Polaris Phoenix 200 2012 Factory Service & Work Shop Manual

2012-2013 PHOENIX™ SERVICE MANUAL FOREWORD The information printed within this publication includes the latest product information at time of print. The most recent version of this Service Manual is available in electronic format at www.polarisdealers.com . This Service Manual is designed primarily for use by certified Polaris Master Service Dealer  technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator's perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service Manual, contact an authorized dealer for service. We value your input and appreciate any assistance you can provide in helping make these publications more useful. Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual/Service Literature Question'. Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department, 2100 Hwy 55, Medina, MN 55340. Publication Printed August 2012 (PN 9923979) © Copyright 2012 Polaris Sales Inc. All information contained within this publication is 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 discrepancies may result between the actual vehicle and the information presented in this publication. 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 U.S.A.

UNDERSTANDING MANUAL SAFETY LABELS AND DIRECTIONS Throughout this manual, important information is brought to your attention by the following symbols: SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator, bystander or person(s) inspecting or servicing the vehicle. SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage. NOTE: NOTE provides key information by clarifying instructions. IMPORTANT: IMPORTANT provides key reminders during disassembly, assembly and inspection of components. TRADEMARKS POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity-Vac, Registered Trademark of Neward Enterprises, Inc. Torx, Registered Trademark of Textron Some Polaris factory publications can be downloaded from www.polaris.com, purchased from www.purepolaris.com or by contacting the nearest Polaris dealer. WARNING CAUTION CAUTION

1 GENERAL MAINTENANCE 2 ENGINE 3 FUEL SYSTEM 4 BODY / STEERING SUSPENSION 5 BRAKES 6 FINAL DRIVE 7 CVT / TRANSMISSION 8 ELECTRICAL 9

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923979 - 2012-2013 Phoenix 200 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VIN AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL. 2012 PHOENIX 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL. 2013 PHOENIX 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 PAINT CODES: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 REPLACEMENT KEYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 MISCELLANEOUS SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

1.2 GENERAL INFORMATION 9923979 - 2012-2013 Phoenix 200 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL NUMBER DESIGNATIONS Model Number Designation Example: A13PB20AF VEHICLE IDENTIFICATION NUMBER VIN Number Designation Example: 4XAPB20A0D3000000 GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** A = ATV 12 13 P = Phoenix B = 2x4 Shaft Displacement in cc divided by 10 and rounded to two digits (i.e. 20 = 196cc) A = ORV * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. World Mfg. ID Vehicle Descriptors Vehicle Identifiers Chassis Driveline Engine Size Engine Modifier Category Check Digit Model Year * Mfg. Location Individual Serial No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A P B 2 0 A 0 D 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013

1.3 GENERAL INFORMATION 1 9923979 - 2012-2013 Phoenix 200 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL INFORMATION Engine Designation Number ES20PFE - Single, Air Cooled, SOHC 4 Stroke, Electric Start 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. 1 2

1.4 GENERAL INFORMATION 9923979 - 2012-2013 Phoenix 200 Service Manual © Copyright 2012 Polaris Sales Inc. GENERAL SPECIFICATIONS MODEL.......2012 PHOENIX 200 MODEL NUMBER.......A12PB20AB 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

1.5 GENERAL INFORMATION 1 9923979 - 2012-2013 Phoenix 200 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2012 PHOENIX 200 MODEL NUMBER: A12PB20AB 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 (PS-4) Synthetic Extreme Duty / 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 Meters (Feet) Ambient Temperature Below 40 F Below 5 C Above +40 F Above +5 C 0-1800 (0-6000) 102 98 1800+ (6000+) 96 92 Altitude Meters (Feet) Shift Weight 0-1800 (0-6000) 6 @ 14.7 grams 1800+ (6000+) 6 @ 11 grams (PN 0453091)

1.6 GENERAL INFORMATION 9923979 - 2012-2013 Phoenix 200 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL.......2013 PHOENIX 200 MODEL NUMBER.......A13PB20AF 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

Polaris Phoenix 200 2012 Factory Service & Work Shop Manual

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