Polaris Offroad Vehicle 200 Quadricycle User Manual

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but informa-

tion about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician. Please see your dealer for all of your service needs

during (and after) the warranty period.

For more information about Polaris, visit us online at www.polarisin-

dustries.com.

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

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 discrep-

ancies may result between 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 or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in USA

2009 Phoenix 200 Quadricycle Owner’s Manual

P/N 9922082

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TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 22

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Emission Control Systems . . . . . . . . . . . . . . . 47

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . . 82

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 83

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 86

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 90

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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INTRODUCTION

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and sym-

bols 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.

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INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual

can result in severe injury or death. This vehicle is not a toy and can be

hazardous to operate. A collision or rollover can occur quickly, even during

routine maneuvers, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and

operating procedures before operating the vehicle.

• Never operate this vehicle without proper instruction. Take a training course.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age.

• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a

Quadricycle/trailer combination on public roads is prohibited.

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INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the

spaces provided. Remove the spare key and store it in a safe place. The

ignition switch must be replaced if all keys are lost.

Engine Serial Number

VIN

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

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SAFETY

Safety Training

When you purchased your new Polaris vehicle, your dealer offered a

hands-on safety training course. You were also provided with printed

materials that explain safe operating procedures. Review this informa-

tion on a regular basis.

If you purchased your vehicle from a party other than a Polaris dealer,

please request free safety training from any authorized Polaris dealer.

Equipment Modifications

The warranty on your Polaris vehicle may be terminated if any equip-

ment has been added, or if any modifications have been made, that

increase speed or power.

The addition of certain accessories, including (but not limited to) mow-

ers, blades, tires, sprayers and large racks may change vehicle handling.

Use only Polaris-approved accessories. Know their function and effect

on the vehicle.

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SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Eye Protection

Helmet

Long Sleeves

Gloves

Long Pants

Boots

Helmet

Always wear a helmet that meets or exceeds established safety stan-

dards.

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.

051039

0006.31

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SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever 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.

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SAFETY

Operator Safety

WARNING

Failure to operate the ATV properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Heed all safety

warnings outlined in this section of the owner’s manual. See the OPERATION

section of the owner’s manual for proper operating procedures.

Read and understand all warnings, cautions and

operating procedures in this manual and on the

safety labels before operating this vehicle.

Never operate this vehicle without proper

instruction. Take a training course. Beginners

should receive training from a certified instructor.

Contact an authorized Polaris dealer or visit the

Polaris web site at www.polarisindustries.com.

Never permit others to operate this vehicle unless

they have read and understand this manual and all

product labels, and have completed a certified

safety training course.

Never allow anyone under 16 years of age to

operate this vehicle.

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SAFETY

Operator Safety

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

area.

• Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where gasoline is stored.

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

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

and water and change clothing.

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

Never start the engine or let it run in an enclosed area. Operate this vehicle only

outdoors or in well-ventilated areas.

Always inspect your vehicle before each use to

verify that it's in safe operating condition. Follow

the inspection and maintenance procedures

outlined in this manual. See page 31.

Always wear an approved helmet that fits

properly. Wear eye protection (goggles or

face shield), gloves, boots, long sleeves and

long pants.

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SAFETY

Operator Safety

Never consume alcohol or drugs before

or while operating this vehicle.

Keep both hands on the handlebars. Keep

both feet on the footrests.

Never carry a passenger. The purpose of

the long seat is to allow the operator to

shift position as needed during operation. It

is not intended for carrying passengers.

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SAFETY

Operator Safety

Never carry a passenger on the rear rack.

Ejection from the vehicle or contact with

moving components can result in serious

injury or death.

Operating on paved surfaces may seriously affect the handling and control of

the Quadricycle and could result in loss of control, accident and/or injury. Avoid

sudden turns or swift movement of the handlebars.

Never operate at excessive speeds. Travel

and turn at speeds appropriate for the

terrain, visibility, operating conditions and

your experience.

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SAFETY

Operator Safety

Always follow the procedures outlined in this

manual for turning. Never turn sharply at

excessive speeds, which can lead to vehicle

overturn. See page 35.

Never attempt jumps or other stunts.

Always follow the procedures outlined in

this manual for driving through water.

Never drive through deep or fast-flowing

water. See page 41.

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SAFETY

Operator Safety

Always follow the procedures outlined in this

manual for driving on hills. See page 37. Never

operate on hills too steep for this vehicle or for

your abilities. Practice on smaller hills before

attempting larger hills. Avoid climbing hills

steeper than 25°.

Always follow the procedures outlined in this

manual for driving downhill and for braking on

hills. See page 39.

Always follow the procedures outlined in this

manual for braking if you stall or roll backwards

while climbing a hill. Never back down a hill. See

page 40.

Always follow the procedures outlined in this

manual for crossing the side of a hill. See page

38. Never attempt to turn this vehicle around on

any hill until you've mastered (on level ground)

the turning technique outlined in this manual.

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SAFETY

Operator Safety

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

proper tire pressure.

Always travel slowly when operating on

unfamiliar terrain. Use extra caution.

Always follow the procedures outlined in this manual for driving in reverse. See

page 43.

Use caution when operating on rough, slippery

or loose terrain.

Always follow the procedures outlined in this manual for operating over

obstacles. See page 42.

Always follow the procedures outlined in this manual for operating on slippery or

loose surfaces. Use extra caution. Always avoid skidding or sliding. See page

36.

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SAFETY

Operator Safety

Never operate this vehicle on a frozen body of water.

Never modify a Quadricycle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly

distributed and securely attached. Reduce speed and follow the instructions in

this manual for carrying cargo or towing. Allow a greater distance for braking.

If this vehicle has been involved in an accident, always have an authorized

Polaris dealer inspect the entire vehicle for possible damage, including (but not

limited to) brake, throttle and steering systems.

Hot components can cause serious burns and fire. Do not touch hot exhaust

system components. Always keep combustible materials away from the exhaust

system.

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

unauthorized use or accidental starting.

For more information about Quadricycle safety, contact

an authorized Polaris Quadricycle dealer or visit the

Polaris web site at www.polarisindustries.com.

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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, con-

tact your Polaris dealer to purchase a replacement. Replacement safety

labels are provided by Polaris at no charge. The part number is printed

on the label.

Rack Warning

Age Warning

No Passenger

Warning

Discretionary

Warning

Tire Pressure/Load

Warning

Clutch Cover

Warning

General

Warning

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SAFETY

Safety Labels and Locations

General Warning

Clutch Cover Warning

7173027

Age Warning

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SAFETY

Safety Labels and Locations

Discretionary Warning

WARNING

Never operate this ATV on HILLS

• Never operate this ATV

on HILLS steeper than

25 degrees 25°.

steeper than 25 degrees

25°.

To prevent overturn on hilly

terrain, use throttle and brakes

gradually, and shift weight uphill.

To prevent flipover on

hilly terrain, when going

up or down, use throttle

and brakes gradually.

7173026

Rack Warning

DO NOT TOW FROM RACK

OR BUMPER. Vehicle

damage or tipover may result

causing severe injury or

death. Tow only from tow

hooks or hitch. Max. Rack 70

lbs. (31.7 kg)

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or

tipover may result causing severe injury or death. Tow only from tow

hooks or hitch. Max. Rack 70 lbs. (31.7 kg)

7173312

Hitch Warning

Exceeding vehicle towing

limit could lead to an

accident. Reduce speed

when towing a trailer. Read

owner's manual for details.

Trailer Tongue Weight should

be about 10% of the Gross

Trailer Weight, and should

not exceed 13.6 kg (30 lbs).

Exceeding vehicle towing limit could lead to an accident.

Reduce speed when towing a trailer. Read owner's manual

for details. Trailer Tongue Weight should be about 10% of the

Gross Trailer Weight, and should not exceed 13.6 kg (30 lbs).

MAXIMUM TOWING CAPACITY: 136 KG (300 lbs)

7173312

MAXIMUM TOWING CAPACITY: 136 KG (300 lbs)

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SAFETY

Safety Labels and Locations

“No Passenger” Warning

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of

control, resulting in SEVERE INJURY

or DEATH.

Tire Pressure/Load Warning

Improper tire pressure or overloading

can cause loss of control.

Loss of control can result in severe

injury or death.

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)

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa)

Rear: 4.0 psi (27.6 kPa)

•

7175749

• Maximum weight capacity: 285 lbs.

(129 kg)

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FEATURES AND CONTROLS

Switches and Levers

Light

Switch

Start

Switch

Main Key

Switch

Turn Signal

Switch

Hazard Warning

Switch

Horn

Switch

Choke

Lever

Main Key Switch

Turn the main switch to the OFF position to stop the engine and

end all electrical power to the vehicle.

The main key switch must be in the ON position before starting

the engine. The headlights are not on in this position.

Move the key switch to the LIGHTS ON position to turn the

headlight on.

WARNING! Do not attach a large key fob or key ring to the main switch. It may

contact the gas tank cap when turning, causing an interruption to the electrical

system and an unexpected engine shut-down during operation.

Start Switch

Press the start switch toward the handlebar to engage the starter.

Tip: The starter will not engage unless the rear brakes are applied. See page 32

for engine starting procedures.

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FEATURES AND CONTROLS

Switches and Levers

Light Switch

Use the headlight switch to change the lights from high beam to low

beam. Move the main key switch to the LIGHTS ON position to turn the

headlight on.

Choke Lever

The choke assists in starting a cold engine. See page 32.

Horn Switch

Press the horn button to alert others of your presence.

Hazard Warning Switch

Push the hazard warning switch to cause all turn indicators to

flash simultaneously. Use this feature to alert others of an emer-

gency or other situation requiring caution.

Turn Signal Switch

Move the switch either left or right to activate the corresponding

turn signal. Return the switch to the center position to end the sig-

nal.

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FEATURES AND CONTROLS

Switches and Levers

Throttle Lever

Press the throttle lever to increase

engine speed and vehicle

movement. Release the lever to

reduce engine speed and vehicle

movement.

ETC

WARNING! Failure to check or

maintain proper operation of the throttle

system can result in an accident if the

throttle lever sticks during operation.

Check the lever for proper operation

before starting the engine. Check

occasionally during operation.

Throttle Lever

Do not start or operate a Quadricycle with sticking or improperly oper-

ating throttle controls.

Contact your dealer for repair if throttle problems arise.

The Electronic Throttle Control (ETC) stops the engine in the event of a

throttle system malfunction. Do not modify the ETC system or replace it

with other throttle mechanisms.

Rear Brake Lever

The brake lever operates the rear

brakes only. Squeeze the brake lever

toward the handlebar to apply the

rear brakes.

Since the brake lever operates the

rear brakes only, it is not as effective

as the all-wheel foot brake.

If the rear wheels begin to skid or slide while using this brake, reduce

lever pressure.

WARNING! Aggressively applying the rear brake when backing down a hill may

cause rear tipover. Aggressively applying the rear brake while moving forward

may cause the rear wheels to skid and result in loss of control.

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FEATURES AND CONTROLS

Foot Brake

The all-wheel foot brake is located on

the right footrest. Press the brake pedal

forward with your foot to engage all

four brakes, providing maximum stop-

ping power.

Inspect and maintain the brake fluid

level as outlined in this manual. See

page 58.

Foot Brake

Parking Brake

1. Squeeze the brake lever.

2. Push the parking brake lock

down to engage the lock.

3. Release the brake lever.

4. To release the parking brake

lock, squeeze and release the

brake lever. The parking brake

will release automatically.

WARNING! Operating the vehicle while the parking brake is engaged could

result in an accident or fire. Always check to be sure the parking brake is

disengaged before operating.

The parking brake may relax if left on for a long period of time. Always

block the wheels to prevent rolling. Never depend on the parking brake

alone if the vehicle is parked on a hill. Always block the wheels to pre-

vent rolling.

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FEATURES AND CONTROLS

Indicator Lights

View vehicle functions on the instrument panel. Each light illuminates

when the feature is activated.

Hazard Warning

Turn Signal

Indicator

High Beam

Indicator

Neutral Gear

Indicator

Reverse Gear

Indicator

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust

the mirrors before driving the Quadricycle.

Mirrors

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FEATURES AND CONTROLS

Fuel Tank Cap

Always refuel with the engine

stopped, and outdoors or in a

well ventilated area. Refuel on a

level surface.

Fuel Valve

Remove the fuel tank cap to add

fuel to the fuel tank. The gauge

in the cap shows the approxi-

mate amount of fuel remaining.

Use either leaded or unleaded

gasoline with a minimum pump

octane number of 87=(R+ M/2)

octane. Do not use E-85 fuel.

Fuel 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.

OFF

RES

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).

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FEATURES AND CONTROLS

Transmission Gear Selector

The transmission gear selector is located

on the right side of the vehicle.

Gear Selector

R: Reverse

N: Neutral

F: Forward Gear

To shift gears, brake to a complete stop.

When the engine is idling, move the

lever to the desired gear.

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

moving could cause transmission damage.

Whenever the vehicle is left unattended, always place the transmission

in gear and lock the parking brake.

Kick-Start Lever

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

start the engine until the battery is serviced.

1. Position the vehicle on a level surface.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Fold out the kick-start lever on the left side of the vehicle.

5. Make sure the main key switch is on.

6. Place your foot on the kick-start lever. Thrust your heel downward

to crank the engine.

7. If the engine is cold, use the choke as outlined on page 32.

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

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

lever. If not installed, make sure the rubber cap is installed on the kick-start

shaft to protect the rider. The storage area for the kick-start lever is on the

left side of the frame above the rear swing arm pivot.

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OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Read and

understand all safety warnings outlined in the safety section of this owner’s

manual.

Break-In Period

The break-in period for your new Polaris Quadricycle is the first ten

hours of operation, or the time it takes to use the first two full tanks of

gasoline. No single action on your part is as important as following the

procedures for a proper break-in. Careful treatment of a new engine and

drive components will result in more efficient performance and longer

life for these components.

NOTICE: Do not operate at full throttle or high speeds during the first three

hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 27. Always exercise

extreme caution whenever handling gasoline.

2. Check the oil level. See page 52. Add oil as needed to maintain the

level in the proper range.

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

iarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 31.

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

7. Change both the oil and the filter at 20 hours or one month, which-

ever comes first.

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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 oper-

ate this vehicle.

3. Never carry a passenger on this vehicle.

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

run in an enclosed area.

5. Avoid sudden turns or swift movement of the handlebars when

operating on pavement.

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

visibility such as fog, rain and darkness. Clean headlights 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 attempt wheelies,

jumps, or other stunts. Never remove your hands from the handle-

bars while operating, and always keep both feet on the footrests.

8. Never consume alcohol or drugs before or while operating this vehi-

cle.

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

Always maintain proper tire pressure.

10. Never operate a damaged Quadricycle. After any overturn or acci-

dent, have a qualified service dealer inspect the entire machine for

possible damage.

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

12. Familiarize yourself with all laws and regulations concerning the

operation of this vehicle in your area.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

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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

Brake fluid

Ensure proper level

Foot brake

Ensure proper operation

Front suspension

Rear suspension

Steering

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels/fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Throttle

Ensure proper operation

Indicator lights/switches

Air filter, pre-filter

Air box sediment tube

Headlamp

Ensure operation

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light/tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear approved helmet, goggles, and

protective clothing

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OPERATION

Starting the Engine

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

lated area.

2. Sit on the vehicle.

3. Turn the fuel valve on.

4. Turn the main key switch on.

5. Squeeze the brake lever.

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

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

to the left until it stops.

Tip: The choke is fully on when the lever is 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. Press the start switch.

Choke

Lever

8. Do not press the throttle while starting the

engine.

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OPERATION

Starting the Engine

9. Activate the starter for a maximum of five seconds. Release the start

switch when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

operating the vehicle.

10. If the engine does not start, release the start switch, wait five sec-

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

engine starts.

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

right to allow proper engine warm-up. Vary the engine RPM

slightly with the throttle to aid in warm-up.

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

to the right.

Cold Weather Operation

If the vehicle is used year-round, check the oil level frequently. A rising

oil level could indicate condensation in the bottom of the crankcase,

which can lead to engine damage. Any condensation must be drained.

Tip: Internal engine condensation increases as outside temperature decreases.

If the oil level rises to the top of the sight glass, change the oil immedi-

ately. Always operate the engine long enough to reach operating temper-

ature, which reduces condensation.

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OPERATION

Driving Procedures

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

2. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

3. Squeeze the brake lever.

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

5. Shift the transmission into gear.

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

7. Release the brake lever.

8. Slowly squeeze the throttle lever toward the handlebar to begin

driving. Squeeze the throttle lever further to increase speed.

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

brakes on level surfaces.

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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.

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OPERATION

Driving on Slippery Surfaces

Turn in

direction of

skid

Sideways

skid

Whenever riding on slippery surfaces such as wet trails or loose gravel,

or during freezing weather, follow these precautions:

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

2. Slow down before driving onto slippery surfaces.

3. Be alert. Watch the trail. Avoid quick, sharp turns.

4. Never apply the brakes during a skid. To correct a rear wheel skid,

turn the handlebars in the same direction as the skid and shift body

weight forward.

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OPERATION

Driving Uphill

Braking and handling are greatly affected when operating in hilly ter-

rain. Improper procedure could cause loss of control or overturn. When-

ever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25°

maximum).

3. Always check the terrain

carefully before ascend-

ing any hill.

4. Avoid hills with exces-

sively slippery or loose

surfaces.

5. Keep both feet on the

25° Maximum

footrests.

6. Shift body weight uphill.

7. Drive at a steady rate of speed to avoid stalling.

8. Never open the throttle suddenly or make sudden gear changes.

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

10. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never

apply the rear brakes while rolling backwards.

Apply the foot brake gradually. When fully stopped, squeeze the brake

lever as well.

Dismount on the uphill side, or to either side if the vehicle is pointed

straight uphill. Turn the vehicle around and remount, following the pro-

cedure described on page 40.

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OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could

cause loss of control or overturn. Avoid crossing the side of any hill

unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid hills with excessively slippery or loose surfaces.

3. Avoid crossing the side of a steep hill.

4. Shift body weight uphill.

5. Keep your feet on the footrests.

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

possible, or dismount on the uphill side immediately!

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OPERATION

Driving Downhill

25° Maximum

When driving downhill, follow these precautions:

1. Avoid steep hills (25° maximum).

2. Avoid hills with excessively slippery or loose surfaces.

3. Shift body weight uphill.

4. Drive straight downhill.

5. Slow down. Never go down a hill at high speed.

6. Avoid going down a hill at an angle, which can cause the vehicle to

pitch sharply to one side.

7. Apply the brakes slightly to aid in slowing.

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OPERATION

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill!

Use the K-turn to turn around.

2.4 m

1. Apply the all-wheel foot brake to stop the vehicle.

2. Keep your weight uphill.

3. Squeeze and hold the brake lever while completing steps 4-6.

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

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

cle is pointing straight uphill.

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

7. Slowly release the brake lever and allow the vehicle to roll around

to your right until it's pointing across the hill or slightly downward.

8. Squeeze the brake lever. Remount from the uphill side. Keep your

weight uphill.

9. With the transmission still in forward, start the engine

10. Release the brake lever and drive slowly downhill. Control speed

with the brake lever until the vehicle is on level ground.

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OPERATION

Driving Through Water

Your ATV can operate

through water with a maxi-

mum recommended depth

equal to the bottom of the

footrests. Follow these pro-

cedures when operating

through water:

1. Determine water

depths and current

before entering water.

2. Choose a crossing

where both banks have

gradual inclines.

Maximum Depth

3. Avoid operating

through deep or fast-

flowing water.

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

inspected after operation in water. If the vehicle tips or overturns in

water, or if the engine stops during or after operating in water,

restarting can result in serious engine damage. Transport the vehicle

to your dealer for service before restarting the engine. If this is not

possible, follow the vehicle immersion inspection and drying

procedures outlined on page 71, then see your dealer for service at

the first opportunity.

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

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

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

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

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

Do not make sudden throttle changes.

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OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

2. Be alert. Watch the terrain. Use extra caution

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

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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.

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OPERATION

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle

handling and may cause loss of control or brake instability, which can result in

serious injury or death. Always follow these precautions when hauling cargo:

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of the

operator, accessories, loads in the rack or box and the load on the trailer tongue.

The combined weight of these items must not exceed the maximum weight

capacity.

When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions.

CARRY LOAD AS LOW ON THE RACK AS POSSIBLE. Carrying a load high on

the rack raises the center of gravity of the vehicle and creates a less stable

operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load

and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain or

situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack

sides. Stability and maneuverability may be adversely affected, causing the

vehicle to overturn.

NEVER CARRY CARGO ON THE FRONT OF THE VEHICLE.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 mph (16 kph) while towing a load on a level surface.

Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough

terrain, while cornering, or while ascending or descending a hill.

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OPERATION

Hauling Cargo

31.7 kg

Load Distribution

Read and understand the load distribution warnings listed on the vehicle

warning labels. Never exceed the specified weights. Your Quadricycle

may carry a maximum of 31.7 kg of cargo on the rear rack. It may tow a

maximum of 136 kg with a maximum tongue weight of 13.6 kg.

Load cargo as low as possible. Never carry cargo on the front of the

vehicle. When operating over rough or hilly terrain, reduce cargo and

drive slowly to maintain stable driving conditions.

Slow down. Operate with extreme caution when hauling cargo or tow-

ing loads. Balance, handling and control may be affected.

Towing

Towing is approved OFF-ROAD ONLY. Operating a Quadricycle/trailer

combination on public roads is prohibited. Do not exceed the maximum

capacities when towing. Do not tow any trailer on a grade steeper than

15°.

Phoenix 200

Quadricycle

Maximum Towed Load

(Level Ground)

Maximum Vertical Hitch

Weight

136 kg

13.6 kg

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OPERATION

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow these precau-

tions:

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.

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EMISSION CONTROL SYSTEMS

This vehicle complies with the requirements of European directive 97/

24/EC.

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so

may affect compliance with governmental noise level requirements.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine

design, including factory-set fuel delivery and ignition. The engine and

related components must be maintained at Polaris specifications to

achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the

operator perform. Any other adjustments should be performed by an

authorized Polaris dealer.

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MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average

riding conditions. Vehicles subjected to severe use must be inspected

and serviced more frequently.

Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have a

qualified dealer perform these operations. Record maintenance and ser-

vice in the Maintenance Log beginning on page 90.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

WARNING

Improperly performing the procedures marked with a „ could result in

component failure and cause an accident, which may result in serious injury or

death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

Perform these operations more often for vehicles subjected to

severe use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar Kilometers

Steering

Pre-Ride

Daily

Make adjustments as need

ed. See Pre-Ride Checklist

on page 31.

X Front suspension

X Rear suspension

Tires

X Brake fluid level

X Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

X Engine oil level

X Air filter, pre-filter

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Headlamp/tail

lamp

Check operation; apply

dielectric grease if replacing

X Air filter,

E main element

Weekly

Monthly

Inspect; replace as needed

X Brake pad wear

100

Inspect periodically

Battery

Monthly

200

250

Check terminals; clean; test

Inspect level; change yearly

X Front gearcase oil

(if equipped)

X Transmission oil

Monthly

250

Inspect level; change yearly

Inspect; clean if needed

X Engine breather

E filter (if equipped)

X Engine oil change

1 M

3 M

6 M

250

500

Perform a break-in oil change

E (break-in)

X General

Lubricate all fittings, pivots,

cables, etc.

lubrication

Carburetor float

bowl

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Inspect; adjust; lubricate;

replace if necessary

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.

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Choke cable

6 M

500

Inspect; adjust; lubricate;

replace if necessary

E Carburetor air

Inspect duct for proper seal-

ing/air leaks

intake ducts/flange

Drive belt

Inspect; adjust; replace as

needed

Shift linkage

6 M

500

Inspect; lubricate; adjust

Lubricate

Steering

X Front suspension

500

Lubricate

X Rear suspension

500

Lubricate

X Engine oil change

100

1000

Perform a break-in oil change

at 20 hours

X Oil filter change

100

6 M

12 M

1000

Replace with oil change

Valve clearance

Inspect; adjust

Fuel system/filter

Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

X Engine mounts

100

12 M

1000

Inspect

Exhaust muffler/

pipe

Spark plug

100

12 M

1000

Inspect; replace as needed

Inspect

Ignition Timing

X Wiring

Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

100

200

12 M

24 M

1000

2000

Inspect; clean; replace worn

parts

and driven)

Front wheel

bearings

Inspect; replace as needed

Brake fluid

Change every two years

Adjust as needed

E Idle speed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 48. Items not listed in the

chart should be lubricated at the General Lubrication interval.

Item

Lube

Method

Engine Oil

PS-4 PLUS Performance See page 52.

Synthetic 2W-50

Brake Fluid

DOT 4 Only

See page 58.

See page 55.

Transmission Oil

Polaris AGL Synthetic

Gearcase Lube

Rear Gearcase

Front A-Arms

Premium Angle Drive

Fluid

See page 56.

Polaris Premium U-Joint Inspect; tighten fasteners; grease

Lube

(also after washing vehicle or

driving in water)

Front A-Arms

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MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 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 tempera-

ture operation.

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

engine damage. Always use the recommended oil. Never substitute

or mix oil brands.

Oil Specifications

Lubricant

Capacity

Drain Plug Torque

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

1200 ml

15 Nm

Oil Level

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

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

contaminants such as gas or moisture collecting in the crankcase. If

the oil level rises to the top of the sight glass, change the oil

immediately.

1. Position the vehicle on a level

surface.

2. Start the engine. Allow it to idle

for 30 seconds. Stop the engine.

3. View the oil level through the

sight glass.

4. Remove the fill plug. Add the

recommended oil as needed.

5. Reinstall the fill plug securely.

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MAINTENANCE

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 48. Always change the oil filter

whenever changing oil. Change the oil more often if the vehicle is rou-

tinely subjected to:

• operation in dusty or wet conditions.

• operation when air temperature is below -12° C.

• short trips at -12° to -1° C. (engine fails to reach operating tempera-

ture).

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

oil pump may lose its prime, which could result in engine damage.

Always replace the oil and filter within a few hours of draining the oil.

Do not allow the vehicle to be without oil overnight.

1. Use Polaris-recommended products.

2. Position the vehicle on a level surface.

3. Start the engine. Allow it to idle for two minutes. Stop the engine.

4. Place a drain pan beneath the engine crankcase. Remove the drain

plug. Allow the oil to drain completely.

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

5. Reinstall the drain plug with a new sealing washer.

6. Reinstall the drain plug. Torque to specification (see page 52).

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MAINTENANCE

Oil and Filter Change

7. Place towels under the oil filter.

Using an oil filter wrench, turn

the filter counterclockwise to

remove it.

8. Clean the filter sealing surface

on the crankcase.

9. Lubricate the filter o-ring.

10. Install the new oil filter. After

the filter contacts the engine

surface, turn it 1/2 turn by hand.

11. Remove the oil fill plug. Add

850 ml of the recommended oil

(see page 52).

12. Reinstall the fill plug.

13. Start the engine. Allow it to

idle for two minutes. Stop the

engine.

14. Check for oil leaks.

15. Check the oil level. Add oil as

needed.

16. Discard used oil and filter

properly.

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MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 48.

Transmission Oil Recommendations

Gearcase

Lubricant

Capacity

Drain Plug Torque

Transmission

Premium AGL Synthetic

Gearcase Lubricant

550 ml

24 Nm

Oil Check

1. Position the vehicle on a level

surface. Place the transmission

in gear. Lock the parking brake.

2. View the oil level through the

sight glass. The oil level should

be between 1/4 and 3/4.

3. Remove the fill plug. Add the

recommended oil as needed.

3/4

1/4

4. Reinstall the fill plug.

Oil Change

1. Position the vehicle on a level surface. Place the transmission in

gear. Lock the parking brake.

2. Remove the fill plug.

3. Remove the transmission drain plug.

4. Drain the fluid into a drain pan.

5. Clean and reinstall the drain plug. Torque to specification.

6. Add 550 ml of the recommended fluid.

7. Reinstall the fill plug.

8. Check for leaks. Discard used oil properly.

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MAINTENANCE

Rear Gearcase Oil

Always check and change the rear gearcase oil at the intervals outlined

in the Periodic Maintenance Chart beginning on page 48.

Rear Gearcase Oil Recommendations

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain/Check Plug

Torque

Rear

Gearcase

Premium ATV

Angle Drive Fluid

120 ml

34 Nm

24 Nm

Oil Check

1. Position the vehicle on a level

surface. Place the transmission in

gear. Lock the parking brake.

2. Remove the check plug. View the

oil level. The oil level should be

at the bottom of the plug hole.

3. Remove the fill plug. Add the

recommended fluid as needed.

4. Reinstall the fill plug. Torque to

specification.

5. Reinstall the check plug. Torque

to specification.

Check Plug

Fill Plug

Oil Change

1. Remove the skid plate.

2. Remove the drain plug. Drain the fluid into a drain pan.

3. Clean and reinstall the drain plug with a new sealing washer. Torque

to specification.

4. Remove the fill plug. Add 120 ml of the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks.

7. Reinstall the skid plate. Discard used oil properly.

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MAINTENANCE

Brakes

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could

result in an accident. Maintain brake fluid at the recommended level. Do not

overfill.

Once open, a bottle of brake fluid absorbs moisture from the air, which causes

the boiling temperature of the brake fluid to drop. This can lead to early brake

fade and the possibility of accident. Do not store opened brake fluid. Properly

discard any unused portion.

Under normal operation, a diaphragm extends into the reservoir as fluid

level drops. If the fluid level is low and the diaphragm is not extended, a

leak is likely. The brake system should be inspected by your dealer. Fill

the reservoir as needed whenever the cover is loosened or removed to

ensure proper diaphragm operation. Use Polaris DOT 4 brake fluid. Do

not overfill.

Reservoir levels will decrease as brake pads become worn. When check-

ing the fluid level, the vehicle must be on level ground with the handle-

bars straight. If the fluid level is low, check brake pad thickness before

adding brake fluid. Do not overfill.

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MAINTENANCE

Brakes

Brake Check

Perform the following checks to keep

the brake systems in good operating

condition. Check more often if brakes

are used heavily during normal opera-

tion.

1. Always keep foot brake fluid at an

adequate level. Check the foot brake

system regularly for fluid leaks.

2. Check the brakes for excessive

travel or spongy feel.

3. Check the brake pads for wear, dam-

age or looseness. Replace pads

when they are worn to 1 mm.

1 mm

4. Check the security and surface condition of the brake discs.

Brake Fluid (Foot Brake)

Check brake fluid level before each use of the vehicle.

The brakes should feel firm when they're applied. Spongy or weak

brakes may indicate a fluid leak or low fluid level. A low fluid level

may also mean that brake pads are worn and need to be replaced. Do not

operate the vehicle with spongy or weak brakes. See your dealer for ser-

vice.

1. Locate the foot brake master cylin-

Full

der under the right rear fender.

2. View the fluid level through the res-

ervoir body.

Add

3. Fluid level is full at the MAX mark.

Add brake fluid if the level reaches

the MIN mark.

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MAINTENANCE

Brakes

Brake Lever Travel

Service the brakes when brake

lever travel reaches 65 mm.

Always service the brakes when

there is no longer sufficient

stopping ability at the specified

lever travel setting.

65 mm

Brake Freeplay

Periodically measure the freeplay of the rear brakes. Acceptable free-

play range is 10-20 mm.

To adjust rear brake freeplay, turn the adjuster nut at the rear brake

drum.

10-20 mm

Adjuster Nut

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MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 3-6 mm toe out.

1. Position the vehicle on a

level surface.

2. Set the handlebars in a

straight-ahead position

and secure them in this

position.

3. Place a chalk mark on the

center line of the front

tires approximately 25

cm from the floor, or as

close to the hub/axle cen-

ter 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.

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MAINTENANCE

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts

and bolts. If loose nuts and bolts are found, see your Polaris dealer for

service before operating the vehicle.

Rear Spring

The rear shock absorber spring is

adjusted by rotating the adjuster either

clockwise or counterclockwise to

increase or decrease spring tension.

Adjuster

Accessory springs are available through

your Polaris dealer.

Side Panel Removal

1. Remove the seat.

2. Remove the three fasteners

securing the side panel to

the vehicle.

Fasteners

3. Pull the side panel away

from the vehicle.

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MAINTENANCE

Handlebars

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

adjuster block tightening bolts can cause limited steering or loosening of the

handlebars, resulting in loss of control and serious injury or death. Follow the

adjustment procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for rider preference.

1. Remove the handlebar cover.

2. Loosen (do not remove) the four handlebar clamp bolts.

3. Adjust the handlebar to the desired height.

4. Be sure the handlebars do not contact the gas tank or any other part

of the machine when turned fully to the left or right.

5. Tighten the front handlebar clamp bolts first, then tighten the rear

bolts. Torque to 34 Nm.

Tip: A gap of up to 3 mm should remain at the rear bolts.

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MAINTENANCE

Carburetor

Your Polaris vehicle is calibrated at the factory for optimal performance

at altitudes ranging from zero to 1800 meters and at temperatures of 4

degrees C. or higher. Above 1800 meters the engine air/fuel mixture

becomes too rich and the engine loses approximately 3% of its power

for each 300 meter increase in elevation. Although this power cannot be

regained, adjustments to the carburetor and drive system can be made to

allow more efficient operation. Optional jets and clutch components,

available from your Polaris dealer, are required for operation above

1800 meters. Jetting is required only when operating below 4 degrees C.

at 1800 meters and lower.

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

can cause poor performance, overheating or engine damage. See your

Polaris dealer for more information about jetting.

Carburetor/Engine Idle RPM Adjustment

If necessary, the carburetor can be adjusted.

1. Position the vehicle on a level sur-

face. Place the transmission in gear.

Lock the parking brake.

2. Start the engine. Allow it to idle for

approximately five minutes. Stop

the engine.

Adjuster

3. Turn the carburetor idle screw in

(clockwise) to raise RPM. Turn the

screw out (counterclockwise) to

lower RPM.

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MAINTENANCE

Throttle Cable Freeplay

Adjust throttle cable freeplay at the

handlebar.

1. Slide the boots off the inline cable

adjuster sleeve. Loosen the

adjuster locknut.

2. Turn the adjuster until 1.6-3 mm of

freeplay exists at the lever. Move

the throttle lever back and forth

several times while adjusting.

3. Tighten the lock nut and slide the

boots over the cable adjuster until

they touch at the midpoint of the

adjuster.

1.6-3 mm

Tip: Engine RPM should not increase when steering is turned full left or right.

Readjust cable freeplay if this occurs.

Boot

Sleeve

Lock Nut

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MAINTENANCE

Tires

WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires

or improperly installed tires will affect vehicle handling and could cause an

accident resulting in serious injury or death. Always follow all tire maintenance

procedures as outlined in this manual and on the labels on the vehicle. Always

use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 86 for recom-

mended tire type, size and pressure.

Wheel and Hub Tightening

Wheel hub and bearing tightness and spindle nut retention are critical

items. These services must be performed by an authorized dealer.

Tire Tread Depth

3 mm

Always replace tires

when tread depth is

worn to 3 mm or less.

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MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level surface. Place the transmission in

gear. Lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Safely place jackstands under the

vehicle.

4. Remove the wheel nuts. Remove

the wheel.

Wheel Installation

1. Place the wheel on the wheel hub.

2. Install the wheel nuts finger tight.

3. Carefully remove the jackstands.

4. Torque the wheel nuts to 37 Nm.

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MAINTENANCE

Air Filter

1. Position the vehicle on a

level surface. Place the trans-

mission in gear. Lock the

parking brake.

2. Remove the seat.

3. Release the air box cover

clips. Remove the air box

cover.

4. Loosen the hose clamp and

remove the filter.

5. Remove the pre-filter from

the main filter.

6. Wash the pre-filter in soapy water. Rinse and air dry.

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

needed.

8. Reverse the steps to reinstall all components.

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 86 for the recom-

mended spark plug type and gap for your vehicle.

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

damage. Always use Polaris-recommended spark plugs.

Plug Condition

Torque Specification

New Spark Plug

12-15 Nm

23-27 Nm

Previously Installed Spark Plug

Spark Plug Inspection

Check the spark plug firing end condition after the engine has been

warmed up and the vehicle has been driven at higher speeds. Immedi-

ately check the spark plug for correct color. See page 69.

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

1. Remove the spark plug cap.

2. Using the special wrench pro-

vided in the tool pouch, rotate

the spark plug counterclock-

wise to remove it.

3. Inspect the electrodes for wear

and carbon buildup. Replace

worn or fouled plugs. Verify

that the gap is at specification

before installation.

Spark Plug Cap

4. Reverse the procedure for

spark plug installation. Torque

to specification.

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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 indi-

cates 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 carbu-

retion 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 throt-

tle body/carburetor adjustments.

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MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight

and taillight lenses become dirty during normal operation. Clean lights

frequently and replace burned out lamps promptly. Always make sure

lights are adjusted properly for best visibility.

Headlamp Replacement

To access the assembly from the front, remove the front cover and

unplug the wiring harness. Remove the headlight assembly from the

vehicle.

To access the headlight assembly without removing the front cover,

reach up under the front cab.

1. Remove the rubber cover

from the back of the head-

light.

Rubber

Cover

2. Rotate the socket counter-

clockwise and pull it away

from the headlight assem-

bly.

3. Remove the headlamp and

install the new headlamp.

Socket

4. Reinstall all components.

Taillight/Brake Light 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.

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MAINTENANCE

Vehicle Immersion

If the vehicle stops while fully submerged, major engine damage can

result if the machine is not thoroughly inspected. Take the vehicle to

your dealer before starting the engine.

If it's impossible to take your vehicle to a dealer before starting it, fol-

low the steps outlined below.

1. Move the vehicle out of the water.

2. Turn the fuel valve off.

3. Check the air box and dry any water.

4. Remove the spark plug.

5. Drain any water found in the air box.

6. Loosen the carburetor drain screw and

drain the carburetor.

7. Turn the engine over several times using

the electric start.

8. Dry the spark plug. Reinstall the plug or

install a new plug.

9. Tighten the carburetor drain screw.

Drain

Screw

10. Turn the fuel valve on.

11. Attempt to start the engine. If necessary,

repeat the drying procedure.

12. Have the vehicle serviced by your dealer

promptly, whether you succeed in starting it or not.

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

dure on page 72 for drying.

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MAINTENANCE

Constant Variable Transmission (CVT) System

WARNING

Do not modify any component of the CVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The CVT system has been

precision balanced. Any modification will cause the system to be out of balance,

creating vibration and additional loads on components.

The CVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as

outlined in the owner's manual.

• This CVT system is intended for use on Polaris products only. Do not install it

in any other product.

• Always make sure the CVT housing is securely in place during operation.

CVT Drying

If water is ingested into the CVT system, dry it before operating the

vehicle.

1. Position the vehicle on a level surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

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

Drain the water. Reinstall the drain plug. Torque to 24 Nm.

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

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

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

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

mission into forward gear.

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

9. Take the vehicle to your dealer for service promptly.

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MAINTENANCE

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion

and cause serious injury or death. When removing the battery, always

disconnect the negative (black) cable first. When reinstalling the battery, always

connect the negative (black) cable last.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

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

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

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MAINTENANCE

Battery

Battery Removal

1. Remove the seat.

2. Disconnect the battery hold-down

strap.

3. Disconnect the black (negative)

battery cable first.

4. Disconnect the red (positive)

battery cable last.

5. Lift the battery out of the battery

compartment.

Battery Installation

1. Ensure that the battery is fully

charged.

2. Place the battery in the battery

holder.

3. Connect and tighten the red (posi-

tive) cable first.

4. Connect and tighten the black

(negative) cable last.

5. Attach the hold-down strap

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

tucked away at the front and rear of the battery.

7. Reinstall the seat.

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MAINTENANCE

Battery

Battery Charging

The following battery charging instructions apply only to the installa-

tion of an activated, sealed battery. Read all instructions before proceed-

ing with the installation of this battery.

A sealed battery is already filled with electrolyte. It has been sealed and

is fully charged at the factory. Always keep a sealed battery fully

charged.

• DO NOT pry the sealing strip off.

• DO NOT add any other fluid to this battery.

• A fully charged battery will register 12.8 V or higher.

1. Check battery voltage with a

voltmeter or multimeter.

2. If voltage is low, recharge the

battery at 1.2 amps or less until

the voltage is 12.8 or greater.

Tip: When using an automatic charger,

refer to the charger manufacturer's

instructions for recharging. When

using a constant current charger,

follow the guidelines below.

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

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

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MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it's fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

Polaris recommends maintaining battery charge by using a Polaris Bat-

tery Tender charger or by charging about once a month to make up for

normal self-discharge. Battery Tender can be left connected during the

storage period, and will automatically charge the battery if the voltage

drops below a pre-determined point. See page 82 for the part numbers of

Polaris products.

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping the vehicle clean will extend the life of components.

NOTICE: High water pressure may damage components. Polaris recommends

washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will

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

contact the vehicle.

The best and safest way to clean your Polaris vehicle is with a garden

hose and a pail of mild soap and water.

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

and the lower parts last.

2. Rinse with clean water frequently.

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

Washing Tips

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

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

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

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended),

exercise extreme caution. The water may damage components. Avoid

directing the water stream at the following items:

• Wheel bearings

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Electrical components

• Switches and controls

If an informational or graphic label becomes illegible or comes off, 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.

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MAINTENANCE

Cleaning and Storage

Storage Tips

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

protective film created by fogging and damage could occur. Never

start the engine during the storage period.

Clean the Exterior

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

page 77.

Stabilize the Fuel

1. Fill the fuel tank.

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

Follow the instructions on the container for the recommended

amount. Carbon Clean removes water from fuel systems, stabilizes

fuel and removes carbon deposits from pistons, rings, valves and

exhaust systems.

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

disperse through the fuel in the tank and carburetor.

4. Stop the engine.

5. Turn the fuel valve off.

6. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 53.

Air Filter / Air Box

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

2. Clean the air box.

3. Drain the sediment tube.

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MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Change fluids as recommended in the Periodic

Maintenance Chart beginning on page 48.

• Rear gearcase

• Transmission

• Brake fluid

Fog the Engine

Use Polaris Engine Fogging Oil. Follow label directions carefully.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended

in the Periodic Maintenance Chart beginning on page 48.

Battery Storage

See page 75-76 for storage and charging procedures.

Storage Area/Covers

1. Make sure tire pressure is at specification.

2. Using suitable supports under the frame, raise the vehicle slightly so

that the tires are not touching the ground.

3. Be sure the storage area is well ventilated.

4. Cover the machine with an appropriate cover. Do not use plastic or

coated materials, as they do not allow proper ventilation to prevent

condensation, corrosion and oxidation.

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MAINTENANCE

Transporting the Vehicle

Follow these procedures when trans-

porting the vehicle.

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Turn the fuel valve off.

5. Secure the fuel cap, oil cap and

seat.

6. Remove the key to prevent loss

during transporting.

7. Always tie the frame of the vehicle

to the transporting unit securely

with suitable straps or rope. Do not

attach tie straps to the front

bumper, racks or handlebars.

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POLARIS PRODUCTS

Part

Description

Number

Engine Lubricant

Fogging Oil (355 ml Aerosol)

2870791

2876244

2876245

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lubricant (.95 l)

Premium AGL Synthetic Gearcase Lube (3.8 l)

Pump for 3.8 Liter Jug

2873602

2873603

2870465

2871653

2872276

Premium ATV Angle Drive Fluid (237 ml)

Premium ATV Angle Drive Fluid (9.5 l)

Grease / Specialized Lubricants

2871312

2871322

2871423

2871460

2871515

2871551

2871329

Grease Gun Kit, Premium All Season

Premium All Season Grease (89 ml cartridge)

Premium All Season Grease (414 ml cartridge)

Starter Drive Grease

Premium U-Joint Lube (89 ml)

Premium U-Joint Lube (414 ml)

Dielectric Grease (Nyogel^TM

Additives / Miscellaneous

Carbon Clean Plus (355 ml)

)

2871326

2870652

2872189

2871956

2859044

Fuel Stabilizer (473 ml)

DOT4 Brake Fluid

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Tripped circuit breaker

Low battery voltage

Reset the breaker

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and clean or replace

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Overuse of choke

Drain the fuel system and refuel

Turn the fuel valve on

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Inspect, clean and/or replace spark plugs

Immediately see your Polaris dealer

Recharge the battery to 12.8 VDC

See your dealer

Water or fuel in crankcase

Low battery voltage

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

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TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Idle set too low

Set gap to specs or replace plugs

Adjust idle speed

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your dealer

Possible Rich Fuel Cause

Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your dealer

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water is present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your dealer

Fouled or defective spark plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your dealer

Clean engine exterior; see your Polaris

dealer

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SPECIFICATIONS

Phoenix 200 Quadricycle

Maximum Weight Capacity

129 kg

179 kg

9.5 liters

1200 ml

550 ml

120 m

Dry Weight

Fuel Capacity

Engine Oil Capacity

Transmission Oil

Rear Gearcase Oil

Rear Rack Capacity

Hitch Tongue Weight Capacity

31.7 kg

13.6 kg (rear rack weight and tongue weight not

to exceed 13.6 kg)

Hitch Towing Weight Capacity

Overall Length

Overall Width

Overall Height

Seat Height

136 kg

165 cm

106.7 cm

81.3 cm

Wheelbase

114.3 cm

Ground Clearance

Minimum Turning Radius

Engine Type

14.5 cm

165 cm unloaded

4-Cycle, Single Cylinder

Wet sump

Lubrication

Engine Cooling

Displacement

Bore x Stroke

Alternator Output

Compression Ratio

Carburetor

Air

196 cc

65 x 59

210w @5000 rpm

9.2:1 Full Stroke

1 / 22 mm (VM Type)

Pilot Jet

Main Jet

100

Air Screw

1 Turn Out

Jet Needle

2MKNN-4 clip

DC CDI

Ignition System

Ignition Timing

Spark Plug / Gap

Driving System Type

Shift Type

32° +/- 2° @ 3000 RPM

NGK CR7HSA / 0.6-0.7 mm

Constant Variable Transmission (CVT)

Side Lever (F/N/R)

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SPECIFICATIONS

Phoenix 200 Quadricycle

Drive Ratio, Front

Tires, Front

Tires, Rear

Front Suspension

Rear Suspension

Shock Adjustment

Brakes, Rear (Handlebar)

Brake, Foot

N/A

21x7-10 / 27.6 kPa

20x10-9 / 27.6 kPa

Dual A-Arm w/17.8 cm travel

Mono-Shock Swing Arm w/16.5 cm travel

CAM

Mechanical Drum

Hydraulic, All Wheel

Mechanical, Rear

Front Cover, Hi/Lo 35W Halogen

12V 5W

Brake, Parking

Headlight

Taillight

Brake Light

12V 21W

Battery

12V 12 AH

Electric Start

Speedometer

Neutral Indicator

Reverse Indicator

Tool Kit

Standard

DC Plug-In (rear)

Windshield

Accessory

Jetting Chart

ALTITUDE

AMBIENT TEMPERATURE

(Meters)

Below 5° C

5°C and above

0-1800

1800-3700

102

100

Clutching Chart

Altitude

Roller Weight

(Meters)

Grams Each

6 @ 14.7 grams

6 @ 9.5 grams

0-1800

1800-3700

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WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR

LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in

material or workmanship. This warranty covers the parts and labor charges for repair or

replacement of defective parts which are covered by this warranty. This warranty begins

on the date of purchase. This warranty is transferable to another consumer during the

warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. THE PURCHASER MUST COMPLETE A

QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN

ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. No verification

of registration will be sent to the purchaser as the copy of the Warranty Registration

Form will be the warranty entitlement. If you have not signed the original registration

and received the "customer copy", please contact your dealer immediately. NO WAR-

RANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS

REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-

ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will

void your warranty coverage.

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in

material or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any Quadricycle

that has been altered structurally, modified, neglected, improperly maintained, used for

racing, or used for purposes other than for which it was manufactured, or for any dam-

ages which occur during trailer transit or as a result of unauthorized service or the use of

unauthorized parts. In addition, this warranty does not cover physical damage to paint or

finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in

parts, components or the vehicle due to fire, explosions or any other cause beyond

Polaris' control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the Quadricycle. The exclusive remedy for breach of this war-

ranty shall be, at Polaris' exclusive option, repair or replacement of any defective materi-

als, 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 WAR-

RANTY 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.

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WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO

YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-

tations on how long an implied warranty lasts, so the above limitation may not apply to

you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your Quadricycle requires warranty service, you must take it to a Polaris dealer autho-

rized to repair Polaris Quadricycles. When requesting warranty service you must present

your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-

PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris

suggests that you use your original selling dealer; however, you may use any Polaris

Servicing Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require

any additional assistance they will contact the appropriate personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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INDEX

Air Filter . . . . . . . . . . . . . . . . . . . . . 67

Driving Procedures . . . . . . . . . . . . . . 34

Driving Properly . . . . . . . . . . . . . . . . 34

Driving Through Water . . . . . . . . . . . 41

Driving Uphill . . . . . . . . . . . . . . . . . . 37

Battery . . . . . . . . . . . . . . . . . . . . 73-76

Charging . . . . . . . . . . . . . . . . . 75

Installation . . . . . . . . . . . . . . . . 74

Removal. . . . . . . . . . . . . . . . . . 74

Storage. . . . . . . . . . . . . . . . . . . 76

Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9

Brake

All-Wheel Brake . . . . . . . . . . . 25

Foot Brake . . . . . . . . . . . . . . . . 25

Parking Brake . . . . . . . . . . . . . 25

Rear Brake Lever. . . . . . . . . . . 24

Brake Check. . . . . . . . . . . . . . . . . . . 58

Brake Fluid . . . . . . . . . . . . . . . . . . . 57

Brake Fluid (Foot Brake). . . . . . . . . 58

Brake Freeplay. . . . . . . . . . . . . . . . . 59

Brake Lever Travel . . . . . . . . . . . . . 59

Brake Light . . . . . . . . . . . . . . . . . . . 70

Brake Maintenance . . . . . . . . . . . 57-59

Break-In Period . . . . . . . . . . . . . . . . 29

Engine Break-In. . . . . . . . . . . . . . . . . 29

Engine Fogging . . . . . . . . . . . . . . . . . 80

Engine Idle RPM Adjustment . . . . . . 63

Engine Oil . . . . . . . . . . . . . . . . . . . . . 52

Equipment Modifications . . . . . . . . . . 7

Exhaust Emission Control System . . 47

Eye Protection . . . . . . . . . . . . . . . . . . . 9

Fuel Safety. . . . . . . . . . . . . . . . . . . . . 11

Fuel Tank Cap . . . . . . . . . . . . . . . . . . 27

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 27

Gasoline Handling. . . . . . . . . . . . . . . 11

Gear Selector . . . . . . . . . . . . . . . . . . . 28

Gearcase Oil . . . . . . . . . . . . . . . . . . . 56

Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9

Carburetor . . . . . . . . . . . . . . . . . . . . 63

Carburetor Adjustment . . . . . . . . . . 63

Cargo . . . . . . . . . . . . . . . . . . . . . . 44-45

Choke Lever. . . . . . . . . . . . . . . . . . . 23

Cleaning and Storage. . . . . . . . . . 77-80

Clothing . . . . . . . . . . . . . . . . . . . . . . . 9

Clutching Chart . . . . . . . . . . . . . . . . 87

Cold Weather Operation . . . . . . . . . 33

Constant Variable Transmission . . . 72

CVT Drying. . . . . . . . . . . . . . . . . . . 72

CVT System. . . . . . . . . . . . . . . . . . . 72

Handlebar Adjustment. . . . . . . . . . . . 62

Hauling Cargo . . . . . . . . . . . . . . . 44-45

Hazard Warning Switch. . . . . . . . . . . 23

Headlamp Replacement. . . . . . . . . . . 70

Helmet . . . . . . . . . . . . . . . . . . . . . . . . . 8

Horn Switch. . . . . . . . . . . . . . . . . . . . 23

Idle RPM Adjustment . . . . . . . . . . . . 63

Immersion . . . . . . . . . . . . . . . . . . . . . 71

Indicator Lights . . . . . . . . . . . . . . . . . 26

Drivetrain Break-In . . . . . . . . . . . . . 29

Driving Downhill. . . . . . . . . . . . . . . 39

Driving in Reverse. . . . . . . . . . . . . . 43

Driving on a Sidehill . . . . . . . . . . . . 38

Driving on Slippery Surfaces. . . . . . 36

Driving Over Obstacles . . . . . . . . . . 42

Jetting Chart. . . . . . . . . . . . . . . . . . . . 87

Key Switch . . . . . . . . . . . . . . . . . . . . 22

Kick-Start Lever . . . . . . . . . . . . . . . . 28

K-Turn . . . . . . . . . . . . . . . . . . . . . . . . 40

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INDEX

Levers . . . . . . . . . . . . . . . . . . . . . 22-24

Light Switch . . . . . . . . . . . . . . . . . . . 23

Lights

Headlamp Replacement . . . . . . 70

Indicator Lights. . . . . . . . . . . . . 26

Taillight/Brake Light . . . . . . . . 70

Load Distribution . . . . . . . . . . . . . . . 45

Lubrication Guide. . . . . . . . . . . . . . . 51

Safe Operation Practices. . . . . . . . . . 30

Safety Labels . . . . . . . . . . . . . . . 18-21

Age Warning. . . . . . . . . . . . . . . 19

Clutch Cover Warning . . . . . . . 19

Discretionary Warning . . . . . . . 20

General Warning. . . . . . . . . . . . 19

Hitch Warning . . . . . . . . . . . . . 20

No Passenger Warning . . . . . . . 21

Rack Warning . . . . . . . . . . . . . . 20

Tire Pressure/Load Warning. . . 21

Safety Training . . . . . . . . . . . . . . . . . . 7

Severe Use . . . . . . . . . . . . . . . . . . . . 48

Shifter . . . . . . . . . . . . . . . . . . . . . . . . 28

Side Panel Removal . . . . . . . . . . . . . 61

Sidehilling. . . . . . . . . . . . . . . . . . . . . 38

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Plugs . . . . . . . . . . . . . . . . . 68-69

Spring Adjustments, Rear. . . . . . . . . 61

Start Switch. . . . . . . . . . . . . . . . . . . . 22

Starting the Engine . . . . . . . . . . . 32-33

Starting, Kick-Start Lever. . . . . . . . . 28

Steering Assembly . . . . . . . . . . . . . . 61

Storage . . . . . . . . . . . . . . . . . . . . 77-80

Switches . . . . . . . . . . . . . . . . . . . 22-24

Hazard Warning Switch . . . . . . 23

Horn Switch . . . . . . . . . . . . . . . 23

Light Switch . . . . . . . . . . . . . . . 23

Main Key Switch . . . . . . . . . . . 22

Start Switch. . . . . . . . . . . . . . . . 22

Turn Signal Switch . . . . . . . . . . 23

Maintenance Chart . . . . . . . . . . . 48-50

Maintenance Chart Key . . . . . . . . . . 48

Mirrors . . . . . . . . . . . . . . . . . . . . . . . 26

Modifications . . . . . . . . . . . . . . . . . . . 7

Noise Emission Control System . . . . 47

Oil

Engine . . . . . . . . . . . . . . . . . . . . 52

Rear Gearcase . . . . . . . . . . . . . . 56

Transmission. . . . . . . . . . . . . . . 55

Oil and Filter Change . . . . . . . . . 53-54

Oil Level, Engine . . . . . . . . . . . . . . . 52

Oil Level, Rising. . . . . . . . . . . . . . . . 33

Oil Recommendations

Engine . . . . . . . . . . . . . . . . . . . . 52

Rear Gearcase . . . . . . . . . . . . . . 56

Transmission. . . . . . . . . . . . . . . 55

Oil Specifications, Engine . . . . . . . . 52

Operator Safety. . . . . . . . . . . . . . 10-17

Taillight. . . . . . . . . . . . . . . . . . . . . . . 70

Throttle Cable Freeplay . . . . . . . . . . 64

Throttle Lever . . . . . . . . . . . . . . . . . . 24

Tires . . . . . . . . . . . . . . . . . . . . . . 65-66

Tread Depth . . . . . . . . . . . . . . . 65

Wheel and Hub Tightening. . . . 65

Wheel Installation. . . . . . . . . . . 66

Wheel Removal . . . . . . . . . . . . 66

Toe Alignment . . . . . . . . . . . . . . . . . 60

Towing . . . . . . . . . . . . . . . . . . . . . . . 45

Training. . . . . . . . . . . . . . . . . . . . . . . . 7

Transmission Oil. . . . . . . . . . . . . . . . 55

Transmission System (CVT) . . . . . . 72

Panel Removal . . . . . . . . . . . . . . . . . 61

Parking Brake . . . . . . . . . . . . . . . . . . 25

Parking on an Incline . . . . . . . . . . . . 46

Periodic Maintenance Chart . . . . 48-50

Polaris Product List. . . . . . . . . . . . . . 82

Polishing the Vehicle . . . . . . . . . . . . 78

Pre-Ride Checklist . . . . . . . . . . . . . . 31

Reverse Operation. . . . . . . . . . . . . . . 43

Riding Gear. . . . . . . . . . . . . . . . . . . 8, 9

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INDEX

Transporting the Vehicle . . . . . . . . . 81

Turn Signal Switch . . . . . . . . . . . . . 23

Turning Around on a Hill . . . . . . . . 40

Turning the Vehicle. . . . . . . . . . . . . 35

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . . . 77-78

Wheel and Hub Tightening . . . . . . . . 65

Wheel Installation . . . . . . . . . . . . . . . 66

Wheel Removal . . . . . . . . . . . . . . . . . 66

Vehicle Identification Numbers. . . . . 6

Vehicle Immersion. . . . . . . . . . . . . . 71

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