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2009-2011 Polaris Phoenix 200 Full Service Repair Manual – PDF Download
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2009-2011 Polaris Phoenix 200 Full Service Repair Manual
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Description
2009-2011 Polaris Phoenix 200 Full Service Repair Manual
FILE DETAILS:
2009-2011 Polaris Phoenix 200 Full Service Repair Manual
LANGUAGE:ENGLISH
PAGES:206
DOWNLOADABLE:YES
FILE TYPE:PDF
2009-2011 POLARIS PHOENIX 200 FULL SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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SAMPLE PAGE FROM THE MANUAL:
2009-2011 Polaris Phoenix 200 Full Service Repair Manual
1. Place machine on a smooth level surface.
2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering arm can be used as an indicator of whether the handlebars are straight. The arm should always point straight back from the steering post.
3. Place a chalk mark on the center line of the front tires approximately 10” (25.4 cm) from the floor or as close to the hub/axle center line as possible. NOTE: It is important that the height of both marks be equally positioned in order to get an accurate measurement.
4. Measure the distance between the marks and record the measurement. Call this measurement “A”.
5. Rotate the tires 180° by moving vehicle forward or backward. Position chalk marks facing rearward, even with the hub/axle centerline.
6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle toe-out alignment. This means that measurement (A) is wider than
TABLE OF CONTENTS:
2009-2011 Polaris Phoenix 200 Full Service Repair Manual
9921840_CH 01.pdf............................................................ 1 TABLE OF CONTENTS........................................................ 1 VEHICLE IDENTIFICATION............................................... 2 Model Identification............................................. 2 Engine Designation Number........................................ 2 VIN Identification............................................... 2 VIN and Engine Serial Number Location............................ 2 GENERAL SPECIFICATIONS............................................... 3 MODEL. ................2009 PHOENIX 200.......................... 3 MODEL: 2009 PHOENIX 200 ......................................... 4 VEHICLE INFORMATION.................................................. 5 Publication Numbers.............................................. 5 Paint Codes:..................................................... 5 Replacement Keys................................................. 5 SPECIAL TOOLS........................................................ 6 MISCELLANEOUS SPECIFICATIONS AND CHARTS.............................. 6 Standard Torque Specifications................................... 6 Conversion Table................................................. 7 SAE Tap Drill Sizes.............................................. 8 Metric Tap Drill Sizes........................................... 8 Decimal Equivalents.............................................. 8 Glossary Of Terms................................................ 9 9921840_CH 02................................................................ 11 TABLE OF CONTENTS........................................................ 11 GENERAL VEHICLE INSPECTION AND MAINTENANCE........................... 13 Pre-Ride / Daily Inspection...................................... 13 Polaris Lubricant Symbol Identification.......................... 13 Lubrication Locations............................................ 14 Frame, Nuts, Bolts, and Fastener Inspection...................... 14 Phoenix Handlebar and Component Locations........................ 15 PERIODIC MAINTENANCE CHART........................................... 16 Periodic Maintenance Overview.................................... 16 Maintenance Chart Key............................................ 16 Pre-Ride - 25 Hour Maintenance Interval.......................... 17 50 Hour Maintenance Interval..................................... 18 100 - 300 Hour Maintenance Interval.............................. 19 POLARIS LUBRICANTS AND SERVICE PRODUCTS.............................. 20 Polaris Lubricants, Maintenance, and Service Products............ 20 FUEL SYSTEM AND AIR INTAKE........................................... 21 Fuel System...................................................... 21 Throttle Operation / Inspection.................................. 21 Electronic Throttle Control (ETC) / Throttle Cable Adjustment.... 21 Choke (Enricher) Adjustment...................................... 22 Fuel / Air Mixture Adjustment.................................... 22 Idle Speed Adjustment............................................ 23 Fuel Lines....................................................... 23 Vent Lines....................................................... 23 Fuel Filter...................................................... 23 Carburetor Draining.............................................. 24 Main Air Filter Cleaning......................................... 24 Air Filter / Pre-Filter Service.................................. 24 Air Box Sediment Tube............................................ 25 ENGINE/TRANSMISSION/REAR GEARCASE.................................... 26 Engine Oil Level................................................. 26 Engine Oil and Filter Change .................................... 26 Compression Test................................................. 27 Valve Clearance Adjustment....................................... 27 Engine Mounts.................................................... 28 Engine Fastener Torque .......................................... 28 Kickstart Lever and Operation.................................... 28 Exhaust Cleaning................................................. 28 CVT Drain Plug / Drying.......................................... 29 Transmission Lubrication......................................... 29 Shift Cable Inspection and Adjustment............................ 30 Rear Gearcase Lubrication........................................ 30 ELECTRICAL and IGNITION system....................................... 32 Battery Maintenance.............................................. 32 Spark Plug....................................................... 33 Ignition Timing.................................................. 33 Engine / Frame Ground............................................ 33 STEERING and SUSPENSION.............................................. 33 Steering......................................................... 33 Tie Rod End / Steering Inspection ............................... 34 Camber and Caster................................................ 34 Toe Alignment.................................................... 34 Toe Alignment Adjustment......................................... 35 Front / Rear Suspension Spring Preload Adjustment................ 35 Front Suspension Inspection...................................... 35 Rear Suspension Inspection....................................... 35 BRAKE SYSTEM......................................................... 36 Brake System Inspection.......................................... 36 Front Brake Pad Inspection....................................... 36 Hose / Fitting Inspection........................................ 36 Rear Brake Adjustments........................................... 37 Rear Brake Lever Travel.......................................... 38 Controls......................................................... 38 WHEELS AND TIRES..................................................... 38 Wheels........................................................... 38 Wheel, Hub, and Spindle Torque Table............................. 38 Wheel Removal - Front / Rear..................................... 38 Wheel Installation - Front / Rear................................ 39 Tire Pressure.................................................... 39 Tire Inspection.................................................. 39 9921840_CH 03................................................................ 41 TABLE OF CONTENTS........................................................ 41 TOOLS................................................................ 43 Special Tools.................................................... 43 TORQUE SPECIFICATIONS................................................ 43 Engine Torque Specifications..................................... 43 Torque Patterns.................................................. 44 GENERAL ENGINE SERVICE............................................... 45 Engine Exploded View............................................. 45 Engine Service Data.............................................. 46 ENGINE SERVICE DATA.............................................. 47 Oil Flow Diagram................................................. 48 Piston Identification............................................ 49 Accessible Components............................................ 49 ENGINE SERVICE....................................................... 49 Engine Removal................................................... 49 Engine Installation Notes........................................ 49 Engine Lubrication............................................... 50 Oil Flow Test.................................................... 50 Engine Breather / Oil Separator.................................. 50 TOP-END DISASSEMBLY.................................................. 51 Engine Disassembly............................................... 51 Cam Chain Tensioner Removal...................................... 51 Cam Chain Tensioner Inspection................................... 51 Rocker Arm Shaft Disassembly and Inspection...................... 52 Camshaft Removal................................................. 53 Camshaft Inspection.............................................. 53 Cylinder Head Removal............................................ 54 Cylinder Head Inspection......................................... 55 Cylinder Head Warp Inspection.................................... 55 Combustion Chamber Inspection.................................... 55 Cylinder Head Disassembly........................................ 55 Valve Inspection................................................. 56 Valve Seat Reconditioning........................................ 57 Cylinder Head Assembly........................................... 59 Valve Sealing Test............................................... 60 Cylinder Removal................................................. 60 Cam Chain Follower / Tensioner Blades............................ 60 Piston Removal................................................... 61 Cylinder Inspection.............................................. 61 Cylinder Hone Selection / Honing Procedure....................... 62 Honing to Deglaze................................................ 62 Piston Inspection................................................ 62 Piston Ring Installed Gap........................................ 63 BOTTOM-END DISASSEMBLY............................................... 64 Starter Drive Gear Removal and Inspection........................ 64 Flywheel Removal / Inspection.................................... 64 Starter Drive One-way Clutch Removal and Inspection.............. 65 Crankshaft Drive Sprocket Removal and Inspection................. 65 Balance Shaft Sprocket Removal and Inspection.................... 66 Oil Pump Removal / Drive Chain Inspection........................ 66 CRANKCASE DISASSEMBLY................................................ 67 Crankcase Separation and Cam Chain Removal....................... 67 Crankshaft Removal............................................... 68 Crankshaft / Cam Chain / Sprocket Inspection..................... 68 Crankcase / Bearing Inspection................................... 69 Crankcase Oil Strainer Inspection................................ 69 ENGINE REASSEMBLY.................................................... 69 Bearing / Seal Installation...................................... 69 Crankcase Reassembly............................................. 69 Balance Shaft and Crankshaft Gear Installation................... 70 Oil Pump and Chain Installation.................................. 71 Piston Ring Installation......................................... 72 Piston Installation.............................................. 72 Tensioner Blade Installation..................................... 73 Cylinder Installation............................................ 73 Cylinder Head and Camshaft Installation.......................... 74 Camshaft Timing.................................................. 74 Camshaft Timing - Method 1....................................... 76 Camshaft Timing - Method 2....................................... 77 Rocker Arm / Shaft Installation.................................. 78 Cam Chain Tensioner Installation................................. 78 Intake Valve Clearance Adjustment................................ 78 Exhaust Valve Clearance Adjustment............................... 79 Flywheel Installation............................................ 79 Starter Drive Assembly........................................... 79 Stator Housing Installation...................................... 79 Oil Filter Installation.......................................... 80 TROUBLESHOOTING...................................................... 80 Spark Plug Fouling .............................................. 80 General Troubleshooting.......................................... 80 9921840_CH 04................................................................ 83 TABLE OF CONTENTS........................................................ 83 CARBURETOR EXPLODED VIEW............................................. 84 AIR CLEANER EXPLODED VIEW............................................ 85 FUEL TANK EXPLODED VIEW.............................................. 86 SPECIAL TOOLS........................................................ 87 CARBURETION SYSTEM................................................... 87 Carburetion System Function...................................... 87 Carburetion Specifications....................................... 87 Optional Main Jets............................................... 88 Carburetor Jetting............................................... 88 Carburetor Operation............................................. 88 Float System..................................................... 88 Pilot Jet........................................................ 89 Air Screw........................................................ 89 Air / Fuel Mixture Ratio......................................... 89 Jet Needle....................................................... 90 Needle Jet....................................................... 90 Throttle Opening vs. Fuel Flow................................... 90 Throttle Slide................................................... 90 Main Jet......................................................... 91 Pilot System (Idle - 3/8 Throttle)............................... 91 Slide Cutaway (1/8 - 3/8 Throttle)............................... 92 Jet Needle / Needle Jet (3/8 - 3/4 Throttle)..................... 92 Main System (3/4 to Full Throttle)............................... 93 Fuel Delivery.................................................... 93 Vent System...................................................... 93 CARBURETOR SERVICE................................................... 94 Carburetor Cleaning.............................................. 94 Carburetor Inspection............................................ 94 Float Height Adjustment.......................................... 94 Needle and Seat Leak Test........................................ 95 Carburetor Assembly.............................................. 95 Carburetor Float Bowl Draining................................... 96 Fuel Level Test.................................................. 96 TROUBLESHOOTING...................................................... 97 Fuel Starvation / Lean Mixture................................... 97 Rich Mixture..................................................... 97 Poor Idle........................................................ 97 9921840_CH 05................................................................ 99 TABLE OF CONTENTS........................................................ 99 GENERAL INFORMATION..................................................100 Torque Specifications............................................100 Special Tools....................................................100 PHOENIX BODY.........................................................101 Body Assembly Exploded View......................................101 PHOENIX BODY DISASSEMBLY.............................................102 Seat Removal.....................................................102 Headlight Cover Removal..........................................102 Footrest Removal.................................................102 Front Cab Removal................................................103 Side Panel Removal...............................................103 Rear Cab Removal.................................................103 STEERING / FRONT SUSPENSION..........................................104 Exploded View....................................................104 STEERING SPINDLE.....................................................105 Removal..........................................................105 Installation.....................................................105 BALL JOINT SERVICE...................................................105 Removal..........................................................105 Installation.....................................................106 STEERING POST........................................................107 Assembly.........................................................107 HANDLEBAR BLOCK......................................................108 Installation Procedure...........................................108 A-ARM SERVICE........................................................109 Exploded View....................................................109 A-Arm Replacement................................................109 SHOCK REPLACEMENT....................................................110 Front and Rear Shock Replacement.................................110 SWING ARM REPLACEMENT................................................110 See Chapter 7 For Rear Swing Arm Replacement / Service...........110 DECALS...............................................................110 Replacement......................................................110 9921840_CH 06................................................................111 TABLE OF CONTENTS........................................................111 SPECIFICATIONS.......................................................112 General Specifications...........................................112 Torque Specifications............................................112 SPECIAL TOOLS........................................................112 BRAKE SYSTEM INFORMATION.............................................113 Brake System Service Notes.......................................113 Brake Noise Troubleshooting......................................113 Phoenix Brake System Operation...................................114 FRONT BRAKE SYSTEM...................................................115 Caliper / Master Cylinder Exploded View..........................115 Hydraulic Brake System Operation.................................116 MASTER CYLINDER......................................................117 Front Brake Fluid Replacement and Bleeding Procedure.............117 Master Cylinder Removal..........................................118 Master Cylinder Installation.....................................119 FRONT BRAKE PAD......................................................120 Removal..........................................................120 Installation.....................................................121 FRONT BRAKE DISC.....................................................123 Brake Disc Inspection............................................123 Brake Disc Replacement...........................................123 FRONT BRAKE CALIPER..................................................124 Exploded View....................................................124 Caliper Removal..................................................125 Caliper Disassembly..............................................125 Caliper Inspection...............................................126 Caliper Reassembly...............................................127 Caliper Installation.............................................127 REAR BRAKE SYSTEM....................................................128 Rear Mechanical Brake System Overview / Troubleshooting..........128 REAR BRAKE SYSTEM EXPLODED VIEW..................................129 REAR BRAKE FOOT PEDAL................................................130 Removal..........................................................130 Installation.....................................................130 Foot Brake Pedal Switch Removal..................................130 REAR BRAKE SHOE / DRUM...............................................130 Removal..........................................................130 INSPECTION.......................................................131 Installation.....................................................132 REAR BRAKE ARM.......................................................133 Disassembly......................................................133 Installation.....................................................133 REAR BRAKE PLATE.....................................................134 Removal..........................................................134 Installation.....................................................134 REAR BRAKE FREEPLAY / ADJUSTMENT.....................................134 Refer to Chapter 2 to adjust the rear brakes.....................134 BRAKE SYSTEM TROUBLESHOOTING.........................................135 9921840_CH 07................................................................137 TABLE OF CONTENTS........................................................137 SPECIFICATIONS.......................................................138 Torque Specifications............................................138 Special Tools....................................................138 FRONT HUB............................................................139 Exploded View....................................................139 Hub Removal......................................................140 Hub Disassembly / Inspection.....................................141 Hub Assembly.....................................................141 Hub Installation.................................................142 REAR HUB.............................................................143 Exploded View....................................................143 Hub Removal......................................................144 Hub Installation.................................................144 Hub Inspection...................................................144 SWING ARM / REAR GEARCASE............................................145 Swing Arm Exploded View..........................................145 Swing Arm Removal................................................145 Rear Gearcase - Exploded View....................................147 Rear Gearcase Removal............................................148 Rear Gearcase Disassembly........................................149 Rear Gearcase Assembly...........................................150 Swing Arm Installation...........................................152 REAR AXLE SERVICE....................................................154 Axle Removal / Installation......................................154 Run-Out Inspection (In Axle Tube)................................155 9921840_CH 08................................................................157 TABLE OF CONTENTS........................................................157 SPECIFICATIONS / TOOLS...............................................158 Torque Specifications............................................158 Special Tools....................................................158 SHIFT CABLES / GEAR SELECTOR.........................................158 Shift Cable Inspection and Adjustment............................158 Gear Selector, Shift Arm and Cable Removal / Installation........159 CVT SYSTEM OPERATION.................................................160 CVT Operation Overview...........................................160 CVT Maintenance / Inspection.....................................160 Drive Clutch Operation...........................................160 Driven Clutch Operaton...........................................160 CVT System Drying................................................160 CVT Overheating / Diagnosis......................................162 CVT SYSTEM SERVICE...................................................163 Drive Clutch Service.............................................163 Driven Clutch Service............................................164 Belt Inspection..................................................167 Driven Clutch Bearing Service....................................167 CVT Reassembly...................................................168 TRANSMISSION SERVICE.................................................169 Transmission Disassembly and Inspection..........................169 Input Shaft Removal / Inspection.................................172 Output Shaft Removal / Inspection................................172 Output Shaft Shimming............................................173 Transmission Reassembly .........................................174 Transmission Shift Detent Service................................174 9921840_CH 09................................................................175 TABLE OF CONTENTS........................................................175 SPECIAL TOOLS........................................................176 ELECTRICAL SYSTEM SERVICE NOTES......................................176 Diagnosing Electrical Problems...................................176 ELECTRICAL COMPONENTS EXPLODED VIEW..................................177 TRANSMISSION SWITCH..................................................178 Removal..........................................................178 Inspection / Testing.............................................178 Installation.....................................................178 IGNITION SYSTEM......................................................179 Ignition System Testing..........................................179 RPM Limiter Specifications.......................................180 Electronic Throttle Control (ETC) Switch.........................181 ETC Operation Test...............................................181 Ignition Coil Testing............................................182 CDI Output Test Using Peak Reading Adaptor.......................182 Pulse Coil Output / Resistance Tests ............................182 Ignition System Troubleshooting..................................182 CHARGING SYSTEM......................................................183 Charging System Testing..........................................183 Main Fuse Assembly...............................................184 Stator / Alternator Tests........................................184 Alternator Output Test (AC amp)..................................184 Current Draw - Key Off...........................................185 Charging System “Break Even” Test................................185 HEADLIGHT............................................................186 Phoenix Headlight Adjustment.....................................186 Phoenix Headlight Replacement....................................186 TAILLIGHT............................................................187 Brake Light Switches.............................................187 Tail Light / Brakelight Lamp Replacement.........................187 HANDLEBAR POD SERVICE................................................188 Indicator Lamp Replacement.......................................188 STARTER SYSTEM.......................................................188 Starter Motor Service............................................188 Voltage Drop Test................................................188 Starter System Troubleshooting...................................189 Starter System Testing ..........................................190 BATTERY INFORMATION..................................................191 Battery Identification...........................................191 Battery Inspection / Removal.....................................191 Battery Installation.............................................191 Battery Off Season Storage.......................................192 SEALED LOW MAINTENANCE BATTERY.......................................192 Battery Service..................................................192 Battery Charging ................................................193 Battery Testing..................................................193 Open Circuit Voltage Test........................................193 Battery Load Test................................................194 Battery Charging Procedure.......................................194 CONVENTIONAL BATTERY.................................................194 Battery Activation / Service.....................................194 Battery Inspection...............................................195 Battery Testing..................................................196 Open Circuit Voltage Test........................................196 Specific Gravity Test............................................196 Battery Load Test................................................197 Battery Charging Procedure.......................................197 9921840_CH 10................................................................199 TABLE OF CONTENTS........................................................199 PHOENIX QUADRICYCLE BRAKE SYSTEM.....................................200 Overview.........................................................200 Rear Brake Caliper Removal.......................................201 Rear Brake Disc Service..........................................201 Rear Axle - Caliper Mount Plate Service..........................202 PHOENIX QUADRICYCLE SPEEDOMETER......................................202 Overview.........................................................202 9921840_WIRE DIAGRAM.........................................................205
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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