
When fully stopped, apply the rear brakes and lock the parking
brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described in the owner’ s manual. See page 54.
If the ATV begins rolling
backwards:
Keep weight uphill.
Apply the front brake gradually.
Never apply the rear brake while rolling backwards.
Never apply engine power.
When fully stopped, apply the rear brake as well, and then lock
the parking brake.
Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described in the owner’ s manual. See page 54.
24
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN
HAPPEN
Operating over obstacles could cause loss of control or overturn.
HOW TO AVOID THE
HAZARD
Before operating in a new area, check for obstacles.
Avoid operating over large obstacles such as rocks and fallen
trees when possible. If unavoidable, use extreme caution and
always follow proper procedures as outlined in the owner’s
manual.
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN
HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the ATV could overturn.
HOW TO AVOID THE
HAZARD
On slippery surfaces such as ice, travel slowly and use extra
caution to reduce the chance of skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Improperly operating in reverse.
WHAT CAN
HAPPEN
The ATV could collide with an obstacle or person, resulting in
severe injury.
HOW TO AVOID THE
HAZARD
Before shifting into reverse gear, always come to a complete stop
and check for obstacles or people behind the ATV. When it’s safe
to proceed, back slowly.
25
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV
through deep or
fast-flowing water.
WHAT CAN
HAPPEN
T ires may float, causing
loss of traction and loss of
control, which could lead
to an accident or overturn.
HOW TO AVOID
THE
HAZARD
Avoid operating the ATV
through deep or
fast-flowing water. If it’s
unavoidable to enter
water that exceeds the recommended maximum depth (see page
56), travel slowly, balance your weight carefully, avoid sudden
movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
Wet brakes may have reduced stopping ability. Always test the
brakes after leaving water. If necessary, apply them several
times to let friction dry out the pads.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with improper or
uneven tire pressure.
WHAT CAN
HAPPEN
Use of improper tires, or operation of the ATV with improper or
uneven tire pressure, could cause loss of control or accident.
HOW TO AVOID THE
HAZARD
Always use the size and type of tires specified for the ATV.
Always maintain proper tire pressure as specified.
26
SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating the ATV with improper modifications.
WHAT CAN
HAPPEN
Improper installation of accessories or modification of the ATV
may cause changes in handling which could lead to an accident.
HOW TO AVOID THE
HAZARD
Never modify the ATV through improper installation or use of
accessories. All parts and accessories added to the vehicle must
be genuine Polaris Industries Inc. or equivalent components
designed for use on this ATV and should be installed and used
according to approved instructions. See your authorized Polaris
ATV dealer for more information.
WARNING
POTENTIAL HAZARD
Overloading the ATV or carrying/towing cargo improperly.
WHAT CAN
HAPPEN
Overloading and towing can cause changes in vehicle handling,
which could lead to loss of control or an accident.
HOW TO AVOID THE
HAZARD
Never exceed the stated load capacity for this ATV.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer . Allow a
greater distance for braking.
Always follow the instructions in the owner’ s manual for carrying
cargo or pulling a trailer. See pages 48-49.
27
SAFETY
Operator Safety
WARNING
Operating the ATV on streets or roads, especially in darkness,
could result in an accident and serious injury or death.
Your ATV is not equipped with highway-approved lights. It’s
designed for and must be used for off-road use only. Use caution
and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness.
WARNING
Leaving the keys in the ignition can lead to unauthorized use of
the vehicle resulting in serious injury or death. Always remove
the ignition key when the vehicle is not in use.
WARNING
After any overturn or accident, have a qualified service dealer
inspect the entire vehicle for possible damage, including (but not
limited to) brakes, throttle and steering systems.
WARNING
Safe operation of this rider-active vehicle requires good
judgement and physical skills. Persons with cognitive or physical
disabilities who operate this vehicle have an increased risk of
overturn and loss of control, which could result in severe injury or
death.
CAUTION
Always keep combustible materials away from the exhaust
system. Exposure to the hot components could result in a fire.
28
SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read
and follow the instructions of the decals and other warnings on the
ATV carefully. If any of the decals shown in this manual dif fer from
the decals on your ATV, always read and follow the instructions of the
decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
A
B
C
D
E
F
G
Location A
WARNING
29
SAFETY
Safety Decals and Locations
Location B
Location C
Location D
Operating this ATV if you are under
the age of 16 increases your chance
of severe injury or death.
NEVER operate this ATV if you are
under age 16.
7172559
WARNING
S Moving parts hazar d under belt-c lutch guard. To
prev ent ser ious injury, do not operate v ehicle with
guard remov ed.
S Do not modify engine or clutch. Doing so can cause
part failure, possible imbalance, and
excessive engine RPM, which can result in serious
injury or death.
NO STEP 7173313
WARNING
7172566
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of
control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 4 (27.6)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight)
INCLUDING MACHINE, DRIVER AND CARGO IS 720 LBS. (326 KG)
Location E
WARNING
7173302
Location F
(Under Seat)
S Operation of this vehicle
without the air filter
element will severely damage
the engine.
S Clean pre-filter element often,
more frequent cleaning
required in dusty conditions.
Do not operate vehicle without
pre-filter.
ATTENTION
S Specific
carburetor jetting
7170007
and adjustments are required
depending on temperature
and altitude. See your Owner’ s
Manual.
Factory setting:
40_ to 80_ F. at 0-3000 feet
(5_ to 27_ C. at 0-900 meters).
30
SAFETY
Safety Decals and Locations
Location G
Improper A T V use can result in SEVERE INJUR Y or DEAT H
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
ALWAYS:
7172560
WARNING
MANUFACTURED
IN TAIWAN
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS
NOT INTENDED FOR USE ON PUBLIC ROADS.
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN
QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR
LES CHEMINS PUBLICS.
Reverse Speed is
limited.
Reverse override is
controlled by the
override switch.
See your Owner’s
Manual.
OVERRIDE
SWITCH
7079906
31
SAFETY
Safe Riding Gear
Always wear clothing suited t o the type of riding. ATV riding requires
special protective clothing for comfort and to reduce the chance of
injury.
1. Helmet
Your helmet is the most important piece
of protective gear for safe riding. A
helmet can prevent a severe head injury.
Select an approved helmet that meets or
exceeds your state’s safety standards
and bears either the Department of
Transportation (DOT) label, the
American National Standards Institute
label (ANSI z90. 1), or the Snell
Memorial Foundation label.
2. Eye Protection
Do not depend on sunglasses for proper
eye protection. A pair of goggles or a
helmet face shield offer the best
protection for your eyes. They should
be kept clean and be of shatterproof
design (bearing the markings z2.1 or
VESC 8).
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like
moto-cross boots.
5. 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.
1
2
3
4
5
32
SAFETY
Fuel Safety
WARNING
Gasoline is highly flammable and explosive under certain
conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well
ventilated area.
S Do not smoke or allow open flames or sparks in or near the
area where refueling is performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it off
with soap and water and change clothing.
S Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause loss of
consciousness or death in a short time.
S Turn the fuel valve off whenever the ATV is stored or parked.
WARNING
The engine exhaust from this product contains chemicals known
to cause cancer, birth defects or other reproductive harm.
Operate this vehicle only outdoors or in well-ventilated areas.
33
FEATURES AND CONTRO LS
Electrical Switches
1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on
unless the main key switch is on.
2. Engine Stop Switch - The engine will not
start or run when the switch is i n the OFF
position. Its purpose is t o provide the
operator with a quick means of engine
shutdown in case of an emergency. To stop
the engine, press the lower end of the rocker
switchdowntotheOFF position. Before
starting the engine, press the upper end of the
switchdowntotheON position.
3. Main Key Switch - Turn the main key
switch clockwise to the ON position before
starting the engine. Turn the main switch off
to stop the engine and end all electrical
power to the vehicle.
4. Start Button - To start the engine, make sure
the stop switch is in t he ON position. Turn
the main key switch on. Press the start
button.
WARNING
Activating the override switch while the throttle is open can cause
loss of control, resulting in severe injury or death. Do not activate
the override switch while the throttle is open.
5. Override Switch (Reverse Speed
Limiter) - This vehicle is equipped
with a reverse speed limiter
system. To gain additional power
while backing, depress the override
switch.
1
2
3
4
5
2
3
5
34
FEATURES AND CONTRO LS
Throttle Lever
Press the throttle lever (1) toward
the handlebar to increase engine
speed and vehicle movement.
Engine speed returns to i dle when
the lever is released.
This ATV is equipped with Polaris
Electronic Throttle Control (ETC), which is
designed to reduce the risk of a frozen or stuck throttle. If the throttle
cable should stick in an open position when the operator releases the
throttle lever, the engine will stop, and power to the rear wheels will
cease.
WARNING
Operating an ATV with sticking or improperly operating throttle
controls could cause an accident and lead to severe injury or
death.
Never start or operate an ATV with a sticking or improperly
operating throttle. Always contact your dealer for service if throttle
problems arise.
Failure to check or maintain proper operation of the throttle
system can result in an accident if the throttle lever sticks during
operation. Always check the lever for free movement and return
before starting the engine. Also check occasionally during
operation.
WARNING
The Electronic Throttle Control (ETC) stops the engine in the
event of a throttle system malfunction and is provided for your
safety. Do not attempt to modify the ETC system or replace it
with any after market throttle mechanisms.
Indicator Lights
The Phoenix 200 has neutral and
reverse indicator lights.
N: Neutral (Green)
R: Reverse (Amber)
1
35
FEATURES AND CONTRO LS
Brakes
Master Cylinder
Check the brake fluid level in
the master cylinder before each
use of the ATV. The master
cylinder (1) is located on the right
handlebar.
View the fluid level through the
indicator window (2) on the top of
the master cylinder. This eye will
appear dark when the fluid level is
full. When fluid is low, t he eye will
be clear.
NOTE: When checking the fluid level, position the ATV on level
ground with the handlebars turned so the top of the reservoir
is level. If the fluid level is low, add DOT 3 brake fluid. DO
NOT OVERFILL. See page 99 for the part numbers of
Polaris products.
WARNING
An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
WARNING
After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of an
accident and severe injury or death.
1
2
36
FEATURES AND CONTRO LS
Brakes
WARNING
Applying only one brake could cause loss of control and result in
serious injury or death. Always apply both brakes at the same
time.
Brake Lever (Right)
Squeeze the right brake lever (1)
toward the handlebar to apply the
hydraulic front wheel brakes. THIS
LEVER DOES NOT APPLY THE
REAR BRAKES.
WARNING
Operating the ATV with a spongy brake lever can result in loss of
braking, which could cause an accident.
Never operate the ATV with a spongy-feeling brake lever .
Always test front brake lever travel and master cylinder fluid level
before riding. When squeezed, the lever should feel firm. Any
sponginess would indicate a possible fluid leak or low master cylinder
fluid level, which must be corrected before riding. Contact your dealer
for proper diagnosis and repairs.
Brake Lever (Left)
Squeeze the left brake lever (2)
toward the handlebar to apply the
mechanical rear wheel brakes. THIS
LEVER DOES NOT APPLY THE
FRONT BRAKES.
1
2
37
FEATURES AND CONTRO LS
Brakes
Foot Brake
The foot brake (1) is a
mechanical rear wheel brake.
The foot brake is located on
the i nside of the right
footrest. Apply the brake
with your right foot. This is
identical to squeezing the left
brake lever on the handlebar.
NOTE: If the rear wheels
slide while using the
foot brake, reduce
brake pedal pressure to
brake the rear wheels without skidding.
WARNING
Aggressively applying the rear brake when backing down a hill
may cause rear tipover, which could result in serious injury or
death.
Use caution when applying the rear brake. Do not aggressively
apply the rear brake when going forward. The rear wheels may
skid and slide sideways, causing loss of control and serious injury
or death.
1
1
2
38
FEATURES AND CONTRO LS
Parking Brake
WARNING
Operating the ATV while the parking brake is engaged could
result in an accident and serious injury or death. Always check to
be sure the parking brake is disengaged before operating.
Setting the Parking Brake
1. Squeeze the left brake
lever (1).
2. Push the park brake
lock (2) down. This
will prevent the
lever from
returning to the
released position.
3. To release the
parking brake lock,
squeeze and release the
brake lever. The parking
brake will release automatically.
Important Safeguards
S The parking brake may relax if left on for a long period of time. Al-
ways block the wheels to prevent rolling.
S Never depend on the parking brake alone if the ATV is parked on a
hill. Always block t he wheels t o prevent rolling.
2
1
39
FEATURES AND CONTRO LS
Choke
The choke assists in starting a cold engine. See page 44 for correct
choke and throttle settings during starting.
Fuel Valve
The fuel valve (1) is located
on the left side of the vehicle.
OFF
Turn the valve off
before storage and
when transporting.
ON
Turn the valve on for
normal operation.
RES
Turn the valve to the
reserve setting if the
main fuel supply is
exhausted. Refuel as
soon as possible.
Reserve fuel range is about
7-10 miles (11-16 km).
NOTE: Return the valve to the ON position after refueling.
Fuel Tank
The fuel tank filler cap (2) is l ocated directly below the handlebar. Use
either leaded or unleaded gasoline with a minimum pump octane
number of 87=(R+ M/2) octane. Refer to the specifications section
beginning on page 96 for tank capacity.
Fuel Filter
The in-line fuel filter should be replaced by your dealer after every 100
hours of operation, or annually. Do not attempt to clean the fuel filter.
40
FEATURES AND CONTRO LS
Automatic Transmission Gear Selector
The transmission gear selector (1)
is located on the right side of
the vehicle.
F: Forward Gear
N: Neutral
R: Reverse
Whenever the ATV is left
unattended, always place the
transmission in gear and lock the
parking brake.
CAUTION
Shifting gears with the engine speed above idle or while the
vehicle is moving could cause transmission damage.
To change gears, stop the vehicle, and with the engine idling,
move the lever to the desired gear.
1
F
N
R
41
FEATURES AND CONTRO LS
Kick-Start Lever
If the battery becomes too weak to start the engine, use the kick-start
lever to start the engine until the battery is serviced.
1. Position the vehicle on a level surface.
2. Lock the parking brake.
3. Place the t ransmission in neutral.
1. Fold out the kick-start lever on the l eft side of the ATV.
2. Make sure the stop switch and main key switch are on.
3. Place your foot on the kick-start. Thrust your heel downward to
crank the engine.
NOTE: If the engine is cold, use the choke as outlined on page 44.
4. After the engine has started, fold the kick-start lever back into
place.
NOTE: 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. Store
the kick-start lever under the seat in the rear cab when not
installed.
42
OPERATION
Break-In Period
The break-in period for your new Polaris 4-cycle ATV is defined as the
first ten hours of operation, or the time it takes to use the first two full
tanks of gasoline. No single action on your part is as important as
following the procedures for a proper break-in. C areful treatment of a
new engine will result in more efficient performance and longer life for
the engine. P erform the following procedures carefully.
CAUTION
Excessive heat build-up during the first three hours of operation
will damage close-fitted engine parts. Do not operate at full
throttle or high speeds for extended periods during the first three
hours of use.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 synthetic Oil or another 0W-40 API certified SH oil.
Never substitute or mix oil brands.
1. Fill the fuel tank with gasoline. See page 39.
2. Check the oil level. Add Polaris Premium 4 Synthetic Oil as
needed to maintain the oil level in the recommended range. S ee
page 67.
3. Drive slowly at first. Select an open area that allows room to
familiarize yourself with vehicle operation and handling.
4. Vary 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 43.
6. Pull only light loads (if equipped with a hitch).
7. During the break-in period, change both the oil and the filter at 20
hours, 200 miles or one month, whichever comes first. See page
67.
43
OPERATION
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury
or death could result. Always inspect the vehicle before each use
to ensure it’s in proper operating condition.
Pre-Ride Checklist
Item Remarks See
Page
Brake system / lever travel Ensure proper operation 35, 36,
81, 82
Brake fluid Ensure proper level 35
Foot brake Ensure proper operation 37
Front suspension Inspect, lubricate if necessary 65
Rear suspension Inspect, lubricate if necessary 65
Steering Ensure free operation --
Tires Inspect condition and pressure 29, 90
Wheels / fasteners Inspect, ensure fastener tightness 89
Frame nuts, bolts, fasteners Inspect, ensure tightness --
Fuel and oil Ensure proper levels 67
Coolant level (if applicable) Ensure proper level --
Coolant hoses (if applicable) Inspect for leaks --
Throttle Ensure proper operation 34, 87
Indicator lights / switches Ensure operation 33, 34
Engine stop switch Ensure proper operation 33
Air filter, pre-filter Inspect, clean 91
Air box sediment tube Drain deposits whenever visible --
Headlamp Check operation, apply dielectric
grease when lamp is replaced
72
Brake light / tail lamp Check operation, apply dielectric
grease when lamp is replaced
73
Riding gear Wear helmet, goggles, protective
clothing
31
44
OPERATION
Cold Weather Operation for 4-Cycle Engines
Internal engine condensation increases as outside temperatures
decrease. If the vehicle is used year-round, check the oil level
frequently. A rising oil level could indicate condensation in the bottom
of the crankcase, which can lead to engine damage. Any condensation
must be drained. If the oil level rises to the top of the sight glass,
change the oil immediately.
Always operate the engine long enough to reach operating temperature,
which reduces condensation.
Starting the Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can
cause loss of consciousness resulting in severe injury or death.
Never run an engine in an enclosed area.
1. Position the vehicle on a level surface.
2. Turn the fuel valve on.
3. Sit on the vehicle.
4. If the engine is cold, use full choke by
pushing the choke lever (1) all the way to the
left. A warm engine will not require the use
of the choke.
NOTE: The choke is fully on when the lever is
pushed completely to the left. The
choke is off when the lever is pushed
completely to the right. The choke can be adjusted
gradually, depending on how much choke is needed for
starting.
5. Place the engine stop switch in the ON position, then turn the main
key switch on.
NOTE: Do not press the throttle while starting the engine.
1
45
OPERATION
Starting the Engine
6. Squeeze the left brake lever.
NOTE: The starter will not engage unless the rear brake is applied.
Always squeeze and hold the left brake lever before
attempting to start the engine.
7. Press t he start button.
8. Activate the starter for a maximum of five seconds, releasing the
button when the engine starts. If it doesn’t start, release the starter,
wait five seconds, then activate for another five seconds. Repeat
until the engine starts.
9. If the engine slows or stops, position the choke lever half way to
allow proper engine warm up. Vary the RPM slightly with the
throttle to aid in warm up.
10. When the engine idles smoothly, push the choke lever all the way
to the right.
CAUTION
Operating the vehicle immediately after starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle.
46
OPERATION
Driving Safely
Driving Procedures
1. Sit upright. Keep your feet on the footrests. Keep both hands on the
handlebars.
2. Start t he engine and allow it to warm up, then shift the transmission
into gear.
3. Check your surroundings and determine your path of travel.
4. Slowly squeeze the throttle lever toward the handlebar to begin
driving. Squeeze the throttle lever further to increase speed.
5. Drive slowly. Practice maneuvering and using the throttle and brakes
on level surfaces.
47
OPERATION
Driving Safely
Making Turns
1. To make a turn, steer in the direction of the turn, leaning your
upper body to the inside of the turn while supporting your weight
on the outer footrest. Use the same leaning technique for turning
in reverse.
2. Practice turning at slow speeds before attempting to turn at faster
speeds.
WARNING
T urning at sharp angles or at excessive speeds can result in
vehicle overturn and lead to serious injury. Avoid turning at sharp
angles. Never turn at high speeds.
48
OPERATION
Driving Safely
Hauling Cargo an d Towing
If the Polaris accessory rear rack or hitch are installed on your ATV, the
ATV m ay carry or tow a maximum of 300 lbs. (136 kg) with a
maximum tongue weight of 30 lbs. (13 kg). Maximum rear rack
capacity is 70 lbs. (31.7 kg) of cargo. Always read and understand the
load distribution warnings listed on the rack and hitch warning labels.
Never exceed the specified weights. Never carry cargo on the front of
the ATV.
Cargo should be evenly distributed and mounted as low as possible on
the rear rack. When operating over rough or hilly terrain, reduce speed
and cargo or towed load to maintain stable driving conditions.
70 lbs.
(31.7 kg)
49
OPERATION
Driving Safely
Hauling Cargo an d Towing
WARNING
S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR
BRAKING WHEN HAULING CARGO OR TOWING.
S When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions.
S CARR Y LOADS AS LOW ON THE RACK AS POSSIBLE. Car-
rying a load high on the rack raises the center of gravity of the
vehicle and creates a less stable operating condition.
S SECURE ALL LOADS BEFORE OPERATING. Unsecured
loads can create unstable operating conditions, which could
result in loss of control of the vehicle.
S 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.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL
PROBLEMS. Use extreme caution when applying brakes with a
loaded vehicle and when towing. Avoid terrain or situations that
may require backing downhill.
S 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.
S DO NOT CARRY LOADS ON THE FRONT OF THE VEHICLE.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED
SPEEDS. The vehicle should never exceed 10 mph (16 kph)
while towing a load on a level grass 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.
50
OPERATION
Driving Safely
Driving on Slippery Surfaces
Whenever driving on slippery or loose surfaces such as wet trails,
gravel, snow or ice, follow these precautions:
1. Slow down before driving onto slippery surfaces.
2. Use extra caution.
3. Be alert. Watch the trail. Avoid quick, sharp turns.
NOTE: To correct a rear wheel skid, turn the handlebars in the same
direction as the skid and shift body weight forward.
WARNING
Failure to exercise care when operating on slippery surfaces can
result in loss of tire traction and cause loss of control, accident,
and serious injury or death.
Never apply the brakes during a skid. Do not operate on
excessively slippery surfaces. Always reduce speed and use
additional caution.
25_
51
OPERATION
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these
precautions:
1. Drive straight uphill.
2. Avoid steep hills (25_ maximum).
3. Avoid hills with excessively
slippery or loose surfaces.
4. Keep your feet on the
footrests.
5. Shift your weight uphill.
6. Drive at a steady rate of
speed to avoid stalling.
7. Be alert. Be prepared to
take emergency action.
This may include
dismounting quickly.
8. Never go over t he top of a hill at high speed.
If all forward speed is lost:
1. Keep your weight uphill.
NOTE: If the vehicle begins rolling downhill, never apply engine
power. Never apply the rear brakes while rolling backwards.
2. Gradually squeeze the right--hand brake lever to engage the front
brakes. When fully stopped, apply the rear brake as well, then lock
the park brake.
3. Dismount on uphill side, or to either side if ATV is pointed straight
uphill. Turn the ATV around and remount, following the procedure
described on page 54.
WARNING
Braking and handling are greatly affected when operating in hilly
terrain. Improper procedure could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
52
OPERATION
Driving Safely
Driving Downhill
Whenever descending a hill, follow these precautions:
1. Drive straight downhill.
2. Shift your weight rearward.
3. Slow down.
4. Never go down a hill at high speed.
5. Squeeze the (left--hand) rear brake lever slightly toaidinslowing.
Do not apply t he front brakes.
6. Avoid hills with excessively slippery or loose surfaces.
7. Avoid going down a hill at an angle, which can cause the vehicle to
pitch sharply to one side.
NOTE: Familiarize yourself with operation of the rear foot brake.
WARNING
Excessive speed can cause loss of control and lead to serious
injury or death. Always operate slowly when traveling downhill.
53
OPERATION
Driving Safely
Sidehilling
WARNING
Improperly crossing hills or turning on hills can result in loss of
control or vehicle overturn, resulting in severe injury or death.
Avoid crossing the side of a hill when possible. Follow proper
procedures as outlined in the owner’s manual.
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling
is necessary, follow these precautions:
1. Avoid hills with excessively slippery or loose surfaces.
2. Avoid crossing the sides of steep hills.
3. Slow down.
4. Shift your weight uphill.
5. Keep your feet on the footrests.
6. Steer slightly into the hill.
NOTE: If the vehicle begins to tip, quickly turn the front wheels
downhill (if possible) or dismount on the UPHILL side
immediately!
8 ft. (2.4 m)
54
OPERATION
Driving Safely
Turning Around on a Hill
WARNING
Improper hill climbing procedures could cause loss of control or
overturn and result in serious injury or death.
Avoid climbing steep hills (25_ maximum).
Use extreme caution when operating on hills, and follow proper
operating procedures outlined in the owner’s manual.
If the vehicle stalls while climbing a hill, never back down the hill!
Use the K-turn to turn around.
55
OPERATION
Driving Safely
K -Turn/Turning Around on a Hill
1. Squeeze the front (right) brake lever to stop the vehicle.
2. Keep your weight uphill.
3. Lock the parking brake.
4. Leave the transmission in forward gear and shut off the engine.
5. Dismount on the uphill side of the vehicle, or on either side if the
vehicle is pointing straight uphill.
6. Staying uphill of the vehicle, turn the handlebars full left.
7. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it’s
pointing across the hill or slightly downward.
8. Squeeze and hold the left brake lever.
9. Remount the vehicle from the uphill side. Keep your weight uphill.
10. With the transmission still in forward, start the engine.
11. Release the brake and drive slowly downhill. Control speed with
the rear brake until the vehicle is on level ground.
56
OPERATION
Driving Safely
Driving Through Water
Follow these procedures
when operating through
water:
1. Check water depths
and current before
crossing.
2. Avoid operating in
water deeper than the
bottom of the
footrests (1). If it’s
unavoidable, travel
slowly, balance your
weight carefully and avoid sudden movements. Maintain a slow
and steady forward motion. Do not make sudden turns, stops or
throttle changes.
3. Choose a crossing where both banks have gradual inclines.
4. Drive slowly. Avoid rocks and obstacles.
5. Wet brakes may have reduced stopping ability. Always test your
brakes after leaving water. If necessary, apply them lightly several
times to allow friction to dry out the pads.
After running the vehicle in water, it’s critical to have it serviced as
outlined in the maintenance chart. See page 61. The following areas
need special attention: engine oil, transmission oil, rear gearcase and
all grease fittings.
CAUTION
Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined
in the maintenance chart. If your vehicle becomes immersed or
is operated in water that exceeds the footrest level, take it to your
dealer for service before starting the engine.
If your vehicle becomes immersed, and it’s impossible to t ake it to a
dealer before starting it, follow the steps described on page 75. Have
the vehicle serviced by your dealer at the first opportunity.
1
57
OPERATION
Driving Safely
Driving 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.
WARNING
Severe injury or death can result if your vehicle comes in contact
with a hidden obstacle. Not all obstacles are immediately visible.
T ravel with caution in unfamiliar terrain.
58
OPERATION
Driving Safely
Driving in Reverse
Follow these precautions
when operating in reverse:
1. Avoid backing
downhill.
2. Always check for
obstacles or people
behind the vehicle
before backing.
3. Drive slowly.
4. Apply the brakes lightly
for stopping.
5. Avoid turning at sharp
angles.
6. Never apply t he throttle suddenly.
WARNING
Failure to use caution when operating in reverse can result in
serious injury or death. Before shifting into reverse, always come
to a complete stop and check for obstacles or people behind the
vehicle. When it’s safe to proceed, back slowly. Avoid backing on
inclines. Avoid turning at sharp angles.
Do not use the override switch unless additional power is required
for vehicle movement. Use with caution.
NOTE: The override switch should be used with caution as rearward
vehicle speed is greatly increased. Do not operate at wide
open throttle. Open the throttle just enough to maintain a
desired speed.
CAUTION
Excessive throttle operation while in the speed limit mode may
cause fuel to build in the exhaust, resulting in engine popping
and/or engine damage.
59
OPERATION
Driving Safely
ParkingonanIncline
Avoid parking on an incline. If it’s unavoidable, follow these
precautions:
1. Turn the engine off.
1. Place the transmission in gear and lock the parking brake.
2. Always block the rear wheels on the downhill side.
3. Turn the fuel valve off.
60
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so
may affect compliance with state and local noise level requirements.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by
gases are forced back to the combustion chamber by the intake system.
The system does not allow the blow-by gases to enter the atmosphere.
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.
Adjustment to engine idle is the only adjustment Polaris recommends
that the operator perform. Any other adjustments should be performed
by an authorized Polaris dealer.
WARNING
The installation of devices that effectively increase exhaust
emissions beyond their legal limits will void all manufacturer
warranties and may violate laws governing the registration and
operation of this vehicle.
Spark Arrestor
Your Polaris vehicle has a spark arrestor that was tested and approved
in accordance with the USDA Forest Service Standard 5100-1C.
Federal law requires that this spark arrestor be installed and functional
when the vehicle is operated on public lands.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES--002 and
European directives 97/24/EC and 89/336/EEC.
61
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained i n the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine Polaris
parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar
with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following charts are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use must be i nspected and
serviced more frequently.
Severe Use Definition
S Frequent immersion in mud, water or sand
S Racing or race-style high RPM use
S Prolonged l ow speed, heavy load operation
S Extended idle
S Short trip cold weather operation
Maintenance Chart Key
" Perform these procedures more frequently for vehicles subjected to
severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these services.
WARNING
Improperly performing the procedures marked with a J could
result in component failure and lead to serious injury or death.
Have an authorized Polaris dealer perform these services.
62
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
J
Steering -- Pre-Ride --
Make adjustments as need-
e
d
S
e
e
P
r
e
R
i
d
e
C
h
e
c
k
l
i
s
t
"
Front suspension -- Pre-Ride --
j
ed. See Pre-Ride Checklist
on pa
g
e 43.
"
Rear suspension -- Pre-Ride --
o
n
p
a
g
e
4
3
.
Tires -- Pre-Ride --
"
Brake fluid level -- Pre-Ride --
"
Brake lever travel -- Pre-Ride --
Brake system -- Pre-Ride --
Wheels/fasteners -- Pre-Ride --
Frame fasteners -- Pre-Ride --
"
E
Engine oil level -- Pre-Ride --
"
E
Air filter, pre-filter -- Daily -- Inspect; clean often
"
E
Air box sediment
tube
-- Daily -- Drain deposits when visible
Coolant
(if applicable)
-- Daily -- Check level daily, change
coolant every 2 years
Headlamp/tail
lamp
-- Daily -- Check operation; apply
dielectric grease if replacing
"
E
Air filter,
main element
-- Weekly -- Inspect; replace as needed
Recoil housing
(if equipped)
-- Weekly -- Drain water as needed,
check often if operating in
wet conditions
"
J
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
"
Front gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
"
Rear gearcase oil
(if equipped)
25 H Monthly 250 (400) Inspect level; change yearly
"
Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly
"
E
Engine breather
filter (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these services.
63
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
"
General
lubrication
50 H 3M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Carburetor float
bowl
50 H 6M 500 (800) Drain bowl periodically and
prior to storage
J
E
Throttle Cable/
ETC Switch
50 H 6M 500 (800) Inspect; adjust; lubricate;
replace if necessary
J
E
Choke cable 50 H 6M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E
Carburetor air
intake ducts/
flange
50 H 6M 500 (800) Inspect ducts for proper
sealing/air leaks
Drive belt 50 H 6M 500 (800) Inspect; adjust; replace as
needed
Cooling system
(if applicable)
50 H 6M 1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
"
E
Engine oil change 100 H 6M 1000 (1600) Perform a break-in oil
change at one month
"
E
Oil filter change 100 H 6M 1000 (1600) Replace with oil change
J
E
Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust
J
E
Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, fuel valve, filter, pump,
carburetor; replace lines
every two years
"
Radiator
(if applicable)
100 H 12 M 1000 (1600) Inspect; clean external
surfaces
"
Cooling hoses
(if applicable)
100 H 12 M 1000 (1600) Inspect for leaks
"
Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
J
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
J
E
Ignition Timing 100 H 12 M 1000 (1600) Inspect
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these services.
64
MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
"
Wiring 100 H 12 M 1000 (1600) Inspect for wear , routing,
security; apply dielectric
grease to connectors
subjected to water , mud, etc.
J
Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
J
Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
J
Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrestor 300 H 36 M 3000 (4800) Clean out
E
Idle speed -- Adjust as needed
J
Toe adjustment -- Inspect periodically; adjust
when parts are replaced
Headlight aim -- Adjust as needed
" Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
J Have an authorized Polaris dealer perform these services.
65
MAINTENANCE AND LUBRICATION
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 61. Items not listed in
the chart should be l ubricated at the General Lubrication interval.
Item Lube Method
Engine Oil Premium 4 Synthetic 0W40 See page 67.
Brakes DOT 3 fluid only See page 35.
Transmission Premium AGL Synthetic
Gearcase Lube
See page 70.
Rear Gearcase Premium ATV Angle Drive
Fluid
See page 71.
(1) Front A-Arms FGrease Inspect; tighten fasteners;
grease (also after washing
ATV or driving in water)
(1)
(1)
66
MAINTENANCE AND LUBRICATION
Premium 4 Synthetic Lubricant
Polaris P remium 4 All Season synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,
high performance, multi-viscosity oil designed to provide the ultimate
in lubrication performance and protection.
NOTE: See page 99 for the part numbers of Polaris products.
Premium 4 possesses unsurpassed film strength over the widest
possible temperature range. It resists viscosity and frictional
breakdown in ambient temperatures from -40° F. to 120° F. (-40 to
+49° C .) Its exceptional frictional properties result in more efficient
operation, more power output and lower fuel consumption.
Although Polaris Premium 4 is the only oil recommended for use i n
this engine, use of any API certified SH oil is allowable as long as it’s
0W-40. Oil may need to be changed more frequently if Polaris
Premium 4 is not used. Follow the manufacturer’s recommendations
for ambient temperature operation.
CAUTION
Mixing brands or using a non-recommended oil may cause
serious engine damage. We recommend the use of Polaris
Premium 4 synthetic Oil or another 0W-40 API certified SH oil.
Never substitute or mix oil brands.
67
MAINTENANCE AND LUBRICATION
Engine Oil Check
Always check and change the oil at the intervals outlined in the
Periodic Maintenance C hart beginning on page 61. Maintain the oil
level at the center of the sight glass. Do not overfill.
1. Position the vehicle on a level
surface.
2. View the oil level through the
sight glass (1) on the right side
of the vehicle.
NOTE: A rising oil level between
checks in cool weather
driving can indicate
contaminants such as
gas or moisture
collecting in the
crankcase. If the oil
level rises to the top of
the sight glass, change
the oil immediately.
3. Remove the fill plug (2) and add the recommended oil as needed.
4. Reinstall the fill plug.
1
2
68
MAINTENANCE AND LUBRICATION
Oil and Filter Change
CAUTION
If the ATV is left without oil in the system for extended periods,
the oil pump may lose its prime, which could result in engine
damage. Always replace the oil and filter within a few hours of
draining the oil. Do not allow the vehicle to be without oil
overnight.
1. Obtain the correct oil filter and an adequate supply of oil so the oil
and filter change can be completed without interruption.
2. Position the vehicle on a level surface.
3. Clean the area around the drain plug on the bottom of the engine
crankcase.
4. Run the engine for two to three minutes until warm. Stop the
engine.
CAUTION
Hot oil can cause serious burns to skin. Do not allow hot oil to
come into contact with skin.
5. Place a drain pan beneath the engine crankcase and remove the
drain plug. Allow the oil to drain completely.
6. Install a new sealing washer on the drain plug.
NOTE: The sealing surfaces on the drain plug and crankcase should
be clean and free of burrs, nicks or scratches.
69
MAINTENANCE AND LUBRICATION
Oil and Filter Change
7. Reinstall t he drain plug.
Torque to 11 ft. lbs. (15 Nm).
8. Place shop towels beneath
the oil filter. Using an oil
filter wrench, turn the filter
counterclockwise to remove.
9. Using a clean, dry cloth,
clean the filter sealing
surface on the crankcase.
10. Lubricate the gasket on the
new filter with a film of
engine oil. Check to make
sure the gasket is in good
condition.
11. Install the new filter and
turn by hand until the filter gasket contacts the sealing surface,
then turn and additional 1/2 turn.
12. Remove the oil fill plug and add the recommended oil. Refer to
the specifications section beginning on page 96 for capacities. Do
not overfill.
13. Reinstall the fill plug.
14. Start the engine and let it idle for one to two minutes.
15. St op the engine and inspect for leaks.
16. Check the oil level and add oil as necessary to maintain the level at
the center of the sight glass.
17. Dispose of used filter and oil properly.
1
2
70
MAINTENANCE AND LUBRICATION
Gearcase Specification Chart
Gearcase Lubricant Capacity Drain/Check
Plug Torque
Fill Plug
Torque
Transmission Premium AGL Synthetic
Gearcase Lubricant
18.6 oz.
(550 ml)
18 ft. lbs.
(24 Nm)
N/A
Rear
Gearcase
Premium ATV Angle
Drive Fluid
4oz.
(120 ml)
18 ft. lbs.
(24 Nm)
25 ft. lbs.
(34 Nm)
Transmission Oil
Always check and change the transmission oil at t he intervals outlined
in the Periodic Maintenance Chart beginning on page 61. Maintain the
oil level between 1/4 and 3/4 on the sight glass. We recommend the
use of Premium AGL S ynthetic Gearcase Lubricant. Refer to the
gearcase specifications chart on page 70. See page 99 for the part
numbers of Polaris products.
Oil Check
1. Position the vehicle
on a level surface.
2. View the oil level
through the sight
glass (1).
3. Remove the fill
plug (2) and add the
recommended oil as
needed.
4. Reinstall the fill plug.
Oil Change
The t ransmission drain plug is located on the bottom of the vehicle
near the center.
1. Remove the fill plug.
2. Remove the transmission drain plug. Drain the oil into an
appropriate container. Discard used oil properly.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the recommended fluid.
5. Reinstall the fill plug.
6. Check for leaks.
71
MAINTENANCE AND LUBRICATION
Rear Gearcase Oil
Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 61. Maintain the
oil level at the bottom of the check plug hole. We recommend the use
of Polaris Premium ATV Angle Drive Fluid. R efer to the gearcase
specifications chart on page 70. See page 99 for the part numbers of
Polaris products.
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the check plug (1)
and view the oil level.
3. Remove the fill plug (2). Add
the recommended oil as needed.
4. Reinstall the fill plug. Torque
to specification.
5. Reinstall t he check plug.
Torque to specification.
6. Check for leaks.
Oil Change
1. Remove the skid plate.
2. Remove the drain plug. Drain the oil into an appropriate container.
Discard used oil properly.
3. Clean and reinstall the drain plug with a new sealing washer.
Torque to specification.
4. Remove the fill plug and add the recommended gearcase oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the skid plate.
1
2
1
2
72
MAINTENANCE AND LUBRICATION
Lights
WARNING
Poor lighting while driving can result in severe injury or death.
Headlight and taillight lenses become dirty during normal
operation. Wash the headlights frequently to maintain lighting
quality.
Hot components can cause serious burns to skin. Do not service
the headlamps until they’ve cooled sufficiently.
Headlight Lamp Replacement
To access the assembly from the front, remove the front cover and
unplug the wiring harness. R emove 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 (1) from the back
of the headlight.
2. Rotate the socket (2)
counterclockwise and
pullitawayfromthe
headlight assembly.
3. Remove the headlamp.
4. Install the new headlamp.
5. Reinstall all components.
73
MAINTENANCE AND LUBRICATION
Lights
Taillight/Brakelight Lamp Replacement
If the taillight/brakelight does not work the lamp may need to be
replaced.
1. Remove the taillight lens
cover mounting screws (1).
2. Remove the lens
cover and set aside
for reassembly.
3. Remove the lamp (2).
4. Apply dielectric grease to the socket and install a new lamp.
5. Test the taillight/brakelight for proper operation.
6. Reinstall the lens cover.
1
2
1
74
MAINTENANCE AND LUBRICATION
Spark Plugs
Refer to the specifications section beginning on page 96 for spark plug
and gap specifications.
CAUTION
Using non-recommended spark plugs can result in serious engine
damage. Always use Polaris-recommended spark plugs.
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed
up and the vehicle has been driven at higher speeds. Immediately
check the spark plug for correct color.
WARNING
A hot exhaust system and engine can cause serious burns. Wear
protective gloves when removing a spark plug for inspection.
1. Normal
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.
NOTE: The tip should not be white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or
incorrect carburetion adjustments.
2. Wet Fouled
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 injection oil, improper use of the choke, or
incorrect carburetion adjustments.
Spark Plug Removal an d Replacement
1. Remove the spark plug cap (1).
2. Using the special
wrench provided in the
tool pouch, rotate the
spark plug
counterclockwise to
remove.
3. Reverse the procedure
for spark plug installation.
Torque to 14 ft. lbs. (19 Nm).
75
MAINTENANCE AND LUBRICATION
Vehicle Immersion
CAUTION
If your vehicle becomes immersed, major engine damage can
result if the machine is not thoroughly inspected. Take the
vehicle to your dealer before starting the engine.
If it’s impossible to t ake your ATV to a dealer before starting it, follow
the steps outlined below.
1. Move the ATV to dry l and or at the
very least, to water below the footrests.
2. Check the airbox for any water and
dry it if water is present.
3. Turn the fuel valve off.
4. Remove the spark plug.
5. Loosen the carburetor drain screw (1).
6. Turn the engine over several times
using the electric start.
7. Dry t he spark plug and reinstall, or
replace it with a new plug.
8. Tighten the carburetor drain screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If necessary,
repeat the drying procedure.
11. Take the ATV t o your dealer for service as soon as possible,
whether you succeed in starting it or not.
NOTE: If water has been ingested into the transmission, follow the
procedure on page 77 for drying the CVT.
1
76
MAINTENANCE AND LUBRICATION
Spark Arrestor Clean- Out
WARNING
Do not perform clean-out immediately after the engine has been
run, as the exhaust system becomes very hot. Serious burns could
result from contact with the exhaust components.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust contains
poisonous carbon monoxide gas.
Failure to heed these warnings could result in serious injury or
death.
Periodically clean the spark arrestor to
remove accumulated carbon.
1. Remove the three screws (1) and
remove the arrestor from the end of
the m uffler.
2. Use a non-synthetic brush to clean
the arrestor screen. A synthetic
brush may melt if components are
warm. If necessary, blow debris
from the screen with compressed air.
3. Inspect the screen for wear and
damage. Replace if necessary.
4. Remove and inspect the gasket.
Replace if worn or damaged.
5. Reinstall t he gasket and arrestor.
6. Torque screws to 50 in. lbs. (5.6 Nm).
1
77
MAINTENANCE AND LUBRICATION
Constant Variable Transmission (CVT) System
WARNING
Failure to comply with the instructions in this warning can result in
severe injury or death.
Do not modify any component of the CVT system. Doing so may
reduce its strength so that a failure may occur at a high speed.
The CVT system has been precision balanced. Any modification
will cause the system to be out of balance, creating vibration and
additional loads on components.
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
There may be some instances when water is accidently ingested into
the C VT system. Use the following instructions to dry it out before
operating:
1. Remove the drain plug and allow the water to drain. Reinstall the
drain plug.
2. Place the t ransmission in neutral.
3. Start the engine. Apply varying throttle for 10-15 seconds to expel
the m oisture and air-dry the belt and clutches. Do not hold the
throttle wide open for more than 10 seconds.
4. Allow the engine RPM t o settle to idle speed.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Take the vehicle to your dealer for service as soon as possible.
78
MAINTENANCE AND LUBRICATION
Battery
WARNING
Improperly connecting or disconnecting battery cables can result
in an explosion and cause serious injury or death. When
removing the battery, always disconnect the negative (black)
cable first. When reinstalling the battery, always connect the
negative (black) cable last.
Battery Removal
1. Remove the seat.
2. Disconnect the battery
hold-down strap.
3. Disconnect the black
(negative) battery cable
first.
4. Disconnect the red
(positive) battery cable
next.
5. Lift the battery out of
the battery
compartment.
Battery Installatio n
When installing a new battery, make sure it’s fully charged prior to its
initial use. Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can also hinder
vehicle performance. F ollow the battery charging instructions on page
79 before installing t he battery.
1. Ensure that the battery is fully charged.
2. Set 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.
7. Reinstall the seat.
79
MAINTENANCE AND LUBRICATION
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 char ged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
NOTE: Battery charge can be maintained by using a Polaris Battery
Tendert charger (PN 2871076) or by charging about once a
month to make up for normal self-discharge. Battery
Tendert can be left connected during the storage period,
and will automatically charge the battery if the voltage drops
below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to t he
installation of a sealed battery. Read all instructions before proceeding
with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is
to keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1. 2
amps or less until the battery voltage is 12.8 or greater.
NOTE: When using an automatic charger, refer to the charger
manufacturer’s instructions for recharging. When using a
constant current charger, use the following guidelines for
recharging.
WARNING
An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the
battery becomes very warm to the touch. Allow it to cool before
resuming charging.
80
MAINTENANCE AND LUBRICATION
Battery
Battery Charging
NOTE: Always verify battery condition before and 1-2 hours after the
end of charging.
State of
Charge
Voltage Action Charge Time*
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at
3 mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
81
MAINTENANCE AND LUBRICATION
Adjustments
Brakes (Front)
The front brakes are hydraulic disc brakes. These brakes are
self-adjusting.
The following checks are recommended to keep the hydraulic brake
system in good operating condition. Check more often if brakes are
used heavily under normal operation.
WARNING
Never store or use a partial bottle of brake fluid. Brake fluid is
hygroscopic, meaning it rapidly absorbs moisture from the air.
The moisture causes the boiling temperature of the brake fluid to
drop, which can lead to early brake fade and the possibility of
accident or severe injury. After opening a bottle of brake fluid,
always discard any unused portion.
WARNING
An over-full master cylinder may cause brake drag or brake
lock-up, which could result in serious injury or death. Maintain
brake fluid at the recommended level. Do not overfill.
1. Always keep brake fluid at an adequate level (see page 35).
NOTE: Under normal operation, the 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 and the diaphragm
should be replaced. Always fill the reservoir as needed
whenever the cover is loosened or removed to ensure proper
diaphragm operation. Use Polaris DOT 3 brake fluid. Do not
overfill.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear,
damage and looseness.
5. Check the security and surface
condition of the disc.
NOTE: Change the brake pads when
they’rewornto3/64″ (.1 cm).
3/64″ (.1 cm)
82
MAINTENANCE AND LUBRICATION
Adjustments
Brakes (Rear)
Periodically measure the freeplay of the rear brakes. To adjust rear
brake freeplay, turn the adjuster nuts (1) at the rear brake drum.
Brake Lever Travel (Rear)
Service the brakes when
brake lever travel reaches
21/2″ (65 mm). Always
service the brakes when there
is no longer sufficient stopping
ability at the specified lever
travel setting.
1
.40″-.80″
(10-20 mm)
21/2″
(65 mm)
83
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Severe injury or death can result from improper toe alignment and
adjustment. Do not attempt to adjust tie rod alignment. All tie rod
adjustments should be performed by an authorized Polaris dealer .
Toe Alignment
Use t he following procedure to check the toe alignment of t he vehicle.
The recommended toe alignment i s 1/8″ -1/4″ (3-6 mm) toe out.
1. Set the handlebars in a
straight-ahead position.
NOTE: The steering frog can be
used as an indicator of
whether the handlebars
are straight. The frog
should always point
straight back from the
steering post.
2. Place stands (1) in front of
the vehicle, perpendicular to
the rear tires. See
illustration.
3. Tie an elastic string around
the stands, making sure the
string just touches t he side
surface of the rear tires on
each side of the vehicle and
goes around the stands in
front of the vehicle (2).
4. Measure the distance from
the string to the rim at the
front and rear of the front
rim (3). Rear measurement should be 1/16″ -1/8″ (2-3 mm) more
than the front measurement.
NOTE: If you discover improper alignment, see your Polaris dealer
for service.
1
2
3
84
MAINTENANCE AND LUBRICATION
Adjustments
Steering Assembly
The steering assembly of the ATV should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your Polaris
dealer for service before operating the vehicle.
Camber an d Caster
The camber and caster are non-adjustable.
Rear Spring
The rear shock absorber spring is
adjusted by rotating t he adjuster (1)
either clockwise or counterclockwise
to increase or decrease spring tension.
NOTE: Accessory springs are
available through your Polaris
dealer.
1
85
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Improper adjustment of the handlebars or incorrect torquing of
the adjuster block tightening bolts can cause limited steering or
loosening of the handlebars, resulting in loss of control and
possible serious personal injury or death. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.
Handlebars
The handlebars can be adjusted for
rider preference.
1. Remove the handlebar cover.
2. Loosen (do not remove) the
four handlebar bolts.
3. Adjust the handlebar to the
desired height. 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.
4. Torque the front two bolts (1) to
10-12 ft. lbs. (14-17 Nm), then
torque the rear two bolts (2). A
gap of up to 1/8” (3 mm) will
remain at the rear bolts.
1
2
86
MAINTENANCE AND LUBRICATION
Adjustments
Carburetor
IMPORTANT: Your Polaris ATV is calibrated at the factory for
optimal performance at altitudes ranging from zero to 6,000 feet (1800
m) and t emperatures of +40 degrees F. (4 degrees C.) or higher. Above
6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and
the engine loses approximately 3% of its power for each 1000-foot
(304.8 m) increase in elevation. Although this power cannot be
regained, adjustments to the carburetor and drive system can be made
to allow more efficient operation. Optional jets, available from your
Polaris dealer, are required for operation above 6,000 feet and
temperatures below +40 degrees F. (4 degrees C.)
NOTE: 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 the ATV for conditions in your area.
If the engine idle speed is not satisfactory, and all other conditions are
favorable, the carburetor can be adjusted.
1. Start the engine.
2. Lock the parking brake.
3. Allow t he engine to run for approximately five minutes.
4. Adjust the carburetor idle screw either in or out until the desired
idle RPM is reached. T urning the screw in (clockwise) will raise
RPM. Turning the screw out (counterclockwise) will lower RPM .
87
MAINTENANCE AND LUBRICATION
Adjustments
Throttle Cable Freeplay
The throttle cable adjuster is located at the right handlebar.
1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen
the adjuster l ocknut (3).
2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the
thumb lever.
NOTE: While adjusting freeplay, be sure to flip the throttle lever back
and forth several times.
3. Tighten the locknut and slide the boots over the cable adjuster until
they touch at the midpoint of the adjuster.
Side Panel Removal
1. Remove the seat.
2. Remove the three
fasteners (1) securing the
side panel to the vehicle.
3. Pull the side panel away
from the vehicle.
1
2
1
3
1
88
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Operating your ATV with worn tires, improperly inflated tires,
non-standard tires or improperly installed tires will affect vehicle
handling and could cause an accident resulting in serious injury or
death.
Maintain proper tire pressure as described on the decal on your
ATV and in the specifications section of the owner’s manual
beginning on page 96.
Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8″ (.3 cm)
or less.
Wheel Removal
1. Stop the engine.
2. Remove the key from the ignition.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
5. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
6. Remove the wheel nuts and remove the wheel.
89
MAINTENANCE AND LUBRICATION
Adjustments
WARNING
Improperly installed wheels can adversely affect tire wear and
vehicle handling, which can result in serious injury or death.
Always ensure that all nuts are torqued to specification. Do not
service axle nuts that have a cotter pin installed. See your
Polaris dealer .
Wheel Installation
1. Position the vehicle on a level
surface.
2. Lock the parking brake.
3. Place the wheel on the wheel
hub with the valve stem toward
the outside and rotation arrows
on the tire pointing toward
forward rotation.
4. Install the wheel nuts and finger
tighten.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they’ve been
loosened for maintenance service.
Location Specification
Front Wheel Nuts 27 ft. lbs. (37 Nm)
Rear Wheel Nuts 27 ft. lbs. (37 Nm)
90
MAINTENANCE AND LUBRICATION
Adjustments
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical
component operations. All service must be performed by your
authorized Polaris dealer.
Tire Tread Depth
Always replace tires when tread
depth is worn to 1/8″ (3 mm) or less.
See illustration.
WARNING
Operating the vehicle with worn tires will
increase the possibility of skidding,
which could lead to loss of control and
serious injury or death. Always replace
tires when the tread depth measures
1/8″ (3 mm) or less.
WARNING
Use of non-standard size or type of tires or improper tire inflation
may adversely affect vehicle maneuverability and cause loss of
control resulting in serious injury or death. Maintain proper tire
pressure as outlined in this owner’s manual. When replacing a
tire always use original equipment size and type.
1/8I (3 mm)
1
3
2
91
MAINTENANCE AND LUBRICATION
Adjustments
Air Filter Service
1. Remove the seat.
2. Release the clips and remove the air
box cover (1).
3. Loosen the clamp and remove the
filter.
4. Remove the pre-filter (2) from the
main filter (3). Wash the pre-filter
in soapy water , then rinse and let
dry.
5. Reinstall t he pre-filter over the
main filter. (Replace the main filter
if needed.)
6. Reinstall t he filter into t he air box
and tighten the clamp. Do not over
tighten the clamp, as filter damage
could occur.
92
MAINTENANCE AND LUBRICATION
Cleaning and Storage
See page 99 for the part numbers of Polaris products.
Cleaning th e ATV
Keeping your ATV clean will not only improve its appearance but it
can also extend the life of various components. With a few
precautions, your ATV can be cleaned much like an automobile.
Washing the ATV
The best and safest way to clean your ATV is with a garden hose and a
pail of mild soap and water. Use a professional type washing mitten,
cleaning the upper body first and the lower parts last. Rinse with water
frequently and dry with a chamois to prevent water spots.
NOTE: If warning and safety labels are damaged, contact your a
Polaris dealer for free replacement.
Polaris does not recommend the use of a high pressure type car wash
system for washing the ATV. If a high pressure system is used,
exercise extreme care to avoid water damage to the wheel bearings,
transmission seals, body panels, brakes and warning labels.
NOTE: Grease all zerk fittings immediately after washing, and allow
the vehicle to run for a while to evaporate any water that may
have entered the engine or exhaust system.
Waxing the ATV
Your ATV can be waxed with any non-abrasive automotive paste wax.
Avoid the use of harsh cleaners since they can scratch the body finish.
CAUTION
Certain products, including insect repellants and chemicals, will
damage plastic surfaces. Use caution when using these products
near plastic surfaces.
93
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 99 for the part numbers of Polaris products.
CAUTION
Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur . Never
start the engine during the storage period.
Exterior
Make necessary repairs and then clean the ATV thoroughly with mild
soap and warm water to remove all dirt and grime. Don’t use harsh
detergents or high pressure washers. S ome detergents deteriorate rubber
parts. Use dish soap type cleaners only. High pressure washers may
force water past seals.
Fuel Stabilizer
Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It
cleans the fuel system, the combustion chamber and the exhaust ports.
It also prevents bacterial growth and promotes better starting after the
storage period.
1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel
Stabilizer . Follow the instructions on the container for the
rec ommended amounts.
2. Star t the engine and allow it to run for 15-20 minutes so the stabilize r
can disperse through the fuel in the tank and car buretor.
3. Stop the engine.
4. T urn the fuel valve off.
5. Drain the carbur etor bowl.
Oil and Filter
Warm the engine and change the oil and filter.
Air Filter / Air Box
Inspe ct and clea n or re place the pre-c leane r and air filter. Clean the air
box and drain the sediment tube.
94
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Storage Tips
See page 99 for the part numbers of Polaris products.
Fluid Levels
Inspect fluid levels and change fluids if necessary.
S Transmission
S Brake F luid
Engine Fogging
Use Polar is Engine Fogging Oil. Follow label direc tions car ef ully.
CAUTION
Starting the engine during the storage period will disturb the
protective oil film, which can lead to engine damage. Never start
the engine during the storage period.
Lubricate
Inspect all cables and lubricate with Polaris Cable Lubricant. Follow
lubrication guidelines in the maintenance section of t he service or
owner ’s manual to completely grease and lubricate the entire vehicle
with Polaris P remium All Season Grease.
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 appropr iate cover. Do not use plastic or
coa ted materia ls, as they do not allow proper ventilation to prevent
condensa tion, corr osion and oxidation.
95
MAINTENANCE AND LUBRICATION
Cleaning and Storage
Transporting an ATV
Follow these procedures when
transporting an ATV.
1. Turn off the engine and
remove the key to prevent
loss during transporting.
2. Turn the fuel valve off.
3. Be sure the fuel cap, oil cap
and seat are installed
correctly and securely.
4. Always tie the frame of the
ATV to the transporting unit
securely using suitable
straps or rope. The rack,
bumper or handlebars do not
offer enough support for
tie-down while transporting
the unit.
5. Place the t ransmission in
gear and lock the parking
brake.
96
SPECIFICATIONS
2005 Phoenix 200
Capacities
Gross Vehicle Weight 720 lbs. (326 kg)
Dry Weight 395 lbs. (179.2 kg)
Fuel Capacity 2.5 gal. (9.5 l)
Engine Oil Capacity 41 oz. (1200 ml)
Transmission Oil 18.6 oz. (550 ml)
Rear Gearcase Oil 4 oz. (120 ml)
Rear Rack 70 lbs. (31.7 kg)
Tongue Weight 30 lbs. (13.6 kg)(Rear rack weight and tongue
weight not to exceed 30 lbs./13.6 kg)
Tow Capacity 300 lbs. (136 kg)
Turn Radius 65 in. (165.1 cm) unloaded
Ground Clearance 5.7 in. (14.5 cm)
Length 65 in. (165.1 cm)
Width 42 in. (106.7 cm)
Height 42 in. (106.7 cm)
Seat Height 32 in. (81.3 cm)
Wheel Base 45 in. (114.3 cm)
Engine & Cooling
Engine Model Number / Type 4 Cycle, Single Cylinder
Lubrication Wet Sump
Bore x Stroke 65x59
Displacement 196 cc
Compression Ratio 9.2:1 Full Stroke
Engine Cooling Air cooled
Alternator Output (watts) 210w @5000 rpm
Carburetion 1 / 22 mm (VM Type)
Main Jet 108
Pilot Jet 35
Jet Needle 2MKNN-4 clip
Air Screw 1TurnOut
Ignition DC CDI
Timing 32°±2° @ 3000 RPM
SparkPlugType/Gap NGK R7HSA / 0.6-0.7 mm
97
SPECIFICATIONS
2005 Phoenix 200
Drive System
Drive System Type Constant Variable Transmission (CVT)
Shift Type Side Lever F/N/R
Front Drive (ratio) N/A
Front Tires 21x7-10(4psi)
Rear Tires 20x10-9(4psi)
Suspension and Brakes
Front Suspension Dual A-Arm w/7 in. (17.8 cm) travel
Rear Suspension Mono-Shock Swing Arm w/6.5 in. (16.5 cm)
travel
Shock Adjustment CAM
Front Brake Hydraulic Disc
Rear Brake Mechanical Drum
Foot Brake Mechanical Drum, Rear Brake
Park Brake Mechanical, Rear
Features
Headlight Front Cover, Hi/Lo 35W
Taillight 12V 5W
Brake Light 12V 21W
Battery 12V 12 AH
DC Plug-In (Rear) Accessory
Electric Start Standard
Windshield Accessory
Neutral Indicator Standard
Reverse Indicator Standard
Tool Kit Standard
98
SPECIFICATIONS
2005 Phoenix 200
Jetting Chart
Altitude AMBIENT
TEMPERATURE
Below 40° F
(Below 5° C)
+40°F and above
(+5°C and above)
Meters
(Feet)
0-1800
(0-6000)
108 TBD
1800-3700
(6000-12000)
TBD TBD
Clutching Chart
Altitude Roller Weight
Grams Each
Driven Clutch
Spring
Meters
(Feet)
0-1800
(0-6000)
6@14.5grams TBD
1800-3700
(6000-12000)
TBD TBD
99
POLARIS PRODUCTS
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)
2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)
Gearcase / Transmission Lubricants
2873602 Premium AGL Synthetic Gearcase Lube (qt.)
2873603 Premium AGL Synthetic Gearcase Lube (gal.)
2871653 Premium ATV Angle Drive Fluid (8 oz.)
2872276 Premium ATV Angle Drive Fluid (2.5 gal.)
2870465 Pump for Gallon Jug
Grease / Specialized Lubricants
2871322 Premium All Season Grease (3 oz. cartridge)
2871423 Premium All Season Grease (14 oz. cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz.)
2871551 Premium U-Joint Lube (14 oz.)
2871312 Grease Gun Kit
2871329 Dielectric Grease (Nyogelt)
Additives / Miscellaneous
2872889 Brake and Clutch Cleaner
2871326 Carbon Clean Plus (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2870990 DOT3 Brake Fluid
2872893 Engine Degreaser
2871956 LOCTITE 565 Thread Sealant
100
TROUBLESHOOTING
Contact your Polaris dealer for service if you’re unable to identify
solutions using the following charts.
Engine Doesn’t Turn Over
Possible Cause Solution
Tripped circuit breaker Reset the breaker
Low battery voltage Recharge battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present in fuel Drain the fuel system and refuel
Fuel valve is turned off Turn the fuel valve on
Old or non-recommended fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect plug(s), replace if necessary
No spark to spark plug Inspect plug(s), verify stop switch is on
Crankcase filled with water or fuel Immediately see your Polaris dealer
Overuse of choke Inspect, clean and/or replace spark plugs
Clogged fuel filter Replace the filter
Low battery voltage Recharge battery to 12.8 VDC
Mechanical failure See your Polaris dealer
Engine Pings or Knocks
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
101
TROUBLESHOOTING
Engine Backfires
Possible Cause Solution
Weak spark from spark plugs Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with new fuel
Incorrectly installed spark plug wires See your Polaris dealer
Incorrect ignition timing See your Polaris dealer
Mechanical failure See your Polaris dealer
Engine Runs Irregularly, Stalls or Misfires
Possible Weak Spark Cause Solution
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Electronic Throttle Control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Possible Lean Fuel Mixture Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect jetting See your Polaris dealer
Possible Rich Fuel Mixture Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with lower octane fuel
Incorrect jetting See your Polaris dealer
102
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge battery to 12.8 VDC
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your Polaris dealer
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
Overheated engine Clean radiator screen and core if equipped
Clean engine exterior
See your Polaris dealer
103
WARRANTY
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED
WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects
in material or workmanship. Polaris also givesa one year limited warranty on thefinaldrive
chain for failure due to defects. This warranty covers the parts and labor charges for repair
or replacement of defective parts which are covered by this warranty. This warranty begins
on the date of purchase. This warranty is transferrable to another consumer during the war-
ranty 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 AN ATV SAFETY
TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID
WARRANTY ON THE ATV. 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 ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV 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.
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polarislimited 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 ATV that has been al-
tered 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 addi-
tion, 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 ATV
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 ATV. 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 CON-
TRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not p er-
mit 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.
104
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN-
TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT
STATED IN THIS WARRANTY. Some states do not allow limitations on how long an im-
plied warranty lasts, so the above limitation may not apply to you if inconsistent with con-
trolling state law.
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re-
pair Polaris ATVs. 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 war-
ranty 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.
Thiswarranty givesyou specificlegal 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.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recom-
mend the use of Polaris engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered by
warranty.
105
WARRANTY
Exported Veh icles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, T HERE IS NO WAR-
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-
TION.
This policy does not apply to vehicles that have received authorization for export from
Polaris Industries. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you
have any questions.
This policy does not apply to vehicles registered to government officials or military per-
sonnel on assignment outside the country of the selling dealer’ s authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you
move or are traveling within the country where your vehicle was purchased, Warranty or
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells
the same line as your vehicle.
Outside the Country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized Polaris dealer. You must show the dealer
photo identification from the country of the selling dealer’s authorized location as proof
of residence. Upon residence verification, the servicing dealer will be authorized to per-
form the warranty repair.
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance and the
customs department of the destination country before you move. Vehicles importation
rules vary considerably from country to country. You may be required to present docu-
mentation of your move to Polaris Industries in order to continue your warranty cover-
age. You may also be required to obtain documentation from Polaris Industries in order
to register your vehicle in your new country.
How to Get Service
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which
the vehicle was originally purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for war-
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-
cials or military personnel on assignment outside of the country where the vehicle was
purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-763-417-8650
Canada: 1-204-925-7100
106
MAINTENANCE RECORD
DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
107
MAINTENANCE RECORD
DATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS
108
INDEX
A
Adjustments 81-91................
Age Restrictions 7................
Air Filter 91.....................
B
Battery 78-80....................
Battery Charging 79-80.............
Battery Installation 78.............
Battery Removal 78...............
Battery Storage 79................
Brake (Foot-Operated) 37..........
Brake Lever (Left) 36.............
Brake Lever (Right) 36............
Brake Lever Travel 82.............
Brakes 35-37.....................
Brakes (Front) 81.................
Brakes (Rear) 82.................
Break-In Period 42................
C
Camber and Caster 84.............
Carburetor 86....................
Choke 39.......................
Cleaning and Storage 92-95.........
Cleaning the ATV 92..............
Clutching Chart 99................
Cold Weather Operation 44.........
Constant Variable Transmission 77...
CONTROLS 33-41................
Crankcase Emission Control System 6 0
CVT 77........................
CVT Drying 77..................
D
Driving Downhill 52..............
Driving in Reverse 58.............
Driving on Slippery Surfaces 50.....
Driving Over Obstacles 57..........
Driving Procedures 46.............
Driving Safely 46-59...............
Driving Through Water 56..........
Driving Uphill 51................
E
Electrical Switches 33.............
Electromagnetic Interference 60......
EMISSION CONTROL SYSTEMS 60
Engine Fogging 94...............
Equipment Modifications 11........
Exhaust Emission Control System 60.
F
FEATURES 33-41................
Foot Brake 37...................
Front Wheel Hub Tightening 90.....
Fuel Filter 39....................
Fuel Safety 32...................
Fuel Stabilizer 93.................
Fuel Tank 39....................
Fuel Valve 39....................
G
Gear Selector 40..................
Gearcase Oil, Rear 71..............
Gearcase Specification Chart 70......
H
Handlebars 85...................
Hauling Cargo 48-49...............
Headlight Lamp Replacement 72.....
Helmet 31......................
I
Indicator Lights 34................
J
Jetting Chart 99..................
K
K-Turn 54-55....................
Key Switch 33...................
Kick-Start Lever 41...............
L
Light Switch 33..................
Lights 72-73.....................
Lubrication Guide 65..............
109
INDEX
M
Main Switch 33..................
MAINTENANCE AND
LUBRICATION 61-95.........
MAINTENANCE RECORD 106-107.
Making Turns 47.................
Master Cylinder 35...............
N
Noise Emission Control System 60...
O
Oil Change 68-69.................
Oil Check 67....................
OPERATION 42-59...............
Operator Safety 7-27...............
Override Switch 33...............
P
Parking Brake 38.................
ParkingonanIncline 59...........
Periodic Maintenance Chart 61-64....
POLARIS PRODUCTS 99.........
Pre Ride Inspection 43.............
Premium 4 Synthetic Lubricant 66....
R
Rear Gearcase Oil 71..............
Rear Spring 84...................
Reverse Override Switch 33.........
S
Safe Riding Gear 31...............
SAFETY 7-32....................
Safety Decals and Locations 28-30....
Safety Training 7.................
Severe Use 61...................
Side Panel Removal 87............
Sidehilling 53...................
Spark Arrestor 60.................
S
Spark Arrestor Clean-Out 76........
Spark Plug
Removal and Replacement 74...
Spark Plugs 74...................
SPECIFICATIONS 96-98...........
Start Button 33...................
Starting the Engine 44-45...........
Steering Assembly 84.............
Stop Switch 33...................
Storage Tips 93-94................
T
TABLE OF CONTENTS 5.........
Taillight/Brakelight
Lamp Replacement 73.........
Throttle Cable Freeplay 87..........
Throttle Lever 34.................
Tire Tread Depth 90...............
Toe Alignment 83................
Towing 48-49....................
Transmission Gear Selector 40.......
Transmission Oil 70...............
Transporting an ATV 95...........
TROUBLESHOOTING 100-102.....
Turning Around on a Hill 54-55......
V
VEHICLE IDENTIFICAT ION
NUMBERS 6................
Vehicle Immersion 75.............
W
WARRANTY 103-105.............
Washing the ATV 92..............
Waxing the ATV 92...............
WELCOME 3...................
Wheel Installation 89..............
Wheel Nut Torque Specifications 89..
Wheel Removal 88...............
