2007 Polaris Phoenix 200/Sawtooth 200 ATV Service & Repair Manual (P/N 9920849)

This Polaris service manual covers the 2007 Phoenix 200 and Sawtooth 200 with the ES20PFE engine. Publication P/N 9920849 brings together shared service procedures and model-specific bodywork, lighting and driven-clutch information.

• Engine repair: Engine removal, cylinder-head and crankcase disassembly, valve-seat reconditioning, piston inspection, camshaft timing and reassembly procedures.

• Fuel system: Keihin carburetor cleaning, float adjustment, needle-and-seat leak testing, fuel-level checks and troubleshooting for lean mixtures, rich running and poor idle.

• CVT and transmission: Drive and driven clutch service, belt inspection, overheating diagnosis, shift-mechanism inspection and transmission output-shaft shimming.

• Final drive: Front hub bearing replacement, rear axle inspection, swingarm service and rear gearcase disassembly, inspection and bevel-gear shimming.

• Brakes and chassis: Hydraulic brake bleeding, caliper repair, rear drum service, steering inspection, ball-joint replacement and suspension adjustment.

• Electrical diagnosis: Ignition, charging and starter test charts, Electronic Throttle Control checks, component resistance specifications and separate Phoenix and Sawtooth wiring diagrams.

The internal engine measurements and specialist tooling make this manual suited to experienced ATV technicians; Polaris specifies trained Master Service Dealer technicians for CVT maintenance and repair.

Engine Inspection, Timing and Lubrication

The engine chapter distinguishes components accessible in the frame from work requiring engine removal. Cylinder honing and valve-seat reconditioning are covered, while the crankshaft and oil pump are treated as replacement assemblies.

An Oil Flow Diagram traces the lubrication circuit. Camshaft Timing — Method 1 and Method 2 illustrate timing with the stator housing removed or installed.

Flywheel service identifies puller PA-47308 and warns that damage to the crankshaft oil-passage plunge joint can cause loss of oil pressure and severe engine damage.

Carburetor Service and Scheduled Maintenance

Carburetor exploded views and jetting charts accompany explanations of the pilot, needle and main circuits. The inspection procedures address worn metering components, float position and inlet-valve sealing, with symptom lists for hard starting, hesitation and erratic idle.

Maintenance schedules distinguish normal operation from severe use. Air-filter and pre-filter service, spark-arrestor cleaning, engine oil changes and rear gearcase lubrication are covered alongside component-specific torque references.

Clutch Differences and Shaft-Drive Repair

The Phoenix driven clutch has a torque-limiting spring-washer and ball-bearing stack that the Sawtooth does not use. Its service section documents component orientation and warns that the loose parts can separate during removal.

Clutch charts support the inspection and setup information. Transmission work extends to shift forks, dogs, bearings and the external shift detent, with Shaft Collar Tool PA-47309 identified for output-shaft service.

Rear gearcase shimming addresses bevel-gear backlash. The separate transmission output-shaft procedure sets pinion depth; that assembly has no backlash adjustment.

Bodywork, Steering and Brake Service

Separate body-removal sections distinguish Phoenix panels from Sawtooth racks and fascia. The general information section also identifies Vapor Silver and Matte Black frame paint codes.

Dual A-arm suspension coverage includes ball-joint pressing, steering-post assembly and shock replacement. Toe alignment and spring preload are adjustable; camber and caster are not.

Brake service covers front caliper inspection and rebuilding, disc wear checks, and the rear hand- and foot-brake linkage. The brake-noise troubleshooting table connects symptoms with faults such as restricted compensating ports and pistons that fail to return.

Support the ATV securely during elevated chassis work and follow the manual’s electrical-isolation precautions for the applicable procedure.

Ignition, Charging and Starting Faults

Ignition System Testing and Starter System Testing flowcharts organize the electrical checks. The ignition chart separates ETC and transmission-switch faults from coil or CDI faults, helping technicians investigate a no-spark complaint before replacing the CDI module.

Peak Reading Adaptor PV-39991 is specified for CDI and pulse-coil output tests. Charging coverage includes stator testing, key-off current draw and the charging-system break-even test. Starter-motor coverage centers on diagnosis and complete-motor replacement.

A Preview of Valve, Fluid and Belt Specifications

These examples are a small selection of the service specifications provided for both models.

The ES20PFE valve data list 0.003 in. (0.07 mm) intake and exhaust clearance, checked with the cam lobes pointing down. Fluid references give an approximate engine oil capacity of 1.26 US qt. (1.2 L) and a transmission capacity of 18.6 oz. (550 ml).

The CVT inspection section lists a drive-belt width service limit of 0.708 in. (18 mm), alongside checks for uneven wear, glazing and contamination.

Text Search, Bookmarks and Wiring Detail

Navigation and diagram labels: Service text is searchable, and embedded bookmarks link to chapters, individual procedures, wiring diagrams and the index. Text within some embedded tables and the main wiring diagrams is not searchable. Small wiring labels require zooming for comfortable reading.

The download contains one printable, English-language 214-page PDF with nine service chapters. The total already includes the opening chapter-index page, eight Notes pages, two wiring-diagram pages and the four-page alphabetical index.