Polaris Sawtooth User Manual

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.

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

S Snowmobiles 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 produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a F actory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

PrintedinTaiwanandinU.S.A.

2006 Sawtooth Owner’s Manual P/N 9920278

TABLE OF CONTENTS

VEHICLE IDENTIFICATION NUMBERS 4........

SAFETY 5...................................

FEATURES A ND CONTROLS 36...............

OPERATION 46..............................

EMISSION CONTROL SYSTEMS 64............

MAINTENANCE AND LUBRICATION 65.........

SPECIFICATIONS 100........................

POLARIS PRODUCTS 103.....................

TROUBLESHOOTING 104.....................

WARRANTY 107..............................

MAINTENANCE LOG 111......................

INDEX 114...................................

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):

SAFETY

Operator Safety

WARNING

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.

Read and understand your owner’s manual and all warnings before operating a Polaris ATV.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV

RiderCourse

This training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse

or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance program outlined in your owner’s manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

available to you and your eligible family members.

.Youwerealso

by calling ATV Enrollment Express at (800) 887-2887

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.

Signal Words and Symbols

The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual.

S Read this manual and all labels carefully, and follow the operating

procedures described.

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. S Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified safety training course.

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV. S Never operate at excessive speeds. Travel at speeds appropriate for

the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts. S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation.

. Contact ATV

SAFETY

Operator Safety

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manu-

al. P ractice t urning 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.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascend a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn t he ATV around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

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 procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

S Wet brakes may have reduced stopping ability. Test your brakes after

leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

S Always check for obstacles or people behind the ATV before operat-

ing in reverse. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.

S Always use the size and type of tires specified for your ATV, and

always maintain tire pressure as recommended.

SAFETY

Operator Safety

S Never modify an ATV through improper installation or use of acces-

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

S Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use or accidental starting.

FOR MORE INFORMA TION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-3764.

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. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper

instruction. WHAT CAN The risk of an accident is greatly

increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE Beginning and inexperienced operators should complete the ATV

RiderCourse

then regularly practice the skills learned in the course and the operating techniques described in the Owner’s Manual.

For more information about the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org

HAPPEN

HAZARD

offered by Polaris through the SVIA. They should

WARNING

POTENTIAL HAZARD Failure to follow the age

recommendations for this ATV. WHAT CAN Severe injury and/or death could occur

if a child under the minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.

HOW TO AVOID THE No one under the age of 16 should operate a Polaris ATV.

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contact ATV

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN 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 Never carry a passenger. The purpose of the long seat is to

allow the operator to shift position as needed during operation. It is not intended for carrying passengers.

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WARNING

POTENTIAL HAZARD Carrying a passenger on one of the

racks. WHAT CAN A passenger riding on a rack could be

ejected from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death.

HOW TO AVOID THE Never allow passengers to ride on one of the racks.

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HAZARD

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating an ATV on paved

surfaces, including sidewalks, paths, parking lots, and driveways.

WHAT CAN 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.

HOW TO AVOID THE Avoid operating the ATV on pavement. If it’s unavoidable, travel

slowly and avoid sudden turns or stops.

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HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV on

public streets, roads or highways.

WHAT CAN The ATV could collide

with another vehicle. HOW TO AVOID THE Never operate the ATV on any

public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways.

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Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without wearing an

approved helmet, eye protection and protective clothing.

WHAT CAN Operating an ATV without an approved

helmet increases the risk of a severe head injury or death in the event of an accident.

Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.

HOW TO AVOID THE Always wear an approved helmet that

fits properly. Always wear eye protection (goggles or

face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.

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HAZARD

WARNING

POTENTIAL HAZARD Operating the ATV after consuming

alcohol or drugs. WHAT CAN Consumption of alcohol and/or drugs

could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE Never consume alcohol or drugs before or while operating an

ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV at

excessive speeds. WHAT CAN Excessive speed increases

the operator’s chance of losing control of the ATV, which can result in an accident.

HOW TO AVOID THE Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

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WARNING

POTENTIAL HAZARD Attempting wheelies, jumps and

other stunts. WHAT CAN Attempting stunts increases the

chance of an accident, including an overturn.

HOW TO AVOID THE Never attempt wheelies, jumps, or

other stunts. Avoid exhibition driving.

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Operator Safety

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV . WHAT CAN Poor maintenance increases the possibility of an accident or

equipment damage. HOW TO AVOID THE Always inspect your ATV

before each use to make sure it’s in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in the owner’s manual.

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WARNING

POTENTIAL HAZARD Removing hands from the handlebars

or feet from the footrests during operation.

WHAT CAN Removing even one hand or foot can

reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

If the operator’s foot is not firmly planted on the footrest, it could come into contact with the rear wheels and lead to accident or injury.

HOW TO AVOID THE Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating the ATV on unfamiliar terrain.

WHAT CAN Unfamiliar terrain may contain

hidden rocks, bumps, or holes that could cause loss of control or overturn.

HOW TO AVOID THE Travel slowly and use extra caution

when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

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WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating on excessively rough, slippery or loose terrain.

WHAT CAN Operating on excessively

rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.

HOW TO AVOID THE Do not operate on excessively rough, slippery or loose terrain

until you’ve learned and practiced the skills necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of

control and lead to a collision or overturn. HOW TO AVOID THE 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. Never turn at excessive speed.

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HAZARD

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN The vehicle may overturn. HOW TO AVOID THE Never operate on hills too steep for the

ATV or for your abilities. Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

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>25_

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if

the ATV and/or the operator fall through the ice.

HOW TO AVOID THE Never operate the ATV on a frozen

body of water.

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HAZARD

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing could

cause loss of control or overturn. HOW TO AVOID THE

Always follow proper procedures for climbing hills as described in the owner’s manual.

Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25_. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other side of the hill.

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<25_

Operator Safety

WARNING

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN Improperly descending a hill could

cause loss of control or overturn. HOW TO AVOID THE

Always follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is required when braking while traveling downhill. See page 56.

Always check the terrain carefully before descending a hill. Shift your weight backward. Never travel down a hill at

high speed. Avoid traveling down a hill at

an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible. Never travel backwards down a hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and turning

on hills. WHAT CAN Improperly crossing or

turning as hills could cause loss of control or overturn.

HOW TO AVOID THE 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. See page 58. Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill. When crossing the side of a Always follow proper procedures as described in the owner’s

manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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hill:

Operator Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or improperly

dismounting while climbing a hill. WHAT CAN The vehicle could overturn. HOW TO AVOID THE

Maintain steady speed when climbing a hill.

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SAFETY

If all forward speed is Keep your weight uphill. Gradually apply the front brakes (right lever). When fully stopped, apply the rear brakes and lock the parking

brake. Dismount on uphill side, or to either side if ATV is pointed straight

uphill. Turn the ATV around and remount, following the procedure described in the owner’s manual. See page 58.

If the ATV begins rolling Keep weight uphill. Apply the front brake gradually . Never apply the rear brake while rolling backwards. Never apply engine power. When fully stopped, apply the rear brake as well, and then lock

the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight

uphill. Turn the ATV around and remount, following the procedure described in the owner’s manual. See page 58.

lost:

backwards:

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Operating over obstacles could

cause loss of control or overturn. HOW TO AVOID THE Before operating in a new

area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner’s manual.

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WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN Skidding or sliding can cause loss

of control. If the tires regain traction

unexpectedly, the ATV could overturn.

HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

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Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or

fast-flowing water. WHAT CAN Tires may float, causing loss of traction

and loss of control, which could lead to an accident or overturn.

HOW TO AVOID THE Avoid operating the ATV through deep

or fast-flowing water. If it’s unavoidable to enter water that exceeds the recommended maximum depth (see page 60), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN The ATV could collide with an

obstacle or person, resulting in severe injury.

HOW TO AVOID THE Before shifting into reverse

gear, always come to a complete stop and check for obstacles or people behind the ATV. When it’s safe to proceed, back slowly.

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WARNING

POTENTIAL HAZARD Operating this ATV with improper tires,

or with improper or uneven tire pressure.

WHAT CAN Use of improper tires, or operation of

the ATV with improper or uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE Always use the size and type of tires

specified for the ATV. Always maintain proper tire pressure

as specified.

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HAZARD

Operator Safety

WARNING

POTENTIAL HAZARD Operating the ATV with improper

modifications. WHAT CAN Improper installation of accessories or

modification of the ATV may cause changes in handling which could lead to an accident.

HOW TO AVOID THE Never modify the ATV through improper

installation or use of accessories. All parts and accessories added to the vehicle must be genuine 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.

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SAFETY

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