2008 POLARIS PHEONIX SAWTOOTH 200 ATV Repair Manual

2008 PHOENIX SERVICE MANUAL FOREWORD 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 service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340. 2008 Phoenix Service Manual PN 9921499 © Copyright 2007 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.polarisindustires.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 INTERNATIONAL 10

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: 2008 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 8 P B 2 0 A B } 4 X A P B 2 0 A * 8 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.................2008 PHOENIX 200 MODEL NUMBER.......A08PB20AB,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: 2008 PHOENIX 200 MODEL NUMBER: A08PB20AB,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 2008 Phoenix 200 A08PB20AB,AD 9921495 9921496 2008 Phoenix 200 Quadricycle A08PB20EB 9921503 9921504 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.

2008 POLARIS PHEONIX SAWTOOTH 200 ATV Repair Manual

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