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Polaris Sawtooth Owner's Manual

Polaris 2006 atv owner's manual
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  • Page 3 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 4 S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever...
  • Page 5 Copyright 2005 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.

  • Page 6: Table Of Contents

    EMISSION CONTROL SYSTEMS MAINTENANCE AND LUBRICATION SPECIFICATIONS POLARIS PRODUCTS TROUBLESHOOTING WARRANTY ......

  • Page 8: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers in the spaces provided. Remove the spare key and store it in a safe place. If both keys are lost, the ignition switch must be replaced. Vehicle Model Number: Frame VIN (1): Engine Serial Number (2):...

  • Page 9: Safety

    Failure to follow the warnings contained in this manual can result in serious injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 10: Operator Safety

    Operator Safety Know Your Vehicle and Riding Area You are responsible for your personal safety, the safety of others and the protection of the environment. Read and understand your owner’s manual. It includes important information about Quadricycle safety. Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.
  • Page 11 S Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCourse S Never allow anyone under 16 years of age to operate this ATV.
  • Page 12 Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. S Always have the ATV inspected by an authorized Polaris dealer if it’s been involved in an accident. S Never operate on hills too steep for the ATV or for your abilities.
  • Page 13 SAFETY Operator Safety S Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special pro- cedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill.

  • Page 14: Equipment Modifications

    We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
  • Page 15 ATV safely and could be susceptible to accident or injury. HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. offered by Polaris through the SVIA. They should contact ATV <...
  • Page 16 SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 17 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury.
  • Page 18 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 19 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that’s proper for the terrain, visibility and operating conditions, and your experience.
  • Page 20 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it’s in safe operating condition.
  • Page 21 SAFETY Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 22 SAFETY Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds.
  • Page 23 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water.
  • Page 24 SAFETY Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner’s manual.
  • Page 25 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual.
  • Page 26 SAFETY Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If all forward speed is lost: Keep your weight uphill.
  • Page 27 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible.
  • Page 28 SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 29 SAFETY Operator Safety WARNING POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle or person, resulting in severe injury. HOW TO AVOID THE HAZARD Before shifting into reverse gear, always come to a complete stop and check for obstacles or people behind the ATV.
  • Page 30 Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.
  • Page 31 SAFETY Operator Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV.
  • Page 32 SAFETY Operator Safety WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

  • Page 33: Safety Decals And Locations

    ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
  • Page 34 Safety Decals and Locations Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. S Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.
  • Page 35 SAFETY Safety Decals and Locations IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 4 (27,6) REAR 3 (20,7) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 765 LBS. (348 KG) Reduce speed and allow greater distance for braking when carrying cargo.

  • Page 36: Override Switch

    Safety Decals and Locations Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER operate: ALWAYS: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ...

  • Page 37: Safe Riding Gear

    SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

  • Page 38: Fuel Safety

    Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

  • Page 39: Features And Controls

    FEATURES AND CONTROLS Electrical Switches 1. Light Switch/Hi-Lo Beam Control - The lights won’t turn on unless the main key switch is on. 2. Engine Stop Switch - The engine will not start or run when the switch is in the OFF position.

  • Page 40: Features And Controls

    Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. 5. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed limiter system.

  • Page 41: Throttle Lever

    Engine speed returns to idle when the lever is released. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle...

  • Page 42: Master Cylinder

    If the fluid level is low, add DOT 3 brake fluid. DO NOT OVERFILL. See page 103 for the part numbers of Polaris products. WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
  • Page 43 FEATURES AND CONTROLS Brakes WARNING Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time. Brake Lever (Right) Squeeze the right brake lever (1) toward the handlebar to apply the hydraulic front wheel brakes.

  • Page 44: Foot Brake

    Brakes Foot Brake The foot brake (1) is a mechanical rear wheel brake. The foot brake is located on the inside of the right footrest. Apply the brake with your right foot. This is identical to squeezing the left brake lever on the handlebar. NOTE: If the rear wheels slide while using the...

  • Page 45: Parking Brake

    FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1.

  • Page 46: Fuel Filter

    FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. See page 48 for correct choke and throttle settings during starting. Fuel Filter The in-line fuel filter should be replaced by your dealer after every 100 hours of operation, or annually. Do not attempt to clean the fuel filter. Fuel Tank The fuel tank filler cap (A) is located directly below the handlebar.
  • Page 47 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (A) is located on the right side of the vehicle. F: Forward Gear N: Neutral R: Reverse Whenever the ATV is left unattended, always place the transmission in gear and lock the parking brake.

  • Page 48: Kick-Start Lever

    Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Lock the parking brake. 3. Place the transmission in neutral. 1.

  • Page 49: Break-In Period

    OPERATION Break-In Period The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.

  • Page 50: Operation

    Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Item Brake system / lever travel Brake fluid Foot brake Front suspension Rear suspension...

  • Page 51: Starting The Engine

    OPERATION Cold Weather Operation for 4-Cycle Engines Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the crankcase, which can lead to engine damage. Any condensation must be drained.
  • Page 52 Starting the Engine 6. Squeeze the left brake lever. NOTE: The starter will not engage unless the rear brake is applied. Always squeeze and hold the left brake lever before attempting to start the engine. 7. Press the start button. 8.

  • Page 53: Driving Safely

    OPERATION Driving Safely Driving Procedures 1. Sit upright. Keep your feet on the footrests. Keep both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 54: Making Turns

    Driving Safely Making Turns 1. To make a turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.
  • Page 55 OPERATION Driving Safely Hauling Cargo and Towing Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals.
  • Page 56 Driving Safely Hauling Cargo and Towing WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death. Always follow these precautions when hauling cargo: S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

  • Page 57: Driving On Slippery Surfaces

    OPERATION Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions: 1. Slow down before driving onto slippery surfaces. 2. Use extra caution. 3. Be alert. Watch the trail. Avoid quick, sharp turns. NOTE: To correct a rear wheel skid, turn the handlebars in the same direction as the skid and shift body weight forward.

  • Page 58: Driving Uphill

    Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25_ maximum). 3. Avoid hills with excessively slippery or loose surfaces. 4. Keep your feet on the footrests. 5. Shift your weight uphill. 6.

  • Page 59: Driving Downhill

    OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive straight downhill. 2. Shift your weight rearward. 3. Slow down. 4. Never go down a hill at high speed. 5. Squeeze the (left- -hand) rear brake lever slightly to aid in slowing. Do not apply the front brakes.
  • Page 60 Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Avoid crossing the side of a hill (sidehilling) if possible.

  • Page 61: Turning Around On A Hill

    OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
  • Page 62 Driving Safely K-Turn/Turning Around on a Hill 1. Squeeze the front (right) brake lever to stop the vehicle. 2. Keep your weight uphill. 3. Lock the parking brake. 4. Leave the transmission in forward gear and shut off the engine. 5.

  • Page 63: Driving Through Water

    OPERATION Driving Safely Driving Through Water Follow these procedures when operating through water: 1. Check water depths and current before crossing. 2. Avoid operating in water deeper than the bottom of the footrests (A). If it’s unavoidable, travel slowly, balance your weight carefully and avoid sudden movements.

  • Page 64: Driving Over Obstacles

    Driving Safely Driving Over Obstacles 1. Always check for obstacles before operating in a new area. 2. Be alert. Watch the terrain. Use extra caution. 3. Never operate over large obstacles. 4. Avoid hazards such as logs, rocks and low branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 65: Driving In Reverse

    OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Avoid backing downhill. 2. Always check for obstacles or people behind the vehicle before backing. 3. Drive slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles.

  • Page 66: Parking On An Incline

    OPERATION Driving Safely Parking on an Incline Avoid parking on an incline. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 1. Place the transmission in gear and lock the parking brake. 2. Always block the rear wheels on the downhill side. 3.

  • Page 67: Emission Control Systems

    CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 68: Maintenance And Lubrication

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 111.

  • Page 69: Maintenance And Lubrication

    " Engine breather " filter (if equipped) Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) Pre-Ride Pre-Ride Pre-Ride...
  • Page 70 100 H Ignition Timing 100 H Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 500 (800) 500 (800)
  • Page 71 Idle speed Toe adjustment Headlight aim Perform these procedures more often for vehicles subjected to severe use. " E Emission-Related Service Have an authorized Polaris dealer perform these services. Maintenance Interval (whichever comes first) Miles (Km) 12 M 1000 (1600) Inspect for wear, routing, 12 M 1000 (1600) Inspect;...

  • Page 72: Lubrication Guide

    MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Engine Oil Brakes Transmission Rear Gearcase...

  • Page 73: Engine Oil

    See page 103 for the part numbers of Polaris products. Oil may need to be changed more frequently if Polaris oil is not used. Always use 0W50 oil. Follow the manufacturer’s recommendations for ambient temperature operation.

  • Page 74: Engine Oil Check

    MAINTENANCE AND LUBRICATION Engine Oil Check Maintain the oil level at the center of the sight glass. Do not overfill. 1. Position the vehicle on a level surface. 2. View the oil level through the sight glass (A) on the right side of the vehicle.

  • Page 75: Oil And Filter Change

    MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Always replace the oil and filter within a few hours of draining the oil.
  • Page 76 MAINTENANCE AND LUBRICATION Oil and Filter Change 7. Reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm). 8. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove. 9. Using a clean, dry cloth, clean the filter sealing surface on the crankcase.

  • Page 77: Transmission Oil

    1/4 and 3/4 on the sight glass. We recommend the use of Premium AGL Synthetic Gearcase Lubricant. Refer to the gearcase specifications chart on page 74. See page 103 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level surface.

  • Page 78: Rear Gearcase Oil

    Periodic Maintenance Chart beginning on page 65. Maintain the oil level at the bottom of the check plug hole. We recommend the use of Polaris Premium ATV Angle Drive Fluid. Refer to the gearcase specifications chart on page 74. See page 103 for the part numbers of Polaris products.

  • Page 79: Headlight Lamp Replacement

    MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they’ve cooled sufficiently.
  • Page 80 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws (A). 2. Remove the lens cover and set aside for reassembly. 3. Remove the lamp (B). 4.

  • Page 81: Spark Plugs

    CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.

  • Page 82: Vehicle Immersion

    MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

  • Page 83: Spark Arrestor Clean-Out

    MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out WARNING Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Wear eye protection and gloves. Never run the engine in an enclosed area.

  • Page 84: Cvt Drying

    Always follow all recommended maintenance procedures. See your dealer as outlined in the owner’s manual. This CVT system is intended for use on Polaris products only. Do not install it in any other product. Always make sure the CVT housing is securely in place during operation.

  • Page 85: Battery Removal

    MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

  • Page 86: Battery Charging

    NOTE: Battery charge can be maintained by using a Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. Battery...
  • Page 87 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action charger @ standard amps specified on top of battery)

  • Page 88: Brakes (Front)

    Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill. 2. Check the brake system for fluid leaks.

  • Page 89: Brakes (Rear)

    MAINTENANCE AND LUBRICATION Adjustments Brakes (Rear) Periodically measure the freeplay of the rear brakes. To adjust rear brake freeplay, turn the adjuster nuts (A) at the rear brake drum. (10-20 mm) Brake Lever Travel (Rear) Service the brakes when brake lever travel reaches 2 1/2″...

  • Page 90: Toe Alignment

    Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check the toe alignment of the vehicle.

  • Page 91: Steering Assembly

    Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.
  • Page 92 Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference.

  • Page 93: Carburetor/Idle Rpm

    MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.

  • Page 94: Throttle Cable Freeplay

    MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay The throttle cable adjuster is located at the right handlebar. 1. Slide the boots (A) off the inline cable adjuster sleeve (B). Loosen the adjuster locknut (C). 2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the thumb lever.

  • Page 95: Wheel Removal

    MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the specifications section of the owner’s manual beginning on page 100.

  • Page 96: Wheel Installation

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. Wheel Installation 1. Position the vehicle on a level surface.

  • Page 97: Front Wheel Hub Tightening

    Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (3 mm) or less.
  • Page 98 MAINTENANCE AND LUBRICATION Adjustments Air Filter Service 1. Remove the seat. 2. Release the clips and remove the air box cover (A). 3. Loosen the clamp and remove the filter. 4. Remove the pre-filter (B) from the main filter (C). Wash the pre-filter in soapy water, then rinse and let dry.

  • Page 99: Cleaning And Storage

    If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.

  • Page 100: Storage Tips

    It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer. Follow the instructions on the container for the recommended amounts.

  • Page 101: Engine Fogging

    MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 103 for the part numbers of Polaris products. Fluid Levels Inspect fluid levels and change fluids if necessary. S Transmission S Brake Fluid Engine Fogging Use Polaris Engine Fogging Oil. Follow label directions carefully.

  • Page 102: Transporting An Atv

    MAINTENANCE AND LUBRICATION Cleaning and Storage Transporting an ATV Follow these procedures when transporting an ATV. 1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off. 3. Be sure the fuel cap, oil cap and seat are installed correctly and securely.

  • Page 103: Specifications

    SPECIFICATIONS Gross Vehicle Weight Dry Weight Fuel Capacity Engine Oil Capacity Transmission Oil Rear Gearcase Oil Front Rack Rear Rack Tongue Weight Tow Capacity Turn Radius Ground Clearance Length Width Height Seat Height Wheel Base Engine Model Number / Type Lubrication Bore x Stroke Displacement...

  • Page 104: Specifications

    Drive System Type Shift Type Front Drive (ratio) Front Tires Rear Tires Front Suspension Rear Suspension Shock Adjustment Front Brake Rear Brake Foot Brake Park Brake Headlight Taillight Brake Light Battery DC Plug-In (Rear) Electric Start Windshield Neutral Indicator Reverse Indicator Tool Kit SPECIFICATIONS Drive System...

  • Page 105: Jetting Chart

    SPECIFICATIONS Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters (Feet) Below 40° F +40°F and above (Below 5° C) (+5°C and above) 0-1800 (0-6000) 1800-3700 (6000-12000)* 92.5 *Change to a #40 pilot jet if operating the ATV at these higher elevations. Clutching Chart Altitude Roller Weight Meters (Feet)

  • Page 106: Polaris Products

    Grease Gun Kit 2871329 Dielectric Grease (Nyogelt) Additives / Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2870990 DOT3 Brake Fluid Engine Degreaser 2872893 2871956 LOCTITE 565 Thread Sealant POLARIS PRODUCTS...

  • Page 107: Troubleshooting

    TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid connections Engine Turns Over, Fails to Start...

  • Page 108: Troubleshooting

    TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs See your Polaris dealer...
  • Page 109 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...

  • Page 110: Limited Warranty

    WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.

  • Page 111: Warranty

    HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to re- pair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 112 How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice...
  • Page 113 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.

  • Page 114: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...

  • Page 115: Maintenance Log

    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 116 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 117 INDEX Adjustments ....Age Restrictions ....Air Filter ..... Battery .

  • Page 118: Index

    Parking on an Incline ... Periodic Maintenance Chart Polaris Products ....Pre-Ride Inspection ... . .

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2006 sawtooth

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