2009-2010 Polaris Phoenix 200 ATV Repair Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN AND ENGINE SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2009 PHOENIX 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 PAINT CODES:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 MISCELLANEOUS SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number ES20PFE - Single, Air Cooled, SOHC 4 Stroke, Electric Start VIN Identification VIN and Engine Serial Number Location The vehicle identification number (1) and engine serial number (2) are important for vehicle identification. The vehicle identification number (VIN) is stamped on the LH lower front of the frame. } Machine Model Number Identification } } Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option A 0 9 P B 2 0 A B } 4 X A P B 2 0 A * 9 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier  Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 1 2

1.3 GENERAL INFORMATION 1 GENERAL SPECIFICATIONS MODEL.................2009 PHOENIX 200 MODEL NUMBER.......A09PB20AB,AD,EB ENGINE MODEL............................ES20PFE Category Dimension Length 65 in. / 165.1 cm Width 42 in. / 106.7 cm Height 42 in. / 106.7 cm Wheel Base 45 in. / 114.3 cm Ground Clearance 5.7 in. / 14.5 cm Dry Weight 395 lbs. / 179.2 kg Gross Vehicle Weight 720 lbs. / 326 kg Front Rack Capacity n/a Rear Rack Capacity 70 lbs. / 31.7 kg Towing Capacity 300 lbs. / 136 kg Hitch Tongue Weight 30 lbs. / 13.6 kg

1.4 GENERAL INFORMATION MODEL: 2009 PHOENIX 200 MODEL NUMBER: A09PB20AB,AD,EB ENGINE MODEL: ES20PFE JETTING CHART CLUTCH CHART Engine Platform Aeon 4 stroke, Single Cylinder Engine Model Number ES20PFE Engine Displacement 196cc Number of Cylinders 1 Bore & Stroke (mm) 65 x 59 mm Compression Ratio 9.2:1 Compression Pressure 160-190 psi Engine Idle Speed 1500 ± 100 Rpm Cooling System/Capacity Oil/ Air Overheat Warning n/a Lubrication Wet Sump Oil Requirements Polaris 2W-50 / 1.26qt (1.2L) Exhaust System USFS Approved Carburetor Carburetor model Keihin VM 22mm Main Jet 98 Pilot Jet 40 Jet Needle 2MKNN - 4 clip Needle Jet n/a Pilot/Air Screw 2.25 Turns Out (Initial setting, varies by ATV) Float Height Parallel To Float Bowl Fuel Delivery Gravity Feed System Fuel Capacity / Requirement 2.5 gal. (9.5 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 210 w @ 5000 RPM Voltage Regulator 3-Phase Lights: High Beam 35 watts Low Beam 35 watts Brake 21 watts Tail 5 watts Ignition System CDI Ignition Ignition Timing 32 ± 2 BTDC @ 3000 RPM Spark plug / Gap NGK CR6HSA .024 - .028 in./ .6-.7 mm Battery / Model / Amp Hr Maintenance-Free - 12 Amp Hr Circuit Breakers Harness 15 amp Starting Electric / Kick Start Backup Indicator Panel Neutral / Reverse Drivetrain Transmission Type Inline F/N/R Transmission Capacity 18.6 oz. (550 ml) Rear Gearcase Capacity 4 oz. (120 ml) Drive Type Shaft Clutch Type CVT Non EBS Belt 0452496 Steering / Suspension Front Suspension / Shock Dual A-arm / Coil over Shocks Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Mono Shock Swingarm / Coil over shock Rear Travel 6.5 in. / 16.5 cm Ground Clearance 5.7 in. / 14.5 cm Shock Preload Adjustment Front / Rear Front - Cam Rear - Cam Turning Radius 64 in. / 106.7 cm unloaded Toe Out 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Tire/Rim Size - Front 21 x 7 - 10 / 4-156 Tire/Rim Size - Rear 20 x 10 - 9 / 4-110 Air Press. F/R Tires Front - 4 psi (28 kPa) Rear - 4 psi (28 kPa) Brake - Front RH Control Dual Hydraulic Disc Brake - Rear LH Control / Foot Brake Single Drum Mechanical Brake Fluid Polaris DOT 3 Brake Fluid Altitude Ambient Temperature Below 40 F Below 5 C Above +40 F Above +5 C Meters (Feet) 0-1800 (0-6000) 102 98 above 1800 (above 6000) 96 92 Altitude Shift Weight Meters (Feet) 0-1800 (0-6000) 6 @ 14.7 grams 1800-3700 (6000 - 12000) 6 @ 11 grams (PN 0453091)

1.5 GENERAL INFORMATION 1 VEHICLE INFORMATION Publication Numbers NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from www.purepolaris.com. Paint Codes: Replacement Keys Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the original. Should both keys become lost, ignition switch replacement is required. Year Model Model No. Owner’s Manual PN Parts Manual PN 2009 Phoenix 200 A09PB20AB,AD 9921841 9921842 2009 Phoenix 200 Quadricycle A09PB20EB 9922082 9922083 PAINTED PART COLOR DESCRIPTION POLARIS NUMBER Frame Vapor Silver P-385 Frame Matte Black P-458 Key Blank 0453013

1.6 GENERAL INFORMATION SPECIAL TOOLS Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . MISCELLANEOUS SPECIFICATIONS AND CHARTS Standard Torque Specifications The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

1.7 GENERAL INFORMATION 1 Conversion Table °C to °F: 9/5 (°C + 32) = °F °F to °C: 5/9 (°F - 32) = °C Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 = mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = km km x .6214 = mile (mi.) Ounces (oz.) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz.) lb. x .454 = kg kg x 2.2046 = lb. Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in) Imperial pints (Imp pt.) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt.) Imperial quarts (Imp qt.) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt.) Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.) US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.) US quarts (US qt.) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt.) US gallons (US gal) x 3.785 = Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa) p(3.14)xR2x H (height) = Cylinder Volume

1.8 GENERAL INFORMATION SAE Tap Drill Sizes Metric Tap Drill Sizes Decimal Equivalents Thread Size / Drill Size Thread Size / Drill Size #0-80 3/64 1/2-13 27/64 #1-64 53 1/2-20 29/64 #1-72 53 9/16-12 31/64 #2-56 51 9/16-18 33/64 #2-64 50 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 45 3/4-10 21/32 #4-40 43 3/4-16 11/16 #4-48 42 7/8-9 49/64 #5-40 38 7/8-14 13/16 #5-44 37 1-8 7/8 #6-32 36 1-12 59/64 #6-40 33 1 1/8-7 63/64 #8-32 29 1 1/8-12 1 3/64 #8-36 29 1 1/4-7 1 7/64 #10-24 24 1 1/4-12 1 11/64 #10-32 21 1 1/2-6 1 11/32 #12-24 17 1 1/2-12 1 27/64 #12-28 4.6mm 1 3/4-5 1 9/16 1/4-20 7 1 3/4-12 1 43/64 1/4-28 3 2-4 1/2 1 25/32 5/16-18 F 2-12 1 59/64 5/16-24 I 2 1/4-4 1/2 2 1/32 3/8-16 O 2 1/2-4 2 1/4 3/8-24 Q 2 3/4-4 2 1/2 7/16-14 U 3-4 2 3/4 7/16-20 25/64 Tap Size Drill Size Decimal Equivalent Nearest Fraction 3x.50 #39 0.0995 3/32 3x.60 3/32 0.0937 3/32 4x.70 #30 0.1285 1/8 4x.75 1/8 0.125 1/8 5x.80 #19 0.166 11/64 5x.90 #20 0.161 5/32 6x1.00 #9 0.196 13/64 7x1.00 16/64 0.234 15/64 8x1.00 J 0.277 9/32 8x1.25 17/64 0.265 17/64 9x1.00 5/16 0.3125 5/16 9x1.25 5/16 0.3125 5/16 10x1.25 11/32 0.3437 11/32 10x1.50 R 0.339 11/32 11x1.50 3/8 0.375 3/8 12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32

1.9 GENERAL INFORMATION 1 Glossary Of Terms ABDC: After bottom dead center. ACV: Alternating current voltage. Alternator: Electrical generator producing voltage alternating current. ATDC: After top dead center. BBDC: Before bottom dead center. BDC: Bottom dead center. BTDC: Before top dead center. CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches. Clutch Buttons: Plastic bushings which aid rotation of the movable sheave in the drive and driven clutch. Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch face. Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive clutch to close and grip the drive belt. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase. Measure at various points especially at PTO. CVT: Centrifugal Variable Transmission (Drive Clutch System) DCV: Direct current voltage. Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and out-of-round in the cylinder bore. Electrical Open: Open circuit. An electrical circuit which isn't complete. Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load. (i.e. a bare wire touching the chassis). End Seals: Rubber seals at each end of the crankshaft. Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt. ft.: Foot/feet. Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction. g: Gram. Unit of weight in the metric system. gal.: Gallon. ID: Inside diameter. in.: Inch/inches. Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb. kg/cm2: Kilograms per square centimeter. kg-m: Kilogram meters. Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction. l or ltr: Liter. lbs/in2: Pounds per square inch. Left or Right Side: Always referred to based on normal operating position of the driver. m: Meter/meters. Mag: Magneto. Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings. Mechanical energy is converted to electrical energy in the stator. mi.: Mile/miles. mm: Millimeter. Unit of length in the metric system. 1 mm = approximately .040". Nm: Newton meters. OD: Outside diameter. Ohm: The unit of electrical resistance opposing current flow. oz.: Ounce/ounces. Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. qt.: Quart/quarts. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases. Reservoir Tank: The fill tank in the liquid cooling system. Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms, resulting in energy conversion to heat. RPM: Revolutions per minute. Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck piston rings. Stator Plate: The plate mounted under the flywheel supporting the battery charging coils. TDC: Top dead center. Piston's most outward travel from crankshaft. Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit. Watt: Unit of electrical power. Watts = amperes x volts. WOT: Wide open throttle.

NOTES GENERAL INFORMATION 1.10

2009-2010 Polaris Phoenix 200 ATV Repair Manual

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