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PARTS MANUAL PN 9919965 and MICROFICHE PN 9919966 11/04
E 2004 Polaris Sales Inc.
PHOENIX 200Model #A05PB20AAModel #A05PB20AB
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TABLE OF CONTENTSPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
Parts Manual
AACCESSORY PARTS C6. . . . . . . . . . . . . . . . . .AIR CLEANER B1. . . . . . . . . . . . . . . . . . . . . . .AXLE, REAR WHEEL C1. . . . . . . . . . . . . . . . . .
BBRAKE, FRONT B12. . . . . . . . . . . . . . . . . . . . .BRAKE, REAR B13. . . . . . . . . . . . . . . . . . . . . . .BUMPER B6. . . . . . . . . . . . . . . . . . . . . . . . . . .
CCAB B7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR A14. . . . . . . . . . . . . . . . . . . . . . .CRANKCASE A5. . . . . . . . . . . . . . . . . . . . . . . .CRANKCASE COVER, LH A7. . . . . . . . . . . . . .CRANKCASE COVER, RH A8. . . . . . . . . . . . . .CRANKSHAFT A4. . . . . . . . . . . . . . . . . . . . . . .CYLINDER HEAD A3. . . . . . . . . . . . . . . . . . . . .
DDECALS C5. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE ASSEMBLY, REAR A6. . . . . . . . . . . . . .DRIVE CLUTCH A10. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH A11. . . . . . . . . . . . . . . . . . . . .
EELECTRICAL PARTS C4. . . . . . . . . . . . . . . . . .EXHAUST B2. . . . . . . . . . . . . . . . . . . . . . . . . .
FFOOTREST B5. . . . . . . . . . . . . . . . . . . . . . . . .FRAME BODY B3. . . . . . . . . . . . . . . . . . . . . . .
FFUEL TANK B8. . . . . . . . . . . . . . . . . . . . . . . . .
GGENERATOR A12. . . . . . . . . . . . . . . . . . . . . . . .
HHANDLEBAR B14. . . . . . . . . . . . . . . . . . . . . . . .HEADLIGHT C3. . . . . . . . . . . . . . . . . . . . . . . . .
PPISTON A4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
SSEAT B7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR A12. . . . . . . . . . . . . . . . . . .STEERING C2. . . . . . . . . . . . . . . . . . . . . . . . . .SUSPENSION B9. . . . . . . . . . . . . . . . . . . . . . .SWING ARM B5. . . . . . . . . . . . . . . . . . . . . . . .SWING ARM, REAR B4. . . . . . . . . . . . . . . . . . .
TTAILLIGHT C3. . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION A13. . . . . . . . . . . . . . . . . . . . .
VVALVE CAM A9. . . . . . . . . . . . . . . . . . . . . . . . .
WWHEEL, FRONT B10. . . . . . . . . . . . . . . . . . . . . .WHEEL, REAR B11. . . . . . . . . . . . . . . . . . . . . . .
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
A3
CYLINDER HEADPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
24
7
22
11
6
10
21
E 2004 Polaris Sales Inc.
9
1320
1516
18
14
17
19
23
3
4
33
3534
2 29
30
12
32
5
1
25
9
15
16
18
14
17
5
5831
26
28
27
27
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452400 4 Bolt2 0452395 1 Cover, Cylinder Head3 0452125 1 Breather, Crankcase, Lower4 0451766 4 Screw5 0450142 6 Pin, Dowel6 0452380 1 Guide, Valve Intake7 0452378 1 Seat, Intake8 0452402 1 Plug, Spark9 0452382 2 O-Ring10 0452381 1 Guide, Valve Exhaust11 0452379 1 Seat, Exhaust12 0452398 2 Bolt, Stud13 0452383 1 Valve, Intake14 0452388 2 Seat, Valve, Spring, Outer15 0452385 2 Spring, Valve, Outer16 0452386 2 Spring, Valve, Inner17 0452389 4 Clip, Retainer18 0452387 2 Retainer, Valve, Spring
19 0452390 2 Seal, Valve20 0452384 1 Valve, Exhaust21 0452376 1 Gasket, Cylinder22 0452375 1 Cylinder23 0452391 1 Gasket24 0452377 1 Head, Cylinder25 0452401 2 Bolt26 0452404 1 Insulator, Manifold27 0450880 4 Nut28 0452405 2 Bolt, Stud29 0452396 1 Manifold30 0452397 1 O-Ring31 0452403 1 Gasket, Manifold32 0452399 2 Bolt, Stud33 0452392 1 O-Ring, Head Cover34 0452394 1 O-Ring, Head Cover Cap35 0452393 1 Cap, Head Cover
11/04
A4
CRANKSHAFT and PISTONPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
14
12
8
20
1521
9
17
11
19
7
18
E 2004 Polaris Sales Inc.
4
4
13
10
65
3
816
21
16
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452445 1 Tube, Oil, Crankshaft2 0452444 1 Spring, Oil3 0452442 1 Nut, Flange4 0450264 2 Washer5 0452441 1 Nut, Lock6 0452440 1 Washer, Gear7 0452434 1 Gear, Balance8 0452427 2 Bearing, Ball9 0452435 1 Shaft, Balance10 0452439 1 Key, Woodruff11 0452436 1 Sprocket, Oil Pump
12 0452437 1 Gear, Balance, Driven13 0452438 1 Nut, Lock14 0452428 1 Sprocket, Timing15 0452426 1 Kit, Crankshaft16 0452443 2 Clip, Piston Pin17 0452433 1 Pin, Piston18 0452431 1 Ring (Set)19 0452432 1 Piston20 0452429 1 Key, Woodruff21 0452430 1 Key, Woodruff
11/04
A5
CRANKCASEPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
6
23
17
36
1813
33
3
1
5
1514
30
10
22
28
20
169
2
34
441
8
1912
27
31
35
21
2632
29
2437
E 2004 Polaris Sales Inc.
40
39
38
33
35
25
11
7
22
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452344 2 Bolt2 0452335 2 Bolt, Stud3 0452342 2 Pin, Dowel4 0452345 1 Bearing, Ball5 0452348 2 Bearing, Ball6 0452330 1 Bolt7 0452374 1 Washer, Flat8 0452156 1 Bearing, Main Transmission Shaft9 0452336 2 Bolt, Stud10 0452349 1 Bearing, Ball11 0452373 1 Bearing, Needle12 0452337 1 Washer, Flat13 0452125 1 Breather, Crankcase, Lower14 0452347 1 Bearing, Ball15 0452346 1 Bearing, Ball16 0452326 1 Hose, Vent17 0452324 2 Bolt18 0452323 1 Bracket, Motor Mount19 0452325 2 Washer, Flat20 0450268 2 Nut21 0452340 1 Seal, Oil
22 0450142 2 Pin, Dowel23 0452329 1 Switch24 0452138 2 Bolt25 0452129 1 O-Ring26 0452341 1 Seal, Oil27 0452133 1 Washer, Flat28 0452132 1 Bolt, Drain Plug29 0452135 1 Spring, Detent30 0452137 1 Bolt31 0452136 1 Washer, Flat32 0452134 1 Ball, Steel33 0452319 2 Bushing, Rubber34 0452322 1 Crankcase, LH35 0452320 1 Spacer, Collar36 0452321 1 Gasket37 0452368 1 Plug, Drain, Oil38 0452371 1 O-Ring, Drain Plug39 0452370 1 Spring, Screen40 0452369 1 Screen41 0452318 1 Crankcase, RH
11/04
A6
DRIVE ASSEMBLY, REARPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
E 2004 Polaris Sales Inc.
16
2
14
15
17
1
10
9
8
712
11
5
13
6
43
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452343 9 Bolt2 0452333 1 Seal, Sight Glass3 0451813 1 Plug, Oil4 0450154 1 O-Ring5 0452356 1 Gear, Shaft, Output6 0452358 1 Bearing, Needle7 0452353 1 O-Ring8 0452352 1 Shim, Set9 0452351 1 Collar, Gear Shaft
10 0452350 3 Bolt11 0452355 1 Nut, Lock12 0452354 1 Bearing, Ball13 0452357 1 Seal, Oil14 0452334 1 Gasket, Transmission Cover15 0450142 2 Pin, Dowel16 0452332 1 Cover, Transmission17 0452175 1 Seal, Oil
11/04
A7
CRANKCASE COVER, LHPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
E 2004 Polaris Sales Inc.
109
11
14
871
2
34 5
6
18
1716
15
1213
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452359 1 Spindle, Kick Start2 0452360 1 Spring, Kick Start3 0452361 1 Spacer, Kick Start4 0452394 1 O-Ring5 0452363 1 Washer, Flat6 0452364 1 Clip, Retainer7 0452339 1 Clip, Retainer8 0450261 1 Bearing, Ball9 0452328 1 Gasket
10 0452327 1 Cover, Clutch11 0452331 8 Bolt12 0452372 1 Asm., Kick Start13 0451704 1 Bolt14 0451746 1 Cap, Shaft, Kick Starter15 0452126 1 Bolt16 0452367 1 Washer, Flat17 0452366 1 Spring, Kick Start Gear18 0452365 1 Gear, Kick Start, Driven
11/04
A8
CRANKCASE COVER, RHPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
4
10
16
21
1220
7
13
15
18
11
17
14
E 2004 Polaris Sales Inc.
3
89
19
5
22
12
6
10
2021
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452463 1 Bolt2 0452464 1 Washer, Flat, Copper3 0452413 3 Bolt4 0452458 1 Cap, Cover, RH5 0452330 2 Bolt6 0452637 1 Retainer, Sight Glass7 0452343 1 Bolt8 0452460 1 Cap9 0452461 1 O-Ring10 0452342 2 Pin, Dowel11 0452447 1 Gasket, Cover
12 0452450 1 Asm., One Way Clutch13 0452448 1 Flywheel14 0452457 3 Bolt15 0452449 1 Stator16 0452456 2 Screw17 0452455 3 Screw18 0452446 1 Cover, Crankcase, RH19 0452636 1 Shield20 0452401 8 Bolt21 0452459 2 O-Ring22 0452462 1 Filter, Oil
11/04
A9
VALVE CAMPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
171614
19
4
18
15
21
20
101112
1
E 2004 Polaris Sales Inc.
13
89
5
23
7
6
2
3
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452406 1 Asm., Cam Shaft2 0452423 2 Screw, Tappet Adj.3 0452424 2 Nut, Tappet Adj.4 0452414 1 Asm., Decomp. Release5 0452409 2 Arm, Valve, Rocker6 0450268 4 Nut7 0452425 4 Washer8 0452408 1 Bracket, Cam Shaft9 0452410 1 Shaft, Intake, Rocker Arm10 0452413 1 Bolt11 0452412 1 Plate, Rocker arm Shaft
12 0452411 1 Shaft, Exhaust, Rocker Arm13 0452407 1 Chain, Cam14 0452415 1 Guide, Cam Chain, RH15 0452416 1 Tensioner16 0452420 2 Bolt17 0452421 1 Screw18 0452382 1 O-Ring19 0452417 1 Gasket, Tensioner20 0452418 1 Pivot, Guide21 0452419 1 Guide, Cam Chain, LH
11/04
A10
DRIVE CLUTCHPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
4
6
8
5
7
3
2
1
12 9
E 2004 Polaris Sales Inc.
4
10
11
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
0452465 1 Asm., Drive Clutch (Incl. 1-8)1 0452473 3 Bushing, Slide2 0452472 1 Plate, Sheave3 0452471 6 Asm., Roller4 0452470 1 Clip, Cir5 0452468 1 Asm., Sheave (Incl. 4,6)6 0452469 1 Bushing, Sheave
7 0452467 1 Shaft, Drive8 0452466 1 Sheave, Moveable, Drive9 0452474 1 Bushing, Kick Start10 0452792 1 Washer, Plain11 0450529 1 Nut, Flange12 0452496 1 Belt, Drive
11/04
A11
DRIVEN CLUTCHPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
E 2004 Polaris Sales Inc.
9
11
1
7
3 45
6
2
26
24
2223
1920
8
25
10
21
2322
25
1718
1213
14
1615
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
0452477 1 Asm., Driven Clutch (Incl. All less 9)1 0452478 1 Asm., Drive Plate (Incl. 2-7)2 0450052 3 Clip, Cir3 0452480 1 Plate, Drive, Side4 0452481 3 Spring, Clutch5 0452482 3 Weight, Clutch6 0452483 3 Bushing, Rubber7 0452479 1 Plate, Drive, Inner8 0452492 1 Nut9 0452475 1 Hold, Cam10 0452495 1 Clutch, Outer11 0452476 1 Washer12 0452499 1 Retainer, Ball13 0452500 5 Washer, Belleville
14 0452501 1 Guide, Cam15 0452502 1 Nut, Driven16 0452440 2 Washer, Gear17 0452497 1 Clip, Cir18 0452498 8 Ball, Steel19 0452490 1 Spring, Clutch20 0452491 1 Seal, Collar21 0452494 2 O-Ring22 0452488 3 Pin, Guide23 0452489 3 Roller, Guide24 0452487 1 Asm., Sheave, Moveable25 0452493 2 Seal, Driven26 0452484 1 Asm., Sheave, Driven (Incl. Bearings
and Clip)
11/04
A12
GENERATOR/STARTING MOTORPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
3
5
7
2
1011
8
9
4
1
6
E 2004 Polaris Sales Inc.
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452330 4 Bolt2 0452506 1 Cover, Oil Pump3 0452505 1 Chain, Oil Pump4 0450880 1 Nut, Flange5 0452504 1 Sprocket, Oil Pump6 0452511 2 Screw
7 0452503 1 Pump, Oil8 0452509 1 Motor, Starting9 0452510 1 O-Ring10 0452507 1 Asm., Gear Starter11 0452508 1 Gear, Starter
11/04
A13
TRANSMISSIONPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
E 2004 Polaris Sales Inc.
10
12 13
14
16
18
17
20
98
7
22
11
19
12
21
4
6
5
33
34 32
29
28
30
31
3
21
26
25
3623
24
3527
15
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
0452514 1 Asm., Spur Gear (Incl. 11,13)0452519 1 Asm., Reverse Gear (Incl. 17,18)
1 0452789 2 Ring, Retainer2 0452349 1 Bearing, Ball3 0452531 1 Gear, Final Ring4 0452528 1 Shaft5 0452530 1 Gear6 0452529 1 Clip, Cir7 0452525 1 Shaft, Drive8 0452524 1 Washer, Flat9 0450187 1 Clip, Cir10 0452512 1 Collar, Shaft11 0452516 1 Bushing12 0452513 2 Washer, Flat13 0452515 1 Gear, Spur14 0452517 1 Ratchet, Shift15 0452339 1 O-Ring16 0452518 1 Washer, Spline17 0452521 1 Bearing, Needle
18 0452520 1 Gear, Reverse19 0452522 1 Washer, Flat20 0452523 1 Shaft, Transmission21 0452527 1 Gear, Counter22 0452526 1 Shaft, Counter23 0452635 1 Bolt, Detent24 0452134 1 Ball, Steel25 0452634 1 Housing26 0452633 1 Detent27 0452400 1 Bolt28 0452161 1 E-Clip29 0452160 1 Spindle30 0452162 1 Spring, Drum Sensor31 0452163 1 Roller, Drum Sensor32 0452159 1 Drum, Gear Shift Asm.33 0452157 1 Fork, Shift34 0452158 1 Shaft, Gear Shift35 0452330 2 Bolt36 0452135 1 Spring
11/04
A14
CARBURETORPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
23
12
5
22
16
19
920
13
21
4
7
2
24
6
1
3
10
1811
15
14
17
8
E 2004 Polaris Sales Inc.
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452544 1 Asm., Cap2 0452548 1 Spring3 0452551 1 Asm., Jet Needle4 0452554 1 Throttle, Valve5 0452539 1 Needle, Jet6 0452305 1 Asm., Carburetor7 0452537 1 Screw8 0452543 1 Spring9 0452538 1 Choke, Lever10 0452541 1 Asm., Screw11 0452553 1 Jet, Pilot12 0452533 1 Valve, Float
13 0452546 1 Float14 0452535 1 Float, Body15 0452552 1 Asm., Drain Tube16 0452540 3 Asm., Screw17 0452534 1 Pin, Float18 0452555 1 Jet, Main19 0452545 1 Valve, Needle20 0452536 1 O-Ring21 0452547 1 Cover, Diaphragm22 0452549 1 Asm., Screw23 0452550 1 O-Ring24 0452542 1 Clip, Needle
11/04
B1
AIR CLEANERPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
23
26
31
4
29
2
27
332
30
1
28 5
6
7
E 2004 Polaris Sales Inc.
21
25
11
9
14
12
10
820
13
1112
1013
16
15
24
19
1718
22
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
0452556 1 Asm., Air Box (Incl. 1-7,26-32)0452570 1 Asm., Breather Tube (Incl. 15-19,21-25)
1 0452560 1 Cover, Air Box2 0452569 1 Gasket3 0450340 2 Bolt4 0452559 1 Box, Air5 0452566 1 Clamp6 0452567 1 Hose, Drain7 0452568 1 Plug, Trap8 0452579 1 Cover, Duct, Inlet9 0452575 1 Duct, Inlet10 0452578 2 Clamp11 0452574 2 Boot, Duct12 0452577 2 Clamp13 0450824 3 Bolt14 0452576 1 Duct, Outlet15 0452793 1 Spring
16 0452794 1 Tube, Breather, Ventilated17 0452795 1 Clip18 0450701 1 Bolt19 0450054 2 Clip20 0450667 1 Bolt21 0452572 1 Tube, Breather, Inlet22 0452796 3 Clip23 0452307 1 Separator, Oil24 0450880 1 Nut, Flange25 0452573 1 Tube, Breather, Outlet26 0452557 1 Duct27 0452561 1 Clamp28 0452562 1 Clamp29 0452563 1 Boot30 0452564 1 Inlet, Air Box31 0452306 1 Element, Air Cleaner32 0452565 4 Clip
11/04
B2
EXHAUSTPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
4
9
2
7
1
6
10
11
5
E 2004 Polaris Sales Inc.
3
8
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452587 1 Arrester, Spark2 0452582 1 Silencer3 0450684 1 Bolt4 0452584 1 Collar5 0452585 1 Clamp6 0452308 1 Pipe, Exhaust, Front
7 0452580 1 Gasket, Exhaust Pipe8 0450268 2 Nut9 0452583 1 Shield, Headpipe10 0452586 3 Bolt11 0452031 1 Bolt
11/04
B3
FRAME BODYPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
13
10
23
11
8
17
7
24
12
14
15
22
21
19
20
19
E 2004 Polaris Sales Inc.
9
20
13
12
20
7
18
26
5
12
34
27
6
28
1625
11
9
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450966 1 Grip, Transmission Lever2 0452168 1 Knob, Transmission Lever3 0450967 1 Cover4 0450309 1 Bolt5 0452601 1 Lever, Shift6 0450268 2 Nut7 0452597 8 Bolt8 0452596 1 Dampner, Foot Brake Lever9 0452594 2 Plate, Footwell10 0452591 2 Grommet, Seat11 0452598 4 Bolt12 0450800 2 Rubber, Mount13 0452593 2 Bracket14 0450290 2 Rubber, Seat
15 0452590 1 Asm., Frame16 0452602 1 Bracket, Kick Start17 0450309 2 Bolt18 0450271 1 Nut19 0450882 4 Nut20 0450279 5 Washer21 0452592 2 Mount, Engine22 0450559 10 Strap23 0452599 1 Bolt24 0450276 1 Nut, Lock25 0452603 1 Trim, Rubber26 0452600 1 Linkage, Shift27 0452198 1 Washer, Flat28 0450298 1 Bolt
11/04
B4
SWING ARM, REARPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
4
5
1
3
6
15
7
14
12
13
11
8
10
9
2
E 2004 Polaris Sales Inc.
34
13
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452612 1 Nut, Lock2 0452611 1 Bolt, Pivot3 0452609 2 Seal, Oil4 0452608 2 Bearing5 0452604 1 Arm, Swing6 0452617 2 Clamp7 0452616 1 Boot8 0452607 1 Joint, Universal
9 0452606 1 Shaft, Drive10 0452605 1 Spring11 0452610 1 Bolt, Pivot12 0452614 4 Bolt13 0452613 2 O-Ring14 0452615 4 Bolt15 0450882 4 Nut, Lock
11/04
B5
SWING ARM and FOOTRESTPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
2
1
12
5
16
14
11
15
9
46
3
7
10
813
E 2004 Polaris Sales Inc.
9
9
9
4
4
4
7
7
7
3
8
3
8
5
6121314
7
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452215 8 Bolt, Hex2 0452628
045262711
Footrest, LHFootrest, RH
3 0452626 6 Bolt4 0452625 8 Spacer5 0450320 8 Valve, Grease6 0450321 8 Cap, Rubber7 0451762 16 Cap, Rubber8 0450249 8 Nut9 0451763 16 Bushing
10 0451764 2 Bolt11 0452622
045262111
A-Arm, Lower, LHA-Arm, Lower, RH
12 0452630 4 Ring, Snap13 0450279 4 Washer14 0450502 4 Nut15 0452624
045262311
A-Arm, Upper, LHA-Arm, Upper, RH
16 5435861 2 Retainer, Brake Line, Front
11/04
B6
BUMPERPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
3
1
1
2
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452620 2 Bolt2 0452618-385 1 Bumper, Front, Silver3 0452619 1 Support, Bumper, Front
11/04
B7
CAB/SEATPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
19
7
6
8
11
3
5
14
118
4
16
12
10
15
9
13
2
E 2004 Polaris Sales Inc.
20
14
14
14
4
4
4
6
6
65
5
5
3
17
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0451076 4 Rivet, Plastic2 0452653-070 1 Panel, Side, RH, Black3 0451703 2 Screw4 0450622 16 Bolt5 0450710 16 Washer, Flat6 0450741 16 Nut7 0452660 1 Strap, Battery, Rubber8 0450346 1 Rubber, Battery9 0452215 4 Bolt10 0452632-293
0452632-34111
Cab, Rear, Indy RedCab, Rear, Sonic Blue
11 0450345 1 Pad, Protector12 0452651-070 1 Panel, Side, LH, Black13 0452655-070 1 Cover, Fuel Tank, Black14 0450824 4 Bolt15 0452631-293
0452631-34111
Cab, Front, Indy RedCab, Front, Sonic Blue
16 0452638 1 Seat17 9919964 1 Manual, Owners, ’05 Phoenix 20018 0450040 3 Screw19 0452650-070 1 Cover, Headlight, Black20 0452662 1 Boot, Shift, Rubber
11/04
B8
FUEL TANKPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
11
6
5
2
7
10
4
12
3
8
E 2004 Polaris Sales Inc.
4
13
9
9
9
8
8
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452797 AR Hose2 0452770 1 Cap, Fuel (Incl. 3)3 0452641 1 Gasket, Cap4 0450340 2 Bolt5 0452639 1 Tank, Fuel6 0452645 1 Foil, Tank7 0450361 2 Clip
8 0450363-300 AR Hose9 0450054 6 Clip10 0450366 1 Asm., Manual Fuel11 0450701 1 Bolt12 2520462 1 Filter, Fuel13 0452646 1 Clamp
11/04
B9
SUSPENSIONPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
6
1
6
5
4
2
7
E 2004 Polaris Sales Inc.
3
44
4
5
5
5
4
7
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452647 1 Spring, Suspension, Rear2 0452648 1 Shock, Suspension, Rear3 0452649 2 Bolt4 0450249 5 Nut
5 0450820 4 Bolt6 0452652 2 Spring, Suspension, Front7 0452654 2 Shock, Front
11/04
B10
WHEEL, FRONTPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
18
7
1
5
8
12
13
1110
15
14 16
17
19
E 2004 Polaris Sales Inc.
4
9
23
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5133341 2 Spacer2 3610093 2 Seal, Oil3 3514528 2 Bearing4 5133343 2 Spacer5 5133294 2 Hub, Wheel6 5133343 4 Stud7 3514527 2 Bearing8 3610090 2 Seal, Oil9 5133342 2 Spacer10 0452664 2 Spacer
11 0452657 2 Rim, Front12 0452656
045278822
Tire (Maxis, 21x7-10)Tire (Duro)
13 7542459 8 Nut14 7555633 2 Washer, Flat15 7542712 2 Nut16 0450395 2 Pin, Cotter17 0452661 2 Cap, Hub18 0452663 2 Washer19 0450401 2 Valve, Rim
11/04
B11
WHEEL, REARPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
3
2
4
1
9
6
8
5
7
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452679 8 Nut2 0452675 2 Rim, Wheel3 0452677
045267611
Hub, Wheel, LHHub, Wheel, RH
4 045267404527860452787
222
Tire, Rear (Maxxis, 20x11-9)Tire, Rear (Duro, 20x10-9)Tire, Rear (Maxxix, 20x10-9)
5 0452671 2 Washer6 0450395 2 Pin, Cotter7 0452669 2 Nut, Castle8 0452661 2 Cap, Hub9 0450401 2 Valve, Rim
11/04
B12
BRAKE, FRONTPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
1
2
34
5
8
10
1112
13
3
8
3
E 2004 Polaris Sales Inc.
15
14
16
9
7
6
67
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1910590 1 Asm., Master Cylinder, RH2 2202409 1 Kit, Master Cylinder Clamp3 5410988 6 Seal4 4010758 1 Switch, Pressure5 1910884 2 Line, Front Brake, J/B Crimped6 7512325 8 Bolt7 5247752 2 Disc, Brake8 1910499 2 Bolt, Banjo
9 7542122 1 Nut, Nylok10 1910689 2 Asm., Caliper11 7558402 4 Washer, Flat12 7552901 4 Washer, Spring Lock13 7512365 4 Screw14 5435861 2 Retainer, Brake Line, Front15 7517396 2 Screw16 7512297 1 Screw
11/04
B13
BRAKE, REARPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
3
6
1
5
2
4
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452686 2 Spring, Brake Lever2 0452680 1 Cable, Hand Brake, Rear3 0452687 1 Switch, Brake
4 0452682 1 Cable, Foot Brake, Rear5 0450719 1 Pin, Cotter6 0452684 1 Lever, Brake, Foot
11/04
B14
HANDLEBARPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
10
8
14
2
15
5
19
7
11
3
1
17
9
13
16
18
4
6
E 2004 Polaris Sales Inc.
12
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452683 2 Grip, Handlebar2 0452696 1 Control, Throttle3 0450622 2 Bolt4 0452694-070 1 Pod, Handlebar, Black5 0452699 4 Bolt6 0452695 1 Bracket, Pod7 0452688 2 Clamp, Handlebar, Upper8 0452681 1 Asm., Handlebar9 0452693 1 Asm., Switch, LH10 0450836 1 Sensor, Brake
11 0450807 1 Bolt, Brake Lever12 0452692 1 Cam, Brake Lock13 0452691 1 Lever, Brake, LH14 0450692 1 Lock, Brake, Hand15 0450808 1 Nut16 0452690 1 Asm., Brake Lever, LH17 0452685 2 Clamp, Handlebar, Lower18 0452689 1 Cable, Throttle19 0452697 1 Choke, Cable, Manual
11/04
C1
AXLE, REAR WHEELPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
14
13
1211
16
1747
E 2004 Polaris Sales Inc.
10
965 7
32
1
15
18
4
1920
3436
37
27
38
3029
28
31
26
25
4142
434445
11
65
38
3029
2827
65
5
32
46
35
33
32
2124
2223
40
39
48
8
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452718 1 O-Ring2 0452717 2 Retainer3 0452715 3 Bearing4 0452724 1 Arm, Brake, Rear5 0452126 6 Bolt6 0452712 3 Washer, Flat7 0452714 4 Stud, Bolt8 0452775 1 Cap, Rubber9 0452711 1 Plate, Brake10 0452710 1 O-Ring11 0452708 2 O-Ring12 0452705 1 Asm., Brake Shoe, Rear13 0452702 1 Drum, Brake14 0452701 1 Cover, Rear15 0452720 6 Bolt16 0452700 1 Seal17 0452706 1 Shaft, Brake, Rear18 0452722 1 Spring19 0451704 1 Bolt20 0450150 1 Nut21 0452752 1 Seal, Oil22 0452368 1 Cap, Oil Fill23 0452371 1 O-Ring, Drain Plug24 0452754 1 Asm., Cap (Incl. 22,23)
25 0452738 1 Gearcase26 0452737 1 Seal, Oil27 0452730 2 Bearing28 0452734 2 Shim29 0452733 2 Shim30 0452732 2 Shim31 0452736 1 Gear, Ring32 0452751 1 Axle33 0452749 6 Bolt34 0452726 1 Seal, Oil35 0452747 2 Bolt36 0452728 1 Cover, Gearcase37 0452729 1 Gasket, Cover38 0452731 2 Asm., Shim39 0452757 1 Plate, Gearcase40 0452756 4 Spacer, Rubber41 0452739 1 Bearing, Needle42 0452740 1 Gear, Pinion43 0452741 1 Shim44 0452742 1 Bearing45 0452743 1 Nut46 0452745 1 Seal, Oil47 0452698 1 Hose, Breather48 0452758 1 Clip, Cir
11/04
C2
STEERINGPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
23
9
14
1617
1819
12
20
8
2115
4
5
6
7
1
E 2004 Polaris Sales Inc.
1
6
6
20
13
22
1110
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0452709 2 Bushing, Steering, Upper2 0452704 1 Cap, Rubber3 0452713 1 Bracket, Bushing, Upper4 0452716 2 Bolt, Carriage5 0452703 1 Post, Steering6 0450719 8 Pin, Cotter7 0450502 4 Nut, Castle8 0450279 4 Washer9 0452783 2 Asm., Tie Rod (Incl. Ring and Grommet)10 7542432 2 Nut, Jam11 7061113 2 Rod End, RH12 7555806 2 Washer, Flat
13 7542439 2 Nut, Castle14 1822643
182264411
Asm., Steering Knuckle, LHAsm., Steering Knuckle, RH
15 0452707 2 Flangette16 0452719 1 Spacer, Ring17 0452671 1 Washer18 0452669 1 Nut, Castle19 0450395 1 Pin, Cotter20 0450882 4 Nut21 0450261 1 Bearing, Ball22 0452776 2 Bolt, Carriage
11/04
C3
HEADLIGHT/TAILLIGHTPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
4
8
5
109
6
E 2004 Polaris Sales Inc.
3
721
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
0452721 1 Asm., Headlight (Incl. 8-10)0451691 1 Asm., Taillight (Incl. 3-7)
1 0450880 2 Nut2 0450041 2 Washer3 0451800 1 Socket, Taillight4 0451799 1 Gasket, Taillight
5 0450995 1 Bulb, Taillight6 0451709 1 Lens, Taillight7 0451801 2 Bolt8 0452725 1 Socket, Headlight9 0452727 1 Bulb, Headlight10 0452723 1 Lens, Headlight
11/04
C4
ELECTRICAL PARTSPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
8
15
5
18
714
11
17
12
14 13
10 9
6
3
E 2004 Polaris Sales Inc.
12
16
2
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 0450701 4 Bolt2 0452760 1 Rectifier/Regulator3 0452764 1 Bracket, Electrical4 0452759 1 Pad, Rubber5 0452310 1 Asm., CDI Unit (Incl. 4)6 0452762 1 Pouch, Tool7 0450742 1 Strap8 0452744 1 Fuse, Main Harness9 0452761 1 Asm., Starter Relay
10 0452735 1 Asm., Harness, Main Wire11 0450721 11 Strap12 0452746 1 Battery13 0452767 1 Asm., Battery Cable14 0452766 1 Indicator, Reverse15 0452765 1 Indicator, Neutral16 0452763 1 Bolt17 0452309 1 Asm., Ignition Coil18 0452748 1 Asm., Switch, Main
11/04
C5
DECALSPHOENIX 200 A05PB20AA and PHOENIX 200 A05PB20AB
9
52
14
16
15
6
17
4
1
RH
LH
1310
8
E 2004 Polaris Sales Inc.
11
7
3
12
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 71733107173311
11
Decal, Reflector, Red, LHDecal, Reflector, Red, RH
2 71730677173068
11
Decal, Cab, Rear, LHDecal, Cab, Rear, RH
3 7173066 1 Decal, “POLARIS”, Rear4 7173062
717306311
Decal, “PHOENIX”, Tank Side, LHDecal, “PHOENIX”, Tank Side, RH
5 71730647173065
11
Decal, “POLARIS”, Front, LHDecal, “POLARIS”, Front, RH
6 7172559 1 Decal, Age Warning, 16, ATV7 5435424 1 Badge, 50 Years8 7172665 1 Decal, Warn, Disc
9 7078465 1 Logo, Polaris Star10 7079906 1 Decal, Override Switch11 7173308
717330911
Decal, Reflector, Amber, LHDecal, Reflector, Amber, RH
12 7173126 1 Decal, Automatic, Clutch Cover13 7170007 1 Decal, 4 Stroke Carb/Filter14 7172566 1 Decal, Passenger Warning15 7173302 1 Decal, Tire Pressure16 7173313 1 Decal, Warning, No Step, Clutch Cover17 7172560 1 Decal, Warning, General, CPSC
11/04
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PRINTED IN THE USA PARTS MANUAL PN 9919965 and MICROFICHE PN 9919966 11/04
