Polaris 200 Quadricycle - Manual

6 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. Vehicle Model Number: ______________________________________...

7 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 ...

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 Canada bear a U.S. Department of Transportation (DOT) label.Approved helmets in Europe, Asia and ...

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 or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing marki...

10 SAFETY Operator Safety 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 pr...

17 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 th...

18 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 ...

20 SAFETY Safety Labels and Locations Discretionary Warning WARNINGNever operate this ATV on HILLS steeper than 25 degrees 25 ° . To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. Rack Warning DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover m...

21 SAFETY Safety Labels and Locations “No Passenger” Warning WARNINGNEVER 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 ...

22 FEATURES AND CONTROLS Switches and Levers 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 swit...

23 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...

24 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. WARNING! Failure to check or maintain proper operation of the throttle system can result in an accident i...

26 FEATURES AND CONTROLS Indicator Lights View 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 driving the Quadricycle. Reverse Gear Indicator Turn Sign...

28 FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. R: ReverseN: NeutralF: Forward GearTo shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears with the ...

29 OPERATION 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 y...

30 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 p...

31 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 prope...

32 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 col...

33 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. 1...

34 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 an...

35 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 ...

36 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Do not operate on excessively rough, slippery or loose terrain.2. Slow down before driving onto slippery surfaces.3. Be alert. Wa...

37 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...

38 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. Avo...

39 OPERATION Driving Downhill 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 ...

40 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. 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. L...

41 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 hav...

42 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 caution3. Never operate over large obstacles.4. Avoid hazards such as logs, rocks and low branches.

43 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...

44 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:REDUCE SPEED AND ALLOW GREATER DIST...

45 OPERATION Hauling Cargo 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 we...

46 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.

47 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...

48 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 ...

51 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 Synthetic ...

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 Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendat...

53 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...

55 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 Oil Check 1. Position the vehicle on a level surface. Place the transmission in gear. Lock the parking brake...

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 br...

57 MAINTENANCE Brakes 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 br...

58 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. ...

59 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. Brake Freeplay Periodically measure the freeplay of the rear brakes. Acceptable free...

60 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 o...

61 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 eith...

62 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 ...

63 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...

64 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...

65 MAINTENANCE Tires Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual...

66 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 ...

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 the air box cover. 4. Loosen the hose clamp and remove the filter. 5. Remove the pre-filter from the main filt...

68 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. Sp...

69 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...

70 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 Replaceme...

71 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 step...

72 MAINTENANCE Constant Variable Transmission (CVT) System 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 vi...

73 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Bat...

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 battery compartment. Battery Installation 1. Ensure that th...

75 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 seale...

76 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 ...

77 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 repellent...

78 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 bo...

79 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 ...

80 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. Ins...

81 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...

82 POLARIS PRODUCTS Part Number Description Engine Lubricant 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 / Transmission Lubricants 2873602 Premium AGL Synthetic Gearc...

83 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections...

84 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too ...

85 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spa...

86 SPECIFICATIONS Phoenix 200 Quadricycle Maximum Weight Capacity 129 kg Dry Weight 179 kg Fuel Capacity 9.5 liters Engine Oil Capacity 1200 ml Transmission Oil 550 ml Rear Gearcase Oil 120 m Rear Rack Capacity 31.7 kg Hitch Tongue Weight Capacity 13.6 kg (rear rack weight and tongue weight not to e...

87 SPECIFICATIONS Jetting Chart Clutching Chart Phoenix 200 Quadricycle Drive Ratio, Front N/A Tires, Front 21x7-10 / 27.6 kPa Tires, 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 (Handleba...

88 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 ...

89 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 NO...

90 MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS

92 INDEX A Air Filter . . . . . . . . . . . . . . . . . . . . . 67 B Battery . . . . . . . . . . . . . . . . . . . . 73-76 Charging . . . . . . . . . . . . . . . . . 75 Installation . . . . . . . . . . . . . . . . 74 Removal . . . . . . . . . . . . . . . . . . 74 Storage . . . . . . . . . . . . . . ...