Polaris Phoenix 200 - Repair, Service Manual, Wiring Diagrams and Owners Manual

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POLARIS Phoenix 200 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for quad Polaris Phoenix 200.

 
CONTENTS:

SERVICE MANUAL

9921840 CH 01
Table Of Contents
- Vehicle Identification
- Model Identification
- Engine Designation Number
- Vin Identification
- Vin And Engine Serial Number Location
- General Specifications
- Model. 2009 Phoenix 200
- Model: 2009 Phoenix 200
- Vehicle Information
- Publication Numbers
- Paint Codes:
- Replacement Keys
- Special Tools
- Miscellaneous Specifications And Charts
- Standard Torque Specifications
- Conversion Table
- Sae Tap Drill Sizes
- Metric Tap Drill Sizes
- Decimal Equivalents
- Glossary Of Terms
9921840 CH 02
Table Of Contents
- General Vehicle Inspection And Maintenance
- Pre-Ride / Daily Inspection
- Polaris Lubricant Symbol Identification
- Lubrication Locations
- Frame, Nuts, Bolts, And Fastener Inspection
- Phoenix Handlebar And Component Locations
- Periodic Maintenance Chart
- Periodic Maintenance Overview
- Maintenance Chart Key
- Pre-Ride - 25 Hour Maintenance Interval
- 50 Hour Maintenance Interval
- 100 - 300 Hour Maintenance Interval
- Polaris Lubricants And Service Products
- Polaris Lubricants, Maintenance, And Service Products
- Fuel System And Air Intake
- Fuel System
- Throttle Operation / Inspection
- Electronic Throttle Control (Etc) / Throttle Cable Adjustment
- Choke (Enricher) Adjustment
- Fuel / Air Mixture Adjustment
- Idle Speed Adjustment
- Fuel Lines
- Vent Lines
- Fuel Filter
- Carburetor Draining
- Main Air Filter Cleaning
- Air Filter / Pre-Filter Service
- Air Box Sediment Tube
- Engine/Transmission/Rear Gearcase
- Engine Oil Level
- Engine Oil And Filter Change
- Compression Test
- Valve Clearance Adjustment
- Engine Mounts
- Engine Fastener Torque
- Kickstart Lever And Operation
- Exhaust Cleaning
- Cvt Drain Plug / Drying
- Transmission Lubrication
- Shift Cable Inspection And Adjustment
- Rear Gearcase Lubrication
- Electrical And Ignition System
- Battery Maintenance
- Spark Plug
- Ignition Timing
- Engine / Frame Ground
- Steering And Suspension
- Steering
- Tie Rod End / Steering Inspection
- Camber And Caster
- Toe Alignment
- Toe Alignment Adjustment
- Front / Rear Suspension Spring Preload Adjustment
- Front Suspension Inspection
- Rear Suspension Inspection
- Brake System
- Brake System Inspection
- Front Brake Pad Inspection
- Hose / Fitting Inspection
- Rear Brake Adjustments
- Rear Brake Lever Travel
- Controls
- Wheels And Tires
- Wheels
- Wheel, Hub, And Spindle Torque Table
- Wheel Removal - Front / Rear
- Wheel Installation - Front / Rear
- Tire Pressure
- Tire Inspection
9921840 CH 03
Table Of Contents
- Tools
- Special Tools
- Torque Specifications
- Engine Torque Specifications
- Torque Patterns
- General Engine Service
- Engine Exploded View
- Engine Service Data
- Engine Service Data
- Oil Flow Diagram
- Piston Identification
- Accessible Components
- Engine Service
- Engine Removal
- Engine Installation Notes
- Engine Lubrication
- Oil Flow Test
- Engine Breather / Oil Separator
- Top-End Disassembly
- Engine Disassembly
- Cam Chain Tensioner Removal
- Cam Chain Tensioner Inspection
- Rocker Arm Shaft Disassembly And Inspection
- Camshaft Removal
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp Inspection
- Combustion Chamber Inspection
- Cylinder Head Disassembly
- Valve Inspection
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Cylinder Removal
- Cam Chain Follower / Tensioner Blades
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection / Honing Procedure
- Honing To Deglaze
- Piston Inspection
- Piston Ring Installed Gap
- Bottom-End Disassembly
- Starter Drive Gear Removal And Inspection
- Flywheel Removal / Inspection
- Starter Drive One-Way Clutch Removal And Inspection
- Crankshaft Drive Sprocket Removal And Inspection
- Balance Shaft Sprocket Removal And Inspection
- Oil Pump Removal / Drive Chain Inspection
- Crankcase Disassembly
- Crankcase Separation And Cam Chain Removal
- Crankshaft Removal
- Crankshaft / Cam Chain / Sprocket Inspection
- Crankcase / Bearing Inspection
- Crankcase Oil Strainer Inspection
- Engine Reassembly
- Bearing / Seal Installation
- Crankcase Reassembly
- Balance Shaft And Crankshaft Gear Installation
- Oil Pump And Chain Installation
- Piston Ring Installation
- Piston Installation
- Tensioner Blade Installation
- Cylinder Installation
- Cylinder Head And Camshaft Installation
- Camshaft Timing
- Camshaft Timing - Method 1
- Camshaft Timing - Method 2
- Rocker Arm / Shaft Installation
- Cam Chain Tensioner Installation
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Flywheel Installation
- Starter Drive Assembly
- Stator Housing Installation
- Oil Filter Installation
- Troubleshooting
- Spark Plug Fouling
- General Troubleshooting
9921840 CH 04
Table Of Contents
- Carburetor Exploded View
- Air Cleaner Exploded View
- Fuel Tank Exploded View
- Special Tools
- Carburetion System
- Carburetion System Function
- Carburetion Specifications
- Optional Main Jets
- Carburetor Jetting
- Carburetor Operation
- Float System
- Pilot Jet
- Air Screw
- Air / Fuel Mixture Ratio
- Jet Needle
- Needle Jet
- Throttle Opening Vs. Fuel Flow
- Throttle Slide
- Main Jet
- Pilot System (Idle - 3/8 Throttle)
- Slide Cutaway (1/8 - 3/8 Throttle)
- Jet Needle / Needle Jet (3/8 - 3/4 Throttle)
- Main System (3/4 To Full Throttle)
- Fuel Delivery
- Vent System
- Carburetor Service
- Carburetor Cleaning
- Carburetor Inspection
- Float Height Adjustment
- Needle And Seat Leak Test
- Carburetor Assembly
- Carburetor Float Bowl Draining
- Fuel Level Test
- Troubleshooting
- Fuel Starvation / Lean Mixture
- Rich Mixture
- Poor Idle
9921840 CH 05
Table Of Contents
- General Information
- Torque Specifications
- Special Tools
- Phoenix Body
- Body Assembly Exploded View
- Phoenix Body Disassembly
- Seat Removal
- Headlight Cover Removal
- Footrest Removal
- Front Cab Removal
- Side Panel Removal
- Rear Cab Removal
- Steering / Front Suspension
- Exploded View
- Steering Spindle
- Removal
- Installation
- Ball Joint Service
- Removal
- Installation
- Steering Post
- Assembly
- Handlebar Block
- Installation Procedure
- A-Arm Service
- Exploded View
- A-Arm Replacement
- Shock Replacement
- Front And Rear Shock Replacement
- Swing Arm Replacement
- See Chapter 7 For Rear Swing Arm Replacement / Service
- Decals
- Replacement
9921840 CH 06
Table Of Contents
- Specifications
- General Specifications
- Torque Specifications
- Special Tools
- Brake System Information
- Brake System Service Notes
- Brake Noise Troubleshooting
- Phoenix Brake System Operation
- Front Brake System
- Caliper / Master Cylinder Exploded View
- Hydraulic Brake System Operation
- Master Cylinder
- Front Brake Fluid Replacement And Bleeding Procedure
- Master Cylinder Removal
- Master Cylinder Installation
- Front Brake Pad
- Removal
- Installation
- Front Brake Disc
- Brake Disc Inspection
- Brake Disc Replacement
- Front Brake Caliper
- Exploded View
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Reassembly
- Caliper Installation
- Rear Brake System
- Rear Mechanical Brake System Overview / Troubleshooting
- Rear Brake System Exploded View
- Rear Brake Foot Pedal
- Removal
- Installation
- Foot Brake Pedal Switch Removal
- Rear Brake Shoe / Drum
- Removal
- Inspection
- Installation
- Rear Brake Arm
- Disassembly
- Installation
- Rear Brake Plate
- Removal
- Installation
- Rear Brake Freeplay / Adjustment
- Refer To Chapter 2 To Adjust The Rear Brakes.
- Brake System Troubleshooting
9921840 CH 07
Table Of Contents
- Specifications
- Torque Specifications
- Special Tools
- Front Hub
- Exploded View
- Hub Removal
- Hub Disassembly / Inspection
- Hub Assembly
- Hub Installation
- Rear Hub
- Exploded View
- Hub Removal
- Hub Installation
- Hub Inspection
- Swing Arm / Rear Gearcase
- Swing Arm Exploded View
- Swing Arm Removal
- Rear Gearcase - Exploded View
- Rear Gearcase Removal
- Rear Gearcase Disassembly
- Rear Gearcase Assembly
- Swing Arm Installation
- Rear Axle Service
- Axle Removal / Installation
- Run-Out Inspection (In Axle Tube)
9921840 CH 08
Table Of Contents
- Specifications / Tools
- Torque Specifications
- Special Tools
- Shift Cables / Gear Selector
- Shift Cable Inspection And Adjustment
- Gear Selector, Shift Arm And Cable Removal / Installation
- Cvt System Operation
- Cvt Operation Overview
- Cvt Maintenance / Inspection
- Drive Clutch Operation
- Driven Clutch Operaton
- Cvt System Drying
- Cvt Overheating / Diagnosis
- Cvt System Service
- Drive Clutch Service
- Driven Clutch Service
- Belt Inspection
- Driven Clutch Bearing Service
- Cvt Reassembly
- Transmission Service
- Transmission Disassembly And Inspection
- Input Shaft Removal / Inspection
- Output Shaft Removal / Inspection
- Output Shaft Shimming
- Transmission Reassembly
- Transmission Shift Detent Service
9921840 CH 09
Table Of Contents
- Special Tools
- Electrical System Service Notes
- Diagnosing Electrical Problems
- Electrical Components Exploded View
- Transmission Switch
- Removal
- Inspection / Testing
- Installation
- Ignition System
- Ignition System Testing
- Rpm Limiter Specifications
- Electronic Throttle Control (Etc) Switch
- Etc Operation Test
- Ignition Coil Testing
- Cdi Output Test Using Peak Reading Adaptor
- Pulse Coil Output / Resistance Tests
- Ignition System Troubleshooting
- Charging System
- Charging System Testing
- Main Fuse Assembly
- Stator / Alternator Tests
- Alternator Output Test (Ac Amp)
- Current Draw - Key Off
- Charging System “Break Even” Test
- Headlight
- Phoenix Headlight Adjustment
- Phoenix Headlight Replacement
- Taillight
- Brake Light Switches
- Tail Light / Brakelight Lamp Replacement
- Handlebar Pod Service
- Indicator Lamp Replacement
- Starter System
- Starter Motor Service
- Voltage Drop Test
- Starter System Troubleshooting
- Starter System Testing
- Battery Information
- Battery Identification
- Battery Inspection / Removal
- Battery Installation
- Battery Off Season Storage
- Sealed Low Maintenance Battery
- Battery Service
- Battery Charging
- Battery Testing
- Open Circuit Voltage Test
- Battery Load Test
- Battery Charging Procedure
- Conventional Battery
- Battery Activation / Service
- Battery Inspection
- Battery Testing
- Open Circuit Voltage Test
- Specific Gravity Test
- Battery Load Test
- Battery Charging Procedure
9921840 CH 10
Table Of Contents
- Phoenix Quadricycle Brake System
- Overview
- Rear Brake Caliper Removal
- Rear Brake Disc Service
- Rear Axle - Caliper Mount Plate Service
- Phoenix Quadricycle Speedometer
- Overview
9921840 WIRE DIAGRAM


OWNERS MANUAL