Polaris Phoenix 9921841 User Manual

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9921841 Rev 01 Printed in USA

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-3423764 for assistance.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational 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 complete line of apparel, parts and accessories, 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.

Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in USA 2009 Phoenix 200 Owner’s Manual P/N 9921841

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Emission Control Systems . . . . . . . . . . . . . . . 51

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 91

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 94

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 96

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 102

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

INTRODUCTION

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV.

• Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

• Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.

. Contact ATV Enrollment Express at

INTRODUCTION

VIN

Engine Serial Number

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

SAFETY

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV

RiderCourse

training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse

by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

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.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-

3764.

available to you and your eligible family members. This

. You were also provided with

by calling ATV Enrollment Express at (800) 887-2887 or

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

Equipment Modifications

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 modifications to the vehicle for these purposes.

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.

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.

SAFETY

WARNING

Safety Warnings

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.

Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle. See page 7.

Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

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.

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.

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.

Failure to Inspect Before Operating

Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident.

Always inspect the ATV before each use to make sure it's in safe operating condition.

Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

SAFETY

Safety Warnings

Protective Apparel

Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.

Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

Using Alcohol or Drugs

Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.

Never consume alcohol or drugs before or while operating an ATV.

Carrying a Passenger

Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn.

Never carry a passenger on this ATV.

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.

Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads or highways could result in a collision with another vehicle.

Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.

Operating at Excessive Speeds

Operating the ATV at excessive speeds increases the operator's risk of losing control.

Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience.

SAFETY

Safety Warnings

Physical Control of the ATV

Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.

Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn.

Always follow proper procedures for turning as described in the owner's manual.

Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn.

Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 41.

SAFETY

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss of control or overturn.

• Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 43.

• Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• 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.

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 42.

Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 44.

SAFETY

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.

• Always maintain a steady speed when climbing a hill.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the front brakes (right lever).

• When fully stopped, apply the rear brake as well, and then lock the parking brake.

• Lock the parking brake when fully stopped.

• 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 44.

If the ATV begins rolling downhill:

• Keep body weight uphill.

• Apply the front brakes 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 44.

Operating on Steep Hills

Operating on excessively steep hills could cause an overturn.

Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.

SAFETY

Safety Warnings

Improper Tire Maintenance

Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on

safety labels.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 47.

Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.

Do not operate on excessively rough, slippery or loose terrain. Always use extra caution on rough, slippery or loose terrain.

SAFETY

Safety Warnings

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 46.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.

Operating Through Deep Water

Operating the ATV through deep or fastflowing water could cause the tires to float, causing loss of control or overturn.

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

45):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• 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. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice.

Never operate the ATV on a frozen body of water.

SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.

• Never exceed the stated load capacity for this ATV.

• Cargo should be properly distributed and securely attached.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater dis-

tance for braking.

• Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer.

Poor Visibility

Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

Physical Skills

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.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use.

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.

General Warning

WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175376

SAFETY

Discretionary

Warning

General

Warning

Safety Labels and Locations

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 25 degrees 25°. To pre-

vent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill.

• REVERSE operation can be dangerous even at low speeds. Steering

becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.

7175511

SAFETY

“No Passenger”

Warning

Clutch Cover

Warning

Age 16

Warning

Tire Pressure/Load

Warning

Safety Labels and Locations

“No Passenger” Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7175378

Tire Pressure/Load Warning

WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa) Rear: 4.0 psi (27.6 kPa)

• Maximum weight capacity: 285 lbs. (129 kg)

7175749

SAFETY

Safety Labels and Locations

Age 16 Warning

WARNING 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.

7175374

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or death.

NO STEP

7173313

FEATURES AND CONTROLS

Override

Switch

OFF

Start

Button

Light

Switch

Engine

Stop Switch

Main Key

Switch

Switches

Light Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position to operate the headlights.

Engine Stop Switch

Before starting the engine, press the upper end of the switch down to the ON position. To stop the engine, press the lower end of the switch down to the OFF position. The engine will not start or run when the switch is off.

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.

Start Button

To start the engine, make sure the stop switch is in the ON position. Turn the main key switch on. Press the start button.

FEATURES AND CONTROLS

WARNING

Switches

Override Switch (Reverse Speed Limiter)

This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch.

WARNING! Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override button.

Throttle Lever

Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.

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.

Modifications to the electronic throttle control could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is installed and properly routed to the throttle control.

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever is spring loaded. Engine speed returns to idle 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.

FEATURES AND CONTROLS

WARNING

Front Brakes

Brakes

Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.

Aggressively applying the rear brakes when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.

Use caution when applying the rear brakes. Do not aggressively apply the rear brakes when going forward. The rear wheels may skid and slide sideways, causing loss of control, which may result in serious injury or death.

Front Brakes (Right Lever)

Squeeze the right brake lever toward the handlebar to apply the hydraulic front wheel brakes. This lever does not

apply the rear brakes.

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.

FEATURES AND CONTROLS

Rear Brakes

Foot Brake

Brakes

Rear Brakes (Left Lever)

Squeeze the left brake lever toward the handlebar to apply the mechanical rear wheel brakes. This lever does not

apply the front brakes.

Rear Brakes (Foot Brake)

The foot brake is a mechanical rear wheel brake. Using the foot brake is the same as using the left brake lever. Only the rear brake is applied. The foot brake is located on the inside of the right footrest. Operate this brake with your right foot.

If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the rear wheels without skidding.

FEATURES AND CONTROLS

Brakes

Parking Brake

1. Place the transmission in

gear.

2. Squeeze and release the left

brake lever two or three times, then squeeze and hold.

3. Push the parking brake lock

down to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

WARNING

Master

Cylinder

Indicator

Window

Brakes

Brake Fluid

An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.

Check the brake fluid level in the master cylinder before each ride. Always maintain brake fluid at the recommended level.

The master cylinder is located on the left handlebar. Maintain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a level

surface. Make sure the handlebars are straight.

2. View the fluid level through the

indicator window (eye) on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

3. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.

Tip: 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. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

FEATURES AND CONTROLS

Fuel Tank Cap

Fuel Valve

OFF ON RES

Choke

The choke assists in starting a cold engine. Refer to the engine starting procedure on page 36 for correct choke and throttle settings during starting.

Fuel Tank Cap

Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

Do not use E-85 fuel.

Fuel Valve

The fuel valve is located on the left side of the vehicle.

ON: For normal operation. OFF: For vehicle storage

and when transporting. RES: Turn the valve to the

reserve setting if the main fuel supply is exhausted. Refuel as soon as possible. Return the valve to the ON position after refueling.

Reserve fuel range is about 7-10 miles (11-16 km).

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.

FEATURES AND CONTROLS

Gear

Selector

Reverse

Neutral

Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

F: Forward Gear N: Neutral R: Reverse

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is

Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.

Indicator Lights

Indicator lights on the handlebar console illuminate when neutral or reverse gears are selected. The neutral indicator is green. The reverse indicator is amber.

Kick-Start Lever

If the battery is too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced.

1. Position the vehicle on a level surface. Lock the parking brake.

2. Fold out the kick-start lever on the left side of the ATV.

3. Make sure the stop switch and main key switch are on.

4. Place your foot on the kick-start. Thrust your heel downward to

5. If the engine is cold, use the choke as outlined on page 36.

6. After the engine has started, fold the kick-start lever back into place.

Tip: A 10/12 mm wrench is provided in the tool kit for removing or installing the

moving could cause transmission damage.

Place the transmission in neutral.

crank the engine.

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.

OPERATION

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Break-In Period

The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

NOTICE: Excessive heat build-up during the first three hours of operation will

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 30. Always exercise

2. Check the oil level. See page 57. Add oil as needed to maintain the

3. Drive slowly at first. Select an open area that allows room to famil-

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

6. Pull only light loads (if equipped with a hitch).

7. Change both the oil and the filter at 20 hours, 200 miles or one

damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

extreme caution whenever handling gasoline.

level in the proper range.

iarize yourself with vehicle operation and handling.

on the daily pre-ride inspection checklist. See page 35.

month, whichever comes first.

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Operate this vehicle off-road only. Never operate the vehicle on

pavement or on any public street, road or highway, including dirt and gravel roads.

6. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

7. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

8. Never consume alcohol or drugs before or while operating an ATV.

9. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

10. Never operate a damaged ATV. After any overturn or accident, have

a qualified service dealer inspect the entire machine for possible damage.

11. Never operate the ATV on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use.

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/lever travel Ensure proper operation 26

Brake fluid Ensure proper level 29

Foot brake Ensure proper operation 27

Front suspension Inspect, lubricate if necessary 56

Rear suspension Inspect, lubricate if necessary 56

Steering Ensure free operation -

Tires Inspect condition and pressure 66

Wheels/fasteners Inspect, ensure fastener tightness 66

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 30

Coolant level (if applicable) Ensure proper level -

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 25

Indicator lights/switches Ensure operation 24

Engine stop switch Ensure proper operation 24

Air filter, pre-filter Inspect, clean 68

Air box sediment tube Drain deposits whenever visible -

Headlight Check operation, apply Polaris dielec-

Brake light/tail lamp Check operation, apply Polaris dielec-

Riding gear Wear approved helmet, goggles, and

tric grease when lamp is replaced

protective clothing

24 69

OPERATION

Choke

Lever

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti-

lated area.

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Turn the fuel valve on.

5. Sit on the vehicle.

Tip: Do not use the choke if starting a warm engine.

Excessive use of the choke can cause the spark plug to become wet fouled.

6. If the engine is cold, move the choke lever

to the left until it stops.

Tip: The choke is fully on when the lever is com-

pletely to the left. The choke is off when the lever is completely to the right. The choke can be adjusted gradually, depending on how much choke is needed for starting.

7. Place the engine stop switch in the ON

position, then turn the main key switch on.

8. Do not press the throttle while starting the

engine. Squeeze the left brake lever.

Tip: 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.

9. Press the start button.

OPERATION

Starting the Engine

10. Activate the starter for a maximum of five seconds, releasing the

button when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

11. If the engine does not start, release the start button, wait five sec-

12. If the engine slows or stops, move the choke lever half way to the

13. When the engine idles smoothly, move the choke lever completely

Cold Weather Operation

If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained.

Tip: Water accumulation increases as outside temperature decreases.

If the oil level rises to the top of the sight glass, change the oil immediately. Always operate the engine long enough to reach operating temperature, which reduces condensation.

damage. Allow the engine to warm up for several minutes before operating the vehicle.

onds, then attempt to start again. Repeat this procedure until the engine starts.

right to allow proper engine warm-up. Vary the engine RPM slightly with the throttle to aid in warm-up.

to the right.

OPERATION

Driving Procedures

1. Wear a helmet and eye protection. See page 8.

2. Sit upright with both feet on the footrests and both hands on the

handlebars.

3. Start the engine and allow it to warm up.

4. Shift the transmission into gear.

5. Check your surroundings and determine your path of travel.

6. Release the left brake lever and slowly depress the throttle with your

right thumb to begin driving.

7. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

OPERATION

Turning the Vehicle

To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. The same leaning technique should be used for turning in reverse.

Practice making turns at slow speeds before attempting to turn at faster speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

OPERATION

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding

quick, sharp turns, which can cause skids.

4. Never apply the brakes during a skid. Correct a skid by turning the

handlebars in the direction of the skid and shifting your body weight forward.

OPERATION

25° Maximum

Driving Uphill

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25° maximum).

3. Always check the terrain carefully before ascending any hill.

4. Never climb hills with excessively slippery or loose surfaces.

5. Keep both feet on the footrests.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the

throttle suddenly could cause the ATV to flip over backwards.

8. Never go over the top of a hill at high speed.

9. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

5. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

OPERATION

25° Maximum

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Shift body weight uphill.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling downhill can cause

loss of control.

5. Squeeze the rear (left) brake lever gradually. Applying the brakes

too firmly may cause the rear wheels to lock, which could result in loss of control.

OPERATION

8 ft. (2.4 m)

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

1. Squeeze the front (right) brake lever to stop the vehicle.

1. Lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the vehi-

cle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the rear (left) 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.

6. Lock the parking brake. Remount the vehicle from the uphill side,

keeping body weight uphill.

7. Start the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly. Control speed with

the rear brake until the vehicle is on more level ground.

OPERATION

Maximum Depth

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water:

1. Determine water

depths and current before entering water.

2. Choose a crossing

where both banks have gradual inclines.

3. Avoid operating

through deep or fastflowing water.

NOTICE: Major engine damage can result if the vehicle is not thoroughly

4. After leaving water, test the brakes. Apply them lightly several

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

inspected after operation in water. Perform the services outlined in the maintenance chart. See page 52. The following areas need special attention: engine oil, transmission oil, rear gearcase oil, and all grease fittings

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 72, then see your dealer for service at the first opportunity.

times while driving slowly. The friction will help dry out the pads.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for haz-

ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

7. Do not use the override switch unless additional wheel speed is

required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.

NOTICE: 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.

OPERATION

WARNING

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

CARRY LOAD AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 mph (16 kph) while towing a load on a level surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

OPERATION

Maximum

70 lbs. (31.7 kg)

Hauling Cargo

If the Polaris accessory rear rack or hitch are installed on your ATV, the ATV may 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).

Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Always read and understand the load distribution warnings listed on the rack and hitch warning labels. Never carry cargo on the front of the vehicle.

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.

OPERATION

Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

5. Turn the fuel valve off.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to be 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.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

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. All exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

The vehicle compliance labels can be found on the frame tubing of the vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 2004/108/EC.

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on page 102.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour (16 km/h). Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

MAINTENANCE

WARNING

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to

severe use.

E Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as need

X Front suspension - Pre-Ride - X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride - X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride - XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Headlamp/tail lamp

XEAir filter,

main element

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

X Front gearcase oil

(if equipped)

X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly XEEngine breather

filter (if equipped)

X General

lubrication

Carburetor float bowl

Throttle Cable/

ETC Switch

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

25 H Monthly 250 (400) Inspect level; change yearly

25 H Monthly 250 (400) Inspect; clean if needed

50 H 3 M 500 (800) Lubricate all fittings, pivots,

50 H 6 M 500 (800) Drain bowl periodically and

50 H 6 M 500 (800) Inspect; adjust; lubricate;

(Km)

ed. See Pre-Ride Checklist on page 35.

as needed

dielectric grease if replacing

cables, etc.

prior to storage

replace if necessary

Remarks

X Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Choke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;

E Carburetor air

intake ducts/flange

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

Fuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

X Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

Ignition Timing 100 H 12 M 1000 (1600) Inspect

X Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

Clutches (drive and driven)

Front wheel bearings

Brake fluid 200 H 24 M 2000 (3200) Change every two years

Spark arrestor 300 H 36 M 3000 (4800) Clean out

Idle speed - Adjust as needed

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

(whichever comes first)

Hours Calendar Miles

50 H 6 M 500 (800 Inspect duct for proper seal-

100 H 12 M 1000 (1600) Inspect

100 H 12 M 1000 (1600) Inspect; clean; replace worn

100 H 12 M 1000 (1600) Inspect; replace as needed

(Km)

replace if necessary

ing/air leaks

needed

at 20 hours

lines, fuel valve, filter, pump, carburetor; replace lines every two years

security; apply dielectric grease to connectors subjected to water, mud, etc.

parts

when parts are replaced

Remarks

MAINTENANCE

Front A-Arms

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Items not listed in the chart should be lubricated at the General Lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only See page 29.

Transmission Oil Polaris AGL Synthetic

Rear Gearcase Premium ATV Angle Drive

Front A-Arms Polaris Premium U-Joint

Synthetic 2W-50

Gearcase Lube

Fluid

Lube

See page 57.

See page 60.

See page 61.

Inspect; tighten fasteners; grease (also after washing ATV or driving in water)

MAINTENANCE

Sight Glass

Fill Plug

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

Oil Specifications

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

Oil Level

Maintain the oil level at the center of the sight glass. Do not overfill.

NOTICE: A rising oil level between checks in cool weather driving can indicate

1. Position the vehicle on a

2. View the oil level through

3. Remove the fill plug and

4. Reinstall the fill plug

engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Lubricant Capacity Drain Plug Torque

41 oz. (1200 ml) 11 ft. lbs. (15 Nm)

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.

level surface.

the sight glass on the right side of the vehicle.

add the recommended oil as needed.

securely.

MAINTENANCE

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Always change the oil filter whenever changing oil.

NOTICE: If the ATV is left without oil in the system for extended periods, the oil

1. Obtain the correct oil filter and an adequate supply of oil so the oil

2. Position the vehicle on a level surface.

3. Clean the area around the drain plug on the bottom of the engine

4. Run the engine for two to three minutes until warm. Stop the engine.

5. Place a drain pan beneath the engine crankcase and remove the

CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

6. Install a new sealing washer on the drain plug. The sealing surfaces

7. Reinstall the drain plug. Torque to specification.

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.

and filter change can be completed without interruption.

crankcase.

drain plug. Allow the oil to drain completely.

on the drain plug and crankcase should be clean and free of burrs, nicks or scratches.

MAINTENANCE

Oil and Filter Change

8. Place towels under the oil fil-

ter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

9. Using a clean, dry cloth, clean

the filter sealing surface on the crankcase.

10. Lubricate the gasket on the

new filter with a film of engine oil. Check to make sure the gasket is in good condition.

11. Install the new filter and turn

by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove the oil fill plug and add the recommended oil. Do not over-

fill.

13. Reinstall the fill plug.

14. Start the engine and let it idle for one to two minutes.

15. Stop 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. Discard used oil and filter properly.

MAINTENANCE

Sight Glass

Fill Plug

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52. Maintain the oil level between 1/4 and 3/4 on the sight glass. See page 96 for the part numbers of Polaris products.

Transmission Oil Recommendations

Gearcase Lubricant Capacity Drain Plug Torque

Transmission Premium AGL Synthetic

Gearcase Lubricant

Oil Check

1. Position the vehicle on a

level surface.

2. View the oil level

through the sight glass.

3. Remove the fill plug and

add the recommended oil as needed.

4. Reinstall the fill plug.

Oil Change

The transmission 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 appropri-

ate 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.

18.6 oz.

(550 ml)

18 ft. lbs.

(24 Nm)

MAINTENANCE

Check Plug

Fill Plug

Rear Gearcase Oil

Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 52.

Maintain the oil level at the bottom of the check plug hole. We recommend the use of Polaris Premium ATV Angle Drive Fluid. Use of other oils may result in improper operation of components. See page 96 for the part numbers of Polaris products.

Rear Gearcase Oil Recommendations

Gearcase Lubricant Capacity Fill Plug

Rear

Gearcase

Premium ATV

Angle Drive Fluid

4 oz.

(120 ml)

To r q u e

25 ft. lbs.

(34 Nm)

Drain/Check Plug

To r q u e

18 ft. lbs.

(24 Nm)

Oil Check

1. Position the vehicle on a level sur-

face.

2. Remove the check plug and view

the oil level.

3. Remove the fill plug. Add the rec-

ommended oil as needed.

4. Reinstall the fill plug. Torque to

specification.

5. Reinstall the 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.

MAINTENANCE

1 mm

Brakes

Front Brake Inspections

The front (right lever) brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. This brake system is selfadjusting.

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an

adequate level. See page 29.

2. Check the brake system for

fluid leaks.

3. Check the brakes for excessive

travel or spongy feel.

4. Check the friction pads for

wear, damage and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface

condition of the disc.

MAINTENANCE

2 1/2" (65 mm)

Hand Brake

Wing Nut

Foot Brake

Wing Nut

Brakes

Rear Brake Adjustments

The rear (left lever) brakes are mechanical brakes, activated by moving the brake lever toward the handlebar. The foot brake is also a mechanical rear brake.

Adjust the rear brakes when brake lever travel reaches 2 1/2" (65 mm). Always adjust the brakes when there is no longer sufficient stopping ability at the specified lever travel setting.

1. Position the vehicle on a level surface.

2. Block the front wheels.

3. Place the transmission in neutral.

4. Using suitable stands, elevate the rear of the vehicle so the rear

wheels are slightly off the ground.

5. Slowly tighten the hand

brake wing nut while rotating the rear wheels with your hand. When you begin to feel resistance (drag) in the wheel rotation, loosen the wing nut one full turn.

6. Slowly tighten the foot

brake wing nut until the foot brake lever arm begins to move. Loosen the wing nut 1/2 turn so it doesn't influence the hand brake adjustment.

7. Test the hand brake and

the foot brake for proper operation.

MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer.

1. Position the vehicle on a

level surface.

2. Set the handlebars in a

straight-ahead position and secure them in this position.

3. Place a chalk mark on the

center line of the front tires approximately 10" (25.4 cm) from the floor, or as close to the hub/axle center line as possible. Make sure both marks are the same distance from the floor.

4. Measure the distance between the marks and record the

measurement (1).

5. Move the vehicle until the chalk marks are at the rear of the tires,

even with the hub/axle center line.

6. Measure the distance between the marks and record the

measurement (2).

7. Subtract measurement 2 from measurement 1. The difference is the

vehicle toe-out alignment.

8. If you discover improper alignment, see your Polaris dealer for ser-

vice.

MAINTENANCE

Fasteners

Steering Assembly

The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

Side Panel Removal

1. Remove the seat.

2. Remove the three fasteners

securing the side panel to the vehicle.

3. Pull the side panel away

from the vehicle.

MAINTENANCE

WARNING

1/8" (3 mm)

Tires

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 94 for recommended tire type, size and pressure.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

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.

MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level surface.

2. Place the transmission in gear.

3. Stop the engine. Lock the parking brake.

4. Loosen the wheel nuts slightly.

WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

5. Place a suitable stand under the footrest frame to raise the wheel

slightly off the ground.

6. Remove the wheel nuts. Remove the wheel.

Wheel Installation

1. Place the wheel on the wheel hub with the valve stem toward the

outside and the rotation arrows on the tire pointing toward forward rotation.

2. Install the wheel nuts finger tight.

3. Lower the vehicle to the ground.

4. Torque the wheel nuts to specification.

WARNING! Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for service.

Location Nut Torque

Front Wheel 27 ft. lbs. (37 Nm)

Rear Wheel 27 ft. lbs. (37 Nm)

MAINTENANCE

Air Filter

1. Position the vehicle on a

level surface.

2. Place the transmission in

gear.

3. Lock the parking brake.

4. Remove the seat.

5. Release the air box cover

clips, and remove the air box cover.

6. Loosen the clamp and

remove the air filter.

7. Remove the pre-filter from the main filter.

8. Wash the pre-filter in soapy water, then rinse and let dry.

9. Reinstall the pre-filter over the main filter. Replace the main filter if

needed.

10. Reinstall the air filter into the air box. Tighten the clamp, but do not

over-tighten as filter damage could occur.

11. Reinstall the air box cover and the seat.

MAINTENANCE

Rubber

Cover

Socket

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.

Headlamp Replacement

To access the assembly from the front, remove the front cover and unplug the wiring harness. Remove the headlight assembly from the vehicle.

To access the headlight assembly without removing the front cover, reach up under the front cab.

1. Remove the rubber cover

from the back of the headlight.

2. Rotate the socket counter-

clockwise and pull it away from the headlight assembly.

3. Remove the headlamp and

install the new headlamp.

4. Reinstall all components.

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens cover mounting screws.

2. Remove the lens cover.

3. Remove the lamp.

4. Apply dielectric grease to the socket and install a new lamp.

5. Test the light for proper operation.

6. Reinstall the lens cover.

MAINTENANCE

Spark Plug Cap

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 94 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

NOTICE: Using non-recommended spark plugs can result in serious engine

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 71.

CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

1. Remove the spark plug

2. Using the special wrench

3. Reverse the procedure

damage. Always use Polaris-recommended spark plugs.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

cap.

provided in the tool pouch, rotate the spark plug counterclockwise to remove it.

for spark plug installation. Torque to specification.

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil, improper use of the choke, or incorrect throttle body/carburetor adjustments.

MAINTENANCE

Drain

Screw

Vehicle Immersion

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

1. Move the ATV to dry land or at the

very least, to water below the footrests.

2. Turn the fuel valve off.

3. Check the air box and dry any water.

4. Remove the spark plug.

5. Loosen the carburetor drain screw

and drain the carburetor.

6. Turn the engine over several times

using the electric start.

7. Dry the spark plug. Reinstall the

plug or install a new plug.

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If neces-

sary, repeat the drying procedure.

11. Take the ATV to your dealer for service as soon as possible, whether

you succeed in starting it or not.

12. If water has been ingested into the transmission, follow the proce-

dure on page 74 for drying.

MAINTENANCE

WARNING

Screws

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

Use the following procedure to periodically remove accumulated carbon from the arrestor screen.

1. Remove the three screws and

remove the arrestor from the end of the muffler.

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 a worn or damaged gasket.

5. Reinstall the gasket and arrestor.

6. Torque screws to 50 in. lbs. (5.6 Nm).

MAINTENANCE

WARNING

Constant Variable Transmission (CVT) System

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 CVT system. Use the following instructions to dry it out before operating.

1. Remove the CVT drain plug from the bottom of the CVT cover.

2. Allow the water to drain completely. Reinstall the drain plug.

3. Start the engine. Place the transmission in neutral.

4. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for

more than 10 seconds.

5. Allow the engine RPM to settle to idle speed, then shift the trans-

mission into forward gear.

6. Test for belt slippage. If the belt slips, repeat the process.

7. Take the vehicle to your dealer for service as soon as possible.

MAINTENANCE

WARNING

Battery

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 electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

MAINTENANCE

Battery

Battery Removal

1. Remove the seat.

2. Disconnect the battery

hold-down strap.

3. On conventional batteries,

remove the battery vent tube.

4. Disconnect the black

(negative) battery cable first.

5. Disconnect the red

(positive) battery cable last.

6. Lift the battery out of the battery compartment. Be careful not to tip

a conventional battery sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the vehicle.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 79 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat-

teries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease

or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Secure the battery hold-down strap.

8. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

9. Reinstall the seat.

MAINTENANCE

Lower

Mark

Upper

Mark

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

Polaris recommends maintaining battery charge by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 96 for the part numbers of Polaris products.

Tip: Power plug leads may need to be bent down so that the battery cover can

be installed.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Add only distilled water. Tap water contains minerals that are harmful to a battery.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 76.

2. Charge the battery with a charging output no larger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 77. Make sure the positive terminal is

toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the 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.

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.

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 battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufac-

turer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging.

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

100% 12.8-13.0 volts None, check at 3

75%-100% 12.5-12.8 volts May need slight

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,

0%-25% 11.5 volts or less Needs charge with

Voltage Action

mos. from date of

manufacture

charge, if no

charge given,

check in 3 months

desulfating charger

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

None required

3-6 hours

verify state of charge

At least 20 hours

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components.

NOTICE: High water pressure may damage components. Polaris recommends

The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will

damage plastic surfaces. Do not allow these types of products to contact the vehicle.

and the lower parts last.

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items:

• Wheel bearings

• Transmission seals

•Brakes

• Cab and body panels

• Labels and decals

• Electrical components

• Switches and controls If an informational or graphic label becomes illegible or comes off, con-

tact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above.

MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 81.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

4. Stop the engine.

5. Turn the fuel valve off.

6. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 58.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Drain the sediment tube.

protective film created by fogging and damage could occur. Never start the engine during the storage period.

Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

disperse through the fuel in the tank and carburetor.

MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 52.

• Rear gearcase

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

Fog the Engine

Use Polaris Engine Fogging Oil. Follow label directions carefully.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 52.

Battery Storage

See pages 78-79 for storage and charging procedures.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

MAINTENANCE

Transporting the Vehicle

Follow these procedures when transporting the vehicle.

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Turn the fuel valve off.

5. Secure the fuel cap, oil cap and

seat.

6. Remove the key to prevent loss

during transporting.

7. Always tie the frame of the ATV to

the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front bumper, racks or handlebars.

Camber and Caster

Adjuster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension.

Accessory springs are available through your Polaris dealer.

ADJUSTMENTS

3.5 ft. lbs. (4.7 Nm)

25 ft. lbs.

(34 Nm)

Cover

Handlebar

Bolts

Handlebars

WARNING! Improper adjustment of the handlebars or incorrect torquing of the

adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for rider preference.

1. Remove the handlebar cover.

2. Loosen (do not remove) the

four handlebar clamp bolts.

3. Adjust the handlebar to the

desired height.

4. Be sure the handlebars do

not contact the gas tank or any other part of the machine when turned fully to the left or right.

5. Tighten the front handlebar

clamp bolts first, then tighten the rear bolts. Torque to 25 ft. lbs. (34 Nm).

6. Reinstall the handlebar

cover. Tighten screws to 3.5 ft. lbs. (4.7 Nm).

ADJUSTMENTS

Carburetor

Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures 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.)

Tip: Continuous operation of the engine without proper jetting when required

can cause poor performance, overheating or engine damage. See your Polaris dealer for more information about jetting the ATV for conditions in your area.

Carburetor/Engine Idle RPM Adjustment

If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.

1. Place the transmission in gear.

2. Lock the parking brake.

3. Start the engine and allow it to warm up for approximately five minutes.

4. Turn the carburetor idle screw in (clockwise) to raise RPM. Turn the screw out (counterclockwise) to lower RPM.

ADJUSTMENTS

Lock Nut

Sleeve

Boot

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Slide the boots off the inline cable adjuster sleeve. Loosen the adjuster locknut.

2. Turn the adjuster until 1/16" to 1/8" (1.5-3 mm) of freeplay is

achieved at the thumb lever. While adjusting freeplay, be sure to flip the throttle lever back and forth several times.

3. Tighten the lock nut and slide the boots over the cable adjuster until

they touch at the midpoint of the adjuster.

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause Solution

Tripped circuit breaker Reset the breaker

Low battery voltage Recharge the 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 fresh recommended fuel

Fouled or defective spark plug(s) Inspect plugs and replace if necessary

No spark to spark plug Inspect plugs, verify stop switch is on

Overuse of choke Inspect, clean and/or replace spark plugs

Water or fuel in crankcase Immediately see your Polaris dealer

Low battery voltage Recharge the battery to 12.8 VDC

Mechanical failure See your dealer

Engine Backfires

Possible Cause Solution

Weak spark from spark plug 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 fresh recommended fuel

Incorrectly installed spark plug wires See your dealer

Incorrect ignition timing See your dealer

Mechanical failure See your dealer

TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel

Incorrect ignition timing See your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Idle set too low Adjust idle speed

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution

Fouled or defective spark plug(s) Inspect, clean and/or replace spark

Worn or defective spark plug wires See your 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 tank vent line Inspect and replace

Incorrect fuel Replace with recommended fuel

Clogged air filter Inspect and clean or replace

Reverse speed limiter malfunction See your dealer

Electronic throttle control malfunction See your dealer

Other mechanical failure See your dealer

Possible Lean Fuel 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 dealer

Possible Rich Fuel 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 dealer

plug(s)

TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause Solution

Out of fuel Refuel, cycle key to ON position three

Kinked or plugged fuel vent line Inspect and replace

Water is present in fuel Replace with new fuel

Overuse of choke Inspect, clean and/or replace spark plugs

Fouled or defective spark plug(s) Inspect, clean and/or replace spark

Worn or defective spark plug wires See your dealer

Incorrect spark plug gap or heat range Set gap to specs or replace plug

Loose ignition connections Check all connections and tighten

Low battery voltage Recharge the battery to 12.8 VDC

Incorrect fuel Replace with fresh recommended fuel

Clogged air filter Inspect and clean or replace

Reverse speed limiter malfunction See your dealer

Electronic throttle control malfunction See your dealer

Other mechanical failure See your dealer

Overheated engine Clean engine exterior; see your Polaris

times for 5 seconds each, then start

plug(s)

dealer

SPECIFICATIONS

Phoenix 200

Maximum Weight Capacity 285 lbs. (129 kg) (includes weight of operator,

Dry Weight 395 lbs. (179 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 Capacity 70 lbs. (31.7 kg)

Hitch Tongue Weight Capacity 30 lbs. (13.6 kg) (Rear rack weight and tongue

Hitch Towing Weight Capacity 300 lbs. (136 kg)

Overall Length 65 in. (165 cm)

Overall Width 42 in. (106.7 cm)

Overall Height 42 in. (106.7 cm)

Wheelbase 45 in. (114.3 cm)

Ground Clearance 5.7 in. (14.5 cm)

Minimum Turning Radius 65 in. (165.1 cm) unloaded

Engine Type 4-Cycle, Single Cylinder

Lubrication Wet sump

Engine Cooling Air

Displacement 196 cc

Bore x Stroke 65 x 59

Alternator Output 210w @5000 rpm

Compression Ratio 9.2:1 Full Stroke

Carburetor 1 / 22 mm (VM Type)

Pilot Jet 40

Main Jet 98

Air Screw 1 Turn Out

Jet Needle 2MKNN-4 clip

Ignition System DC CDI

Ignition Timing 32° +/- 2° @ 3000 RPM

Spark Plug / Gap NGK CR6HSA / 0.6-0.7 mm

Driving System Type Constant Variable Transmission (CVT)

Shift Type Side Lever (F/N/R)

cargo and accessories)

weight not to exceed 30 lbs./13.6 kg)

SPECIFICATIONS

Phoenix 200

Drive Ratio, Front N/A Tires, Front 21x7-10 / 4 psi (27.6 kPa) Tires, Rear 20x10-9 / 4 psi (27.6 kPa) 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)

Shock Adjustment CAM Brakes, Front Hydraulic Disc Brakes, Rear Mechanical Drum Brake, Foot Mechanical Drum, Rear Brake Brake, Parking Mechanical, Rear Headlight Front Cover, Hi/Lo 35W Halogen Taillight 12V 5W Brake Light 12V 21W Battery 12V 12 AH Electric Start Standard DC Plug-In (rear) Accessory Windshield Accessory Neutral Indicator Standard Reverse Indicator Standard Tool Kit Standard

travel

Jetting Chart

ALTITUDE

Meters (Feet)

0-1800 (0-6000) 102 98

1800-3700 (6000-12000) 96 92

AMBIENT TEMPERATURE

Below 40° F

(Below 5° C)

40°F and above

(5°C and above)

Clutching Chart

Altitude

Meters (Feet)

0-1800 (0-6000) 6 @ 14.7 grams

1800-3700 (6000-12000) 6 @ 9.5 grams

Roller Weight

Grams Each

POLARIS PRODUCTS

Part Number

Description

Engine Lubricant

2870791 Fogging Oi l (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synth etic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Gearcase / Transmission Lubricants

2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL Synthetic Gearcase Lube (gal.) 2870465 Pump for Gallon Jug 2871653 Premium ATV Angle Drive Fluid (8 oz.) 2872276 Premium ATV Angle Drive Fluid (2.5 gal.)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz. cartridge ) 2871460 Starter Drive Grease (2 oz.) 2871515 Premium U-Joint Lube (3 oz.) 2871551 Premium U-Joint Lube (14 oz.) 2871329

Dielectric Grease (Nyogel

)

Additives / Miscellaneous

2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2871956 2859044

Loctite

565 Thread Sealant

Polaris Battery Tender

Charger

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 gives a one year limited warranty on the final drive 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 transferable to another consumer during the warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. 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 troublefree 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 Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the 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 CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

Polaris Phoenix 9921841 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual