2005 Polaris Phoenix 200 Parts Manual
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PARTS MANUAL PN 9919965 and MICROFICHE PN 9919966 11/04
E 2004 Polaris Sales Inc.
PHOENIX 200
Model #A05PB20AA
Model #A05PB20AB
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TABLE OF CONTENTS
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
Parts Manual
A
ACCESSORY PARTS C6 ..................
AIR CLEANER B1 .......................
AXLE, REAR WHEEL C1 ..................
B
BRAKE, FRONT B12 .....................
BRAKE, REAR B13 .......................
BUMPER B6 ...........................
C
CAB B7 ...............................
CARBURETOR A14 .......................
CRANKCASE A5 ........................
CRANKCASE COVER, LH A7 ..............
CRANKCASE COVER, RH A8 ..............
CRANKSHAFT A4 .......................
CYLINDER HEAD A3 .....................
D
DECALS C5 ...........................
DRIVE ASSEMBLY, REAR A6 ..............
DRIVE CLUTCH A10 ......................
DRIVEN CLUTCH A11 .....................
E
ELECTRICAL PARTS C4 ..................
EXHAUST B2 ..........................
F
FOOTREST B5 .........................
FRAME BODY B3 .......................
F
FUEL TANK B8 .........................
G
GENERATOR A12 ........................
H
HANDLEBAR B14 ........................
HEADLIGHT C3 .........................
P
PISTON A4 ............................
S
SEAT B7 ..............................
STARTING MOTOR A12 ...................
STEERING C2 ..........................
SUSPENSION B9 .......................
SWING ARM B5 ........................
SWING ARM, REAR B4 ...................
T
TAILLIGHT C3 ..........................
TRANSMISSION A13 .....................
V
VALVE CAM A9 .........................
W
WHEEL, FRONT B10 ......................
WHEEL, REAR B11 .......................
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
A3
CYLINDER HEAD
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
24
7
22
11
6
10
21
E 2004 Polaris Sales Inc.
9
13
20
15
16
18
14
17
19
23
3
4
33
35
34
2
29
30
12
32
5
1
25
9
15
16
18
14
17
5
5
8
31
26
28
27
27
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452400 4 Bolt
2 0452395 1 Cover, Cylinder Head
3 0452125 1 Breather, Crankcase, Lower
4 0451766 4 Screw
5 0450142 6 Pin, Dowel
6 0452380 1 Guide, Valve Intake
7 0452378 1 Seat, Intake
8 0452402 1 Plug, Spark
9 0452382 2 O-Ring
10 0452381 1 Guide, Valve Exhaust
11 0452379 1 Seat, Exhaust
12 0452398 2 Bolt, Stud
13 0452383 1 Valve, Intake
14 0452388 2 Seat, Valve, Spring, Outer
15 0452385 2 Spring, Valve, Outer
16 0452386 2 Spring, Valve, Inner
17 0452389 4 Clip, Retainer
18 0452387 2 Retainer, Valve, Spring
19 0452390 2 Seal, Valve
20 0452384 1 Valve, Exhaust
21 0452376 1 Gasket, Cylinder
22 0452375 1 Cylinder
23 0452391 1 Gasket
24 0452377 1 Head, Cylinder
25 0452401 2 Bolt
26 0452404 1 Insulator, Manifold
27 0450880 4 Nut
28 0452405 2 Bolt, Stud
29 0452396 1 Manifold
30 0452397 1 O-Ring
31 0452403 1 Gasket, Manifold
32 0452399 2 Bolt, Stud
33 0452392 1 O-Ring, Head Cover
34 0452394 1 O-Ring, Head Cover Cap
35 0452393 1 Cap, Head Cover
11/04
A4
CRANKSHAFT and PISTON
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
14
12
8
20
15
21
9
17
11
19
7
18
E 2004 Polaris Sales Inc.
4
4
13
10
6
5
3
8 16
2
1
16
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452445 1 Tube, Oil, Crankshaft
2 0452444 1 Spring, Oil
3 0452442 1 Nut, Flange
4 0450264 2 Washer
5 0452441 1 Nut, Lock
6 0452440 1 Washer, Gear
7 0452434 1 Gear, Balance
8 0452427 2 Bearing, Ball
9 0452435 1 Shaft, Balance
10 0452439 1 Key, Woodruff
11 0452436 1 Sprocket, Oil Pump
12 0452437 1 Gear, Balance, Driven
13 0452438 1 Nut, Lock
14 0452428 1 Sprocket, Timing
15 0452426 1 Kit, Crankshaft
16 0452443 2 Clip, Piston Pin
17 0452433 1 Pin, Piston
18 0452431 1 Ring (Set)
19 0452432 1 Piston
20 0452429 1 Key, Woodruff
21 0452430 1 Key, Woodruff
11/04
A5
CRANKCASE
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
6
23
17
36
18
13
33
3
1
5
15
14
30
10
22
28
20
16
9
2
34
4
41
8
19
12
27
31
35
21
26
32
29
24
37
E 2004 Polaris Sales Inc.
40
39
38
33
3
5
25
11
7
22
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452344 2 Bolt
2 0452335 2 Bolt, Stud
3 0452342 2 Pin, Dowel
4 0452345 1 Bearing, Ball
5 0452348 2 Bearing, Ball
6 0452330 1 Bolt
7 0452374 1 Washer, Flat
8 0452156 1 Bearing, Main Transmission Shaft
9 0452336 2 Bolt, Stud
10 0452349 1 Bearing, Ball
11 0452373 1 Bearing, Needle
12 0452337 1 Washer, Flat
13 0452125 1 Breather, Crankcase, Lower
14 0452347 1 Bearing, Ball
15 0452346 1 Bearing, Ball
16 0452326 1 Hose, Vent
17 0452324 2 Bolt
18 0452323 1 Bracket, Motor Mount
19 0452325 2 Washer, Flat
20 0450268 2 Nut
21 0452340 1 Seal, Oil
22 0450142 2 Pin, Dowel
23 0452329 1 Switch
24 0452138 2 Bolt
25 0452129 1 O-Ring
26 0452341 1 Seal, Oil
27 0452133 1 Washer, Flat
28 0452132 1 Bolt, Drain Plug
29 0452135 1 Spring, Detent
30 0452137 1 Bolt
31 0452136 1 Washer, Flat
32 0452134 1 Ball, Steel
33 0452319 2 Bushing, Rubber
34 0452322 1 Crankcase, LH
35 0452320 1 Spacer, Collar
36 0452321 1 Gasket
37 0452368 1 Plug, Drain, Oil
38 0452371 1 O-Ring, Drain Plug
39 0452370 1 Spring, Screen
40 0452369 1 Screen
41 0452318 1 Crankcase, RH
11/04
A6
DRIVE ASSEMBLY, REAR
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
E 2004 Polaris Sales Inc.
16
2
14
15
17
1
10
9
8
7
12
11
5
13
6
4
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452343 9 Bolt
2 0452333 1 Seal, Sight Glass
3 0451813 1 Plug, Oil
4 0450154 1 O-Ring
5 0452356 1 Gear, Shaft, Output
6 0452358 1 Bearing, Needle
7 0452353 1 O-Ring
8 0452352 1 Shim, Set
9 0452351 1 Collar, Gear Shaft
10 0452350 3 Bolt
11 0452355 1 Nut, Lock
12 0452354 1 Bearing, Ball
13 0452357 1 Seal, Oil
14 0452334 1 Gasket, Transmission Cover
15 0450142 2 Pin, Dowel
16 0452332 1 Cover, Transmission
17 0452175 1 Seal, Oil
11/04
A7
CRANKCASE COVER, LH
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
E 2004 Polaris Sales Inc.
10
9
11
14
8
7
1
2
3
4
5
6
18
17
16
15
12
13
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452359 1 Spindle, Kick Start
2 0452360 1 Spring, Kick Start
3 0452361 1 Spacer, Kick Start
4 0452394 1 O-Ring
5 0452363 1 Washer, Flat
6 0452364 1 Clip, Retainer
7 0452339 1 Clip, Retainer
8 0450261 1 Bearing, Ball
9 0452328 1 Gasket
10 0452327 1 Cover, Clutch
11 0452331 8 Bolt
12 0452372 1 Asm., Kick Start
13 0451704 1 Bolt
14 0451746 1 Cap, Shaft, Kick Starter
15 0452126 1 Bolt
16 0452367 1 Washer, Flat
17 0452366 1 Spring, Kick Start Gear
18 0452365 1 Gear, Kick Start, Driven
11/04
A8
CRANKCASE COVER, RH
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
4
10
16
21
12
20
7
13
15
18
11
17
14
E 2004 Polaris Sales Inc.
3
8
9
19
5
22
1
2
6
10
20
21
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452463 1 Bolt
2 0452464 1 Washer, Flat, Copper
3 0452413 3 Bolt
4 0452458 1 Cap, Cover, RH
5 0452330 2 Bolt
6 0452637 1 Retainer, Sight Glass
7 0452343 1 Bolt
8 0452460 1 Cap
9 0452461 1 O-Ring
10 0452342 2 Pin, Dowel
11 0452447 1 Gasket, Cover
12 0452450 1 Asm., One Way Clutch
13 0452448 1 Flywheel
14 0452457 3 Bolt
15 0452449 1 Stator
16 0452456 2 Screw
17 0452455 3 Screw
18 0452446 1 Cover, Crankcase, RH
19 0452636 1 Shield
20 0452401 8 Bolt
21 0452459 2 O-Ring
22 0452462 1 Filter, Oil
11/04
A9
VALVE CAM
PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
17
16
14
19
4
18
15
21
20
10
11
12
1
E 2004 Polaris Sales Inc.
13
8
9
5
2
3
7
6
2
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452406 1 Asm., Cam Shaft
2 0452423 2 Screw, Tappet Adj.
3 0452424 2 Nut, Tappet Adj.
4 0452414 1 Asm., Decomp. Release
5 0452409 2 Arm, Valve, Rocker
6 0450268 4 Nut
7 0452425 4 Washer
8 0452408 1 Bracket, Cam Shaft
9 0452410 1 Shaft, Intake, Rocker Arm
10 0452413 1 Bolt
11 0452412 1 Plate, Rocker arm Shaft
12 0452411 1 Shaft, Exhaust, Rocker Arm
13 0452407 1 Chain, Cam
14 0452415 1 Guide, Cam Chain, RH
15 0452416 1 Tensioner
16 0452420 2 Bolt
17 0452421 1 Screw
18 0452382 1 O-Ring
19 0452417 1 Gasket, Tensioner
20 0452418 1 Pivot, Guide
21 0452419 1 Guide, Cam Chain, LH
11/04
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2005 Polaris Phoenix 200 Parts Manual for Models PHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB.
ATVs are the ideal machine for maintenance and repair at home due to their reliable design, relatively simple construction, and ease of repair. With proper care and routine maintenance, your ATV will provide many years of reliable use. Most home mechanics will find ATVs easy to work with and repairs quick and trouble-free.
Scheduled ATV maintenance should occur frequently at regular intervals. This routine maintenance should include changing the oil, inspecting various components, changing the spark plugs, and replacing the fuel and air filters. Having a quality parts manual specific to your ATV will help you identify the parts and assist you during routine maintenance and repair.
Performing routine maintenance on your ATV at home provides many benefits. It is less expensive than having an ATV shop do the maintenance, prolongs the life of your ATV, and provides you with a better understanding of its working components.
Even with diligent routine maintenance, ATVs may require periodic repairs. In the event that you need to repair your ATV, it will likely be easier if you have been doing your own routine maintenance as you will be more familiar with the mechanics of your engine. Access to service manuals and parts catalogues also makes ATV engine repair easier.
Your ATV will provide you with many years of service. Routine maintenance and periodic repairs at home will save you money and prolong the life of your ATV engine.
This manual is 36 pages in English format that enables you to print only what you need. Contents include the following topics with exploded diagrams and part number lists:
- SPECIFICATIONS
- FRONT CAB
- REAR CAB and SEAT
- REAR RACK MOUNTING
- DECALS
- FRONT RACK and BUMPER MOUNTING
- ENGINE MOUNTING
- COOLING SYSTEM
- EXHAUST SYSTEM
- FUEL TANK
- OIL TANK
- AIR BOX
- FRONT DRIVE
- FRONT TIGHTENER
- FRONT STRUT
- CV JOINT BTB
- FRONT WHEEL
- FRONT BRAKE
- CONTROLS -- THROTTLE ASM./CABLE
- CONTROLS MASTER CYLINDER/BRAKE LINE
- STEERING POST
- HANDLEBAR and HEADLIGHT POD
- A--ARM/STRUT MOUNTING
- CENTER TIGHTENER
- SWING ARM/SHOCK MOUNTING
- DRIVE CLUTCH
- DRIVEN CLUTCH
- CLUTCH COVER
- GEARCASE/BRAKE and CHAIN COVER MOUNTING
- REAR BRAKE
- REAR WHEEL DRIVE
- ELECTRICAL/TAILLIGHT
- GEARCASE
- GEAR SELECTOR
- PISTON and CRANKSHAFT
- CRANKCASE and CYLINDER
- RECOIL STARTER
- CARBURETOR
- OIL PUMP
- MAGNETO
- STARTING MOTOR
- TOOL KIT
- PART NUMBER INDEX
