Polaris 200 Quadricycle manual

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P antone 426 C For your nearest Polaris dealer , visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 U.S.A. Part No. 9922082 Rev 01 Printed in USA[...]

1 WELCOME Thank you for purchasin g a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an excit ing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles Always follow the instructions and recommendations in this [...]

2 POLARIS and POLARIS TH E W A Y OUT are registere d trademarks of Pol aris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 F eatures and Controls . . . . . . . . . . . . . . . . . . . 22 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emission Control Systems . . . . . . . . . . . .[...]

4 INTRODUCTION The following signal words and symbol s appear throughout th is manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal inju ry hazard. W ARNING A W ARNING indicates a hazardous [...]

5 INTRODUCTION 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 ro llover can occur quickly , even during routine maneuvers, if you fail to take proper precautions. • Read this owner ’ s manual. Understand [...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er in the spaces provided. Remove the spare ke y and store it in a safe place. The ignition switch must be replaced if all keys are lost. V ehicle Model Number: ___________________________________________________ F rame VIN: _____________ [...]

7 SAFETY Safety T r aining When you purchased your new Polaris vehicle, yo ur dealer offered a hands-on safety training course. Y ou were also pr ovided with printed materials that explain safe operatin g procedures. Review this informa- tion on a regular basis. If you purchased your vehicle from a party other than a Polaris dealer , please request[...]

8 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE ma[...]

9 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 o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make [...]

10 SAFETY Operator Safety Failure to operate the A TV properly can re sul t in a collision, loss of control, accident or overturn, which may result i n serious injury or death. Heed all safety warnings outlined in this section of the owner ’ s manual. See the OPERA TION section of the owner ’s manual for proper operati ng procedures. Read and u[...]

11 SAFETY Operator Safety Handling Gasoline Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • 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 [...]

12 SAFETY Operator Safety Never consume alcohol o r drugs before or while operating this vehicle. Keep both hands on the handl ebars. 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.[...]

13 SAFETY Operator Safety Never carry a passenger on the rear ra ck. Ejection from the vehicle or contact with moving components can result in serious injury or death. Operating on paved surfaces ma y serious ly affect the handling and control of the Quadricycle and could result in loss of control, acci dent and/or injur y . Avoid sudden turns or s[...]

14 SAFETY Operator Safety Always follow the procedures outli ned in this manual for turnin g. Never turn sharply at excessive speeds, which can lead to vehicle overturn. See page 35. Never attempt jumps or other stunts. Always follow the pro cedures outlined in this manual for drivin g through water . Never drive through deep or fast-flowing water [...]

15 SAFETY Operator Safety Always follow the pro cedures 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 smal ler hills before attempting larger hills. Avoid climbing hills steeper than 25 ° . Always follow the pro cedures outlined in this manual for dri[...]

16 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. U se extra cautio n. Always follow the procedures outlined in this manual for driving in reverse. See page 43. Use caution when operating on rough, slippery or loos[...]

17 SAFETY Operator Safety Never operate this vehicle on a frozen body of water . Never modify a Quadricycle through imprope r installation or use of accessories. Never exceed the stated load capacity fo r your vehicle. Cargo must be properl y distributed and securely attached. Reduce speed and foll ow the instructions in this manual for carrying ca[...]

18 SAFETY Safety Labels and Locations W arning labels hav e 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 ma nual differ from the labels on your vehicle, always read and follow the instructio ns of the labels on the vehicle. If an informational or graph[...]

19 SAFETY Safety Labels and Locations < 16 < < < < < < < < 1 1 6 6 6 6 6 6 6 6 < < < < < < < < 1 1 1 1 1 1 1 1 6 6 6 6 6 6 6 6 7173027 General W arning Clutch Cover Warning Age Warning[...]

20 SAFETY Safety Labels and Locations Discretionary W arning W ARNING Never operate this A TV on HILLS steeper than 25 d egrees 25 ° . T o prevent overturn on hilly terrain, use throttle and brakes gradually , and shift weight up hill. Rack W a rning DO NOT TOW FROM RACK OR BUMPER. V ehicle damage or tipover may result causing severe injury or dea[...]

21 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJUR Y or DEA TH. Tire Pressure/Load W arning Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressur[...]

22 FEA TURES AND CONTROLS Switches and Levers Main Key Switch T urn the main switch to the OF F 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 ar e not on in this position. Move the key switch to the LI GHTS ON position to turn the he[...]

23 FEA TURES 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. Ha[...]

24 FEA TURES 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. W ARNING! Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sti cks during operation. C[...]

25 FEA TURES 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, prov iding maximum st op- ping power . Inspect and maintain the brake fluid level as outlined in this manual. See page 58. Parking Brake 1. Squeeze the brake lever . 2. Push the park[...]

26 FEA TURES AND CONTROLS Indicator Light s V iew vehicle functions on the instrument panel. Each light illuminates when the feature is activated. Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before dr iving the Quadricycle. Reverse Gear Indicator T urn Signal Indicator Hazard W arning Indicator High B[...]

27 FEA TURES AND CONTROLS Fuel T a nk Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel to the fuel tank. The gauge in the cap shows the approxi- mate amount of fuel remai ning. Use eithe r leaded or un leaded gasoline with a minimu m pump octane num[...]

28 FEA TURES AND CONTROLS T ransmission Gear Selector The transmission gear selector is located on the right side of the vehicle. R: Reverse N: Neutral F: Forward Gear T o shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear . NOTICE: Shifting gears with the engin e speed above idle or w hile the vehi[...]

29 OPERA TION 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. Rea d and understand all safety warnings outlined in the safety section of this owner ’s manual. Break-In Period The break-in period for yo ur new Po laris Quadricycle is the first te[...]

30 OPERA TION Safe Operation Practices 1. Complete the recommen ded safety training be fore operating this vehicle. See page 7. 2. Do not allow anyone un der 16 year s of age to operate this vehicle. Do not allow anyone w ith cognitive or physical disabi lities to oper- ate this ve hicle. 3. Never carry a passen ger on this vehic le. 4. Engine exha[...]

31 OPERA TION Pre-Ride Checklist Failure to inspect and verify that th e A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 58 59 Brake fluid Ensure pro[...]

32 OPERA TION S t arting the Engine 1. Position the vehicle on a level su rface outdoors or in a well-venti- lated area. 2. Sit on the vehicle. 3. T urn the fuel valve on. 4. T urn 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 un[...]

33 OPERA TION S t arting the Engine 9. Activate the starter for a maximum of five s econds. 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 vehicl e. 10. If the engine does not start, release the [...]

34 OPERA TION Driving Procedures 1. W ear a helmet and eye protection. See page 8. 2. Sit upright. Kee p your feet on th e footrests. Keep both hands on the handlebars. 3. Squeeze the brake lever . 4. Star t the engine and allow it to warm up. 5. Shift the transmission into gear . 6. Check your surroun dings and determine your path of travel. 7. Re[...]

35 OPERA TION T urning the V ehicle T o 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 turn ing in reverse. Practice making turns at slow speeds before attempting to turn at faster speeds. W ARNING! Turning [...]

36 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precaution s: 1. Do not operate on excessively ro ugh, slippery or loose terrain. 2. Slow down before drivin g onto slippery surfaces. 3. Be alert. W atch the trail. A void quick, sharp turns.[...]

37 OPERA TION Driving Uphill Braking and handling are greatly affe cted when operating in hilly ter- rain. Improper pro cedure could cau se loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terrain carefully before ascend- ing any[...]

38 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void hills with excessively slippery or loo[...]

39 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. A void 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. A void going down a hill at an angle, which can cause the ve[...]

40 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Apply the all-wheel foot brake to stop the vehicle. 2. Keep your weight uphill. 3. Squeeze and hold the brake le ver while completing steps 4-6. 4. Leave the transmission in forward and shut o[...]

41 OPERA TION Driving Through W ater Y our A TV 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. 3. A vo id operating thr[...]

42 OPERA TION Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Be alert. W atch the terrain. Use extra caution 3. Never operate over large obstacles. 4. A void hazards such as logs, rocks and low branches.[...]

43 OPERA TION Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the brake s lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly .[...]

44 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing cargo i mproperly can al ter vehicle handling and may cause loss of control or brake instability , which can re sult in serious injury or death. Always follo w these precaution s when hauling cargo: REDUCE SPEED AND ALLOW GREA TER DIST ANCES FOR BRAKING WHEN HAULING CARGO. [...]

45 OPERA TION Hauling Cargo Load Distribution Read and understand the load distribut ion warnings listed on the vehicle warning labels. Never exceed the sp ecified weights. Y our Quadricycle may carry a maxim um of 31.7 kg of c argo 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 possi[...]

46 OPERA TION Parking on an Incline A void parking on an incline. If it' s unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on th e downhill side. 5. T urn the fuel valve off.[...]

47 EMISSION CONTROL SYSTEMS This vehicle complies with the requ irements 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 gover nmental noise level requi rements. Exhaust Emission Control System The emissions from the exhaust of this vehicle[...]

48 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in the fo llowing chart are based up on averag e riding conditions. V ehicles subjected to severe use mu st 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 proce[...]

49 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main te nance interval is re ached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Cale[...]

50 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q E Choke cable 50 6 M 500 Inspect; adjust; lubricate; replace if necessary E Carburetor air intake ducts/flange 50 6 M 500 Inspect duct for proper seal- ing/air leaks Drive belt 50 6 M 500 Inspec t; adjust; replace as neede[...]

51 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Ch art 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 P erformance Synthetic 2W-50 See page 52. Brake Fluid DOT 4 Only See pa[...]

52 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 Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's re commendations fo r ambient tempera- ture operation[...]

53 MAINTENANCE Oil and Filter Change Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 48. Always change the oil filter whenever changi ng oil. Change the oil mo re often if the vehicle is rou- tinely subjected to: • operation in dusty or wet conditions. • operation when air temperat[...]

54 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 tu rn by hand. 1 1. Re[...]

55 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 48. T ransmission Oil Recommendations Oil Check 1. Position the vehicle on a level surface. Place the transmission in gear . Lock the parking brake. 2. V iew the oil level through the sight glas[...]

56 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 Oil Check 1. Position the vehicle on a level surface. Place the transmission in gear . Lock the parking brake. 2. Remove the check plug . V iew the oil lev[...]

57 MAINTENANCE Brakes An over-full master cyl inder may cause brake drag or brake l ock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Once open, a bottle of brake fluid absorb s moisture from the air, which causes the boiling temperature of the brake fluid to drop. This can lead to ea rly bra[...]

58 MAINTENANCE Brakes Brake Check Perform the followin g 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 [...]

59 MAINTENANCE Brakes Brake Lever T ravel Service the brakes when brake lever travel reaches 65 mm. Always service the brakes when there is no longer suff icient stopping ability at the specified lever travel setting. Brake Freeplay Periodically measure the freeplay of the rear brakes. Acceptable free- play range is 10-20 mm. T o adjust rear brake [...]

60 MAINTENANCE T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent 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 approximat[...]

61 MAINTENANCE S teering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, se e 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 [...]

62 MAINTENANCE Handlebars W ARNING! Improper adj ustment of the handleba rs or inco rrect torquing of the adjuster block tightening bolts can caus e limi ted steering or loosenin g of the handlebars, resulting in loss of co ntrol and serious injury or death. Follow the adjustment procedures exactly , or see your Polaris dealer for service. The hand[...]

63 MAINTENANCE Carburetor Y our 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 me ters the engine air/fuel mixture becomes too rich and the engine lo ses approximately 3% of its power for each 300 meter increase in elevatio[...]

64 MAINTENANCE Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar . 1. Slide the boots of f the inline cable adjuster sleeve. Loosen the adjuster locknut. 2. T urn 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. T ighten the lock nut and slid[...]

65 MAINTENANCE Ti r e s Operating your A T V with worn tires, impr operly i nflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Alwa ys follow all tire maintenance procedures as outlined in this manual a nd on the labels on the vehicle. Al way[...]

66 MAINTENANCE Ti r e s Wheel Removal 1. Position the vehicle on a level su rface. Place the tr ansmission in gear . Lock the parking brake. 2. Loosen the wheel nuts slightly . 3. Safely place jackstands under the vehicle. 4. Remove the wheel nut s. Remove the wheel. Wheel Inst allation 1. Place the wheel on the wheel hub. 2. Install the wheel nuts[...]

67 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 th e air box cover . 4. Loosen the hose clamp and remove the filter . 5. Remove the pre-filter from the main filter . 6. W ash the pre-filter in soapy water .[...]

68 MAINTENANCE Spar k P l ug s Sp ark Plug Recommendations Refer to the specifications section be ginning on page 86 for the recom- mended spark plug ty pe and gap for your vehicle. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Sp ark Plug Inspection Check the spark plug f[...]

69 MAINTENANCE Spar k P l ug s Sp ark Plug Condition Normal Spark Pl ug The normal insulator tip is gray , ta n 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 wh ite. A white insulator tip [...]

70 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty duri ng normal operation. Cl ean lights frequently and replace burn ed out lamps promptly . Always make sure lights are adjusted properly for best visibility . Headlamp Replacement T o acces s the assembly from the fro nt,[...]

71 MAINTENANCE V ehicle Immersion If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. T ake the vehicle to your dealer before starting the eng ine. If it's impossible to take your vehicl e to a dealer before starting it, fol- low the steps outlined below . 1. Move the vehicle o[...]

72 MAINTENANCE Const ant V ariable T ransmission (CVT) System Do not modify any component of the CVT system. Doing so may reduce its strength so that a failu re may occur at a high sp eed. The CVT syst em has been precision balanced. Any modi fication will cause the system to be out of balance, creating vibration and additional loads on compo nents[...]

73 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles can result in an explosio n and cause serious injury or death. When removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect the negative (black) cable last. Battery electrolyte is poisonous. It contains sul[...]

74 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 ba ttery compartment. Battery Inst allation 1. Ensure that the battery is fully charged. 2. Place the batter[...]

75 MAINTENANCE Battery Battery Charging The following battery char ging instructions apply only to the installa- tion of an activated, sealed battery . Read all ins tructions before proceed- ing with the installation of this battery . A sealed battery is already filled with electrolyte. It has been sealed and is fully char ged at the factory . Alwa[...]

76 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three mo nths or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e and recharge as needed to mainta in a full charge. Polaris recom[...]

77 MAINTENANCE Cleaning and St orage W ash ing the V ehicle Keeping the vehicle clean will ex tend the life of components. NOTICE: High water pressure may damage comp onents. 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 surface[...]

78 MAINTENANCE Cleaning and St orage W ashing th e V ehicle If a high pressure water system is u sed for cleaning (not recommended), exercise extreme caution. The wa ter may damage components. A void directing the water stream at the following items: • Wheel bearings • T ransmission seals •B r a k e s • Cab and body pa nels • Labels and d[...]

79 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps NOTICE: S t arting the engine during the storage perio d will disturb the protective film created by fogging and damage could occur . Never start the engine during the storage peri od. Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. Se e page 77. Stabilize the[...]

80 MAINTENANCE Cleaning and St orage Sto r ag e Ti ps Fluid Levels Inspect the fluid levels. Change fluids as recommende d in the Periodic Maintenance Chart beginn ing on page 48. • Rear gearcase • T ransmission • Brake fluid Fog the Engine Use Polaris Engine Fogging Oil. Fo l low label directions carefully . Inspect and Lubricate Inspect all[...]

81 MAINTENANCE T ransporting the V ehicle Follow these procedures when trans- porting the vehicle. 1. Stop the engine. 2. Place the transmission in ge ar . 3. Lock the parking brake. 4. T urn the fuel valve of f. 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 t[...]

82 POLARIS PRODUCTS Pa rt Number Description Engine Lubr icant 2870791 Fogging Oil (355 ml Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (.95 l) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (3.8 l) Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (.95 l) 2873603 Premium AGL Synth[...]

83 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution T ripped circuit breake r R eset the brea ker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten [...]

84 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Possible Cause Solution [...]

85 TROUBLESHOOTING Engine Stop s or Loses Power Possible Cause Solution Out of fuel T urn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater is present in fuel Replace with new fuel Overuse of choke Ins pect, clea n a nd/or replace spark plugs Fouled or defective spark plug(s) Insp ect, clean and/or replace sp[...]

86 SPECIFICA TIONS Phoenix 200 Quadricycle Maximum W eight Capacity 129 kg Dry W eight 179 kg Fuel Capacity 9 .5 liters Engine Oil Capacity 1200 ml T ransmission Oil 550 ml Rear Gearcase Oil 120 m Rear Rack Capacity 31.7 kg Hitch T ongue W eight Capacity 13.6 kg (re ar rack weight a nd tongue weight not to exceed 13.6 kg) Hitch T owing W eight Capa[...]

87 SPECIFICA TIONS Jetting Chart Clutching Chart Phoenix 200 Quadricycle Drive Ratio, Front N/A T ires, Front 21x7-10 / 27.6 kPa T ires, Rear 20x10-9 / 27.6 kPa Front Suspension Dual A-Arm w/17.8 cm travel Rear Suspension Mono-Shock Swing Arm w/16.5 cm travel Shock Adjustment CAM Brakes, Rear (Handlebar) Mechanical Drum Brake, Foot Hydraul ic, All [...]

88 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of the Polaris Quadricycle against defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty . Th[...]

89 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND RE MEDIES ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE TWO YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A T ED IN THIS W A RRANTY . Some[...]

90 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

91 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

92 INDEX A Air Filte r . . . . . . . . . . . . . . . . . . . . . 67 B Battery . . . . . . . . . . . . . . . . . . . . 73-76 Charging . . . . . . . . . . . . . . . . . 75 Installation . . . . . . . . . . . . . . . . 74 Removal . . . . . . . . . . . . . . . . . . 74 Storage . . . . . . . . . . . . . . . . . . . 76 Boots . . . . . . . . . . . . . . . [...]

93 INDEX L Levers . . . . . . . . . . . . . . . . . . . . . 22-24 Light Switch . . . . . . . . . . . . . . . . . . . 23 Lights Headlamp Repla cement . . . . . . 70 Indicator Lights . . . . . . . . . . . . . 26 Taillight/Brake Light . . . . . . . . 70 Load Distributi on . . . . . . . . . . . . . . . 45 Lubrication Guide . . . . . . . . . . . . . . .[...]

94 INDEX T Transporting the Vehicle . . . . . . . . . 81 Turn Signal Swit ch . . . . . . . . . . . . . 23 Turning Around on a Hill . . . . . . . . 40 Turning the Vehic le . . . . . . . . . . . . . 35 V Vehicle Identif ication Numbers. . . . . 6 Vehicle Immer sion. . . . . . . . . . . . . . 71 W Warning Symbols . . . . . . . . . . . . . . . . 4 Wash[...]