Polaris 2014 Phoenix 200, Owner'S Manual

Page 1: ...It contains important safety information Adult supervision is required for children under 16 years of age Operation is prohibited for children under 14 years of age PMS 419 Owner s Manual for Maintena...

Page 2: ...r s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to...

Page 3: ...nment and for the rights of others while operting the ATV Never allow a child under the age of 16 to operate an ATV without adult supervision Children differ in skills physical abilities and judgement...

Page 4: ...read and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents to explain anything you don t understand and pay close at...

Page 5: ...ence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle For safe and enjoy...

Page 6: ...en the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions...

Page 7: ...Introduction 4 Safety 7 Features and Controls 24 Operation 32 Emission Control Systems 51 Maintenance 52 Adjustments 87 Troubleshooting 93 Specifications 96 POLARIS Products 98 Warranty 99 Maintenanc...

Page 8: ...ituation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indi...

Page 9: ...tle lever and engine stop switch Adult supervision is required for children under age 16 NEVER allow anyone under 14 years of age to operate this vehicle Never permit a guest to operate the ATV unless...

Page 10: ...ated 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 ____________...

Page 11: ...derCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcemen...

Page 12: ...ds estab lished 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 m...

Page 13: ...protect arms and legs Rid ing 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 A...

Page 14: ...e 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 traini...

Page 15: ...e 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...

Page 16: ...d gloves boots a long sleeved shirt or jacket and long pants Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance an...

Page 17: ...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...

Page 18: ...ng improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Ne...

Page 19: ...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 hil...

Page 20: ...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...

Page 21: ...ollover 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 re...

Page 22: ...rating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or rollover Avoid operating the ATV through deep or fast flowing w...

Page 23: ...tly and replace burned out headlamps promptly Operating a Damaged ATV Operating a damaged ATV can result in an accident After any rollover or accident have a qualified service dealer inspect the entir...

Page 24: ...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 WIT...

Page 25: ...r 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...

Page 26: ...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 ps...

Page 27: ...or children under age 16 NEVER permit children under age 14 to operate this ATV Clutch Cover Warning WARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicl...

Page 28: ...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 befo...

Page 29: ...dent 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 electron...

Page 30: ...ot 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 Squeez...

Page 31: ...he front brakes Rear Brakes Foot Brake The foot brake operates the rear brakes The foot brake is located on the inside of the right footrest Operate this brake with your right foot The foot brake is a...

Page 32: ...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 ma...

Page 33: ...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 le...

Page 34: ...a minimum pump octane number of 87 R M 2 octane Non ethanol fuel is recommended Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Fuel Valve The fuel valve is located on...

Page 35: ...r 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...

Page 36: ...during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drive...

Page 37: ...nd darkness Clean headlights fre quently 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 att...

Page 38: ...icle 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 alwa...

Page 39: ...ondition and pressure 66 Wheels fasteners Inspect ensure fastener tightness 66 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 30 57 Coolant level if applicable E...

Page 40: ...o 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 o...

Page 41: ...to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up 13 When the engine idles smoothly move the choke lever completely to the right Cold Weather Operation I...

Page 42: ...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 depre...

Page 43: ...urn 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...

Page 44: ...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 Ne...

Page 45: ...s 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 stea...

Page 46: ...ssing 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...

Page 47: ...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 b...

Page 48: ...t 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 th...

Page 49: ...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...

Page 50: ...ing 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 unfami...

Page 51: ...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 in...

Page 52: ...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...

Page 53: ...and mounted as low as possible on the rack Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the...

Page 54: ...oid 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 dow...

Page 55: ...take 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...

Page 56: ...and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of approx...

Page 57: ...ead to serious injury or death Have an authorized POLARIS dealer perform these services Symbol Description Perform these operations more often for vehicles subjected to severe use E Emission related s...

Page 58: ...nspect clean often replace as needed Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Wee...

Page 59: ...adjust D E Fuel system filter 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust...

Page 60: ...ated at the General Lubrication interval Item Lube Method Engine Oil PS 4 Extreme Duty 10W 50 4 Cycle Oil See page 57 Brake Fluid DOT 4 Brake Fluid See page 29 Transmission Oil AGL Gearcase Lubricant...

Page 61: ...ommended oil Never substitute or mix oil brands Oil Specifications 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 we...

Page 62: ...oil filter and an adequate supply of oil so the oil and filter change can be completed without interruption 2 Position the vehicle on a level surface 3 Clean the area around the drain plug on the bot...

Page 63: ...re the gasket is in good con dition 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 ad...

Page 64: ...s 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 fil...

Page 65: ...evel 3 Remove the fill plug Add the recommended 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...

Page 66: ...e 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 fl...

Page 67: ...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 n...

Page 68: ...d secure them in this position 3 Place a chalk mark on the center line of the front tires approximately 10 inches 25 4 cm from the floor or as close to the hub axle center line as possible Make sure b...

Page 69: ...ically 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 sec...

Page 70: ...manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 96 for recom mended tire type size and p...

Page 71: ...tion 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 ve...

Page 72: ...x 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 f...

Page 73: ...mbly 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 head light 2 Rotate the socket count...

Page 74: ...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 engin...

Page 75: ...hould not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator ti...

Page 76: ...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 s...

Page 77: ...he spark arrester while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically remove accumulated carbon from the arrester screen 1 Remov...

Page 78: ...rocedures 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 secu...

Page 79: ...duce 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 m...

Page 80: ...e 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 coul...

Page 81: ...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 expl...

Page 82: ...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...

Page 83: ...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...

Page 84: ...dard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months...

Page 85: ...to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body f...

Page 86: ...ler 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 wat...

Page 87: ...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 periodical...

Page 88: ...POLARIS Fuel Sta bilizer Follow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rin...

Page 89: ...ly 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...

Page 90: ...ransmission 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...

Page 91: ...aster 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 a...

Page 92: ...he 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 handleb...

Page 93: ...inuous 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 condi...

Page 94: ...less The maximum unrestricted speed capability is 38 MPH 61 km h or less The dealer CANNOT under any circumstances either prior to the sale or later even at the consumer s request remove or adjust an...

Page 95: ...imit bracket can be removed 1 To adjust the speed limit screw loosen the jam nut 2 Turn the screw inward to reduce the speed Turn the screw outward to increase speed up to the 30 MPH 48 km h maximum T...

Page 96: ...sen 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 ti...

Page 97: ...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 Ov...

Page 98: ...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...

Page 99: ...replace spark plug s 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 ti...

Page 100: ...5 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 Stro...

Page 101: ...30 to 50 45 to 65 Above 60 C Below 35 34 to 23 26 to 15 18 to 7 9 to 2 1 to 10 7 to 18 Above 16 0 600 0 2000 Main Jet 98 98 98 98 98 98 98 98 Pilot Jet 40 40 40 40 40 40 40 40 Clip Position 5 5 5 5 4...

Page 102: ...l 2870465 Pump for Gallon Jug Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 287...

Page 103: ...the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer prepa...

Page 104: ...NY 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 WARRANT...

Page 105: ...he selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another coun...

Page 106: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Page 107: ...ar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a...

Page 108: ...ERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do...

Page 109: ...upplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POL...

Page 110: ...section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECH...

Page 111: ...107 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 112: ...uct Safety 7 Corrosion Removal Chrome 83 Crankcase Emission Control System 51 CVT Drying 74 CVT System 74 D Drivetrain Break In 32 Driving Downhill 43 Driving in Reverse 47 Driving on a Sidehill 42 Dr...

Page 113: ...Sidehilling 42 Signal Words 4 Spark Arrester 73 S Spark Plugs 70 71 Speed Control System 90 91 Spring Adjustments Rear 87 Starting the Engine 36 37 Starting Kick Start Lever 31 Steering Assembly 65 St...

Page 114: ...skills or the conditions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS S use proper...