2006 Polaris Sawtooth Owners Manual

2006 Polaris Sawtooth Manual

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2006 Polaris Sawtooth manual content summary:

  • 2006 Polaris Sawtooth | Owners Manual - Page 1
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    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.
  • 2006 Polaris Sawtooth | Owners Manual - Page 4
    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 Factory Certified Master
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    reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in Taiwan and in U.S.A. 2006 Sawtooth Owner's Manual P/N 9920278 2
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    TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS ...4 SAFETY ...5 FEATURES AND 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 3
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    4
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    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. 1 2 Vehicle Model Number: Frame VIN (1): Engine Serial Number (2): 5
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    fail to take proper precautions. Read and understand your owner's manual and all warnings before operating a Polaris ATV. Age Restrictions This priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible
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    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 damage to the vehicle. NOTE: A note will alert you to important information or instructions. 7
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    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
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    to changing terrain conditions. S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. S Always have the ATV
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    . 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
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    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
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    Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800
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    Operator Safety 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
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    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
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    Operator Safety 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. Operating
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    SAFETY Operator Safety WARNING POTENTIAL HAZARD 20 30 Operating the ATV at 40 excessive speeds. 10 WHAT CAN HAPPEN 50 0 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
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    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. WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand
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    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
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    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. Never turn at excessive speed. WARNING POTENTIAL HAZARD Operating on excessively
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    loss of control or overturn. HOW TO AVOID THE HAZARD < 25_ 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
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    of control or overturn. HOW TO AVOID THE HAZARD 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
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    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 hill: Always
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    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 backwards: Keep weight uphill. Apply the front brake gradually. Never apply the rear brake while rolling
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    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. WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction
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    Operator Safety 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-
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    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
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    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. 27
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    ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking. Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. See pages 52-53. 2/3 1/3 1/3 2/3 28
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    injury or death. Always remove the ignition key when the vehicle is not in use. WARNING After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems. WARNING Safe operation of
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    the decals and other warnings on the ATV carefully. If any of the decals shown in this manual differ from the decals on your 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
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    Safety Decals and Locations SAFETY WARNING 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. 7172559 B WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate
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    terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information. 7172664 E S Operation of this vehicle ATTENTION S Specific without the air filter carburetor jetting element will severely damage
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    PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS. OVERRIDE SWITCH Reverse Speed is limited. Reverse override is controlled by the override switch. See your Owner's Manual. 7079906 33
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    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
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    Fuel Safety 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
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    FEATURES AND CONTROLS Electrical Switches 1 2 5 4 3 1. Light Switch/Hi-Lo Beam Control - The lights won't turn on unless the main key switch is on. 2 2. Engine Stop Switch - The engine will not start or run when the switch is in the OFF position. Its purpose is to provide the operator with a quick
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    Electrical Switches FEATURES AND CONTROLS 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
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    to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks
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    Brakes Master Cylinder FEATURES AND CONTROLS B A Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (A) is located on the right handlebar. View the fluid level through the indicator window (B) on the top of the master cylinder. This eye will appear
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    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. THIS
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    Brakes Foot Brake FEATURES AND CONTROLS 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
  • 2006 Polaris Sawtooth | Owners Manual - Page 45
    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. Squeeze the left brake lever (1). 2. Push
  • 2006 Polaris Sawtooth | Owners Manual - Page 46
    Choke Fuel Filter FEATURES AND CONTROLS The choke assists in starting a cold engine. See page 48 for correct choke and throttle settings during starting. 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
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    FEATURES AND CONTROLS 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. Automatic Transmission Gear Selector A R N F CAUTION
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    AND CONTROLS 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. Fold out the kick-start lever on the left
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    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. Careful
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    Pre-Ride Inspection OPERATION 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. Pre-Ride Checklist Item Brake system / lever travel Brake fluid Foot brake Front
  • 2006 Polaris Sawtooth | Owners Manual - Page 51
    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
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    Starting the Engine 6. Squeeze the left brake lever. NOTE: OPERATION 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. Activate the starter for a maximum of five seconds,
  • 2006 Polaris Sawtooth | Owners Manual - Page 53
    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. Slowly squeeze the
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    Making Turns OPERATION 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. 2. Practice turning at slow speeds before attempting to turn at
  • 2006 Polaris Sawtooth | Owners Manual - Page 55
    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. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as
  • 2006 Polaris Sawtooth | Owners Manual - Page 56
    extra caution. Always attach the tow load to the hitch point designated for your vehicle. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. S USE EXTREME CAUTION when
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    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.
  • 2006 Polaris Sawtooth | Owners Manual - Page 58
    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. 55
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    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
  • 2006 Polaris Sawtooth | Owners Manual - Page 60
    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. If sidehilling is necessary, follow these precautions: 1. Avoid hills with excessively slippery
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    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. If the vehicle stalls while climbing a hill, never back down the hill! Use the K-turn to turn around. 8 ft. (2.4 m) 58
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    Driving Safely K-Turn/Turning Around on a Hill 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. OPERATION Squeeze the front (right) brake lever to stop the vehicle. Keep your weight uphill. Lock the parking brake. Leave the transmission in forward gear and shut off the engine. Dismount on the uphill side of the
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    the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine. If your vehicle becomes immersed, and it's impossible to take it to a dealer before starting it, follow the steps described
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    Driving Safely Driving Over Obstacles OPERATION 1. 2. 3. 4. Always check for obstacles before operating in a new area. Be alert. Watch the terrain. Use extra caution. Never operate over large obstacles. Avoid hazards such as logs, rocks and low branches. WARNING Severe injury or death can result
  • 2006 Polaris Sawtooth | Owners Manual - Page 65
    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. 6. Never
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    Driving Safely Parking on an Incline OPERATION 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. Turn the fuel valve off. 63
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    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. Operation of
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    upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed
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    MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Perform all services at whichever maintenance interval is reached first. (whichever comes first) Hours procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these
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    (1600) " Cooling hoses " Engine mounts Exhaust muffler/ pipe J Spark plug E " J Ignition Timing Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these
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    J Front wheel J Brake fluid Spark arrestor Idle speed J Toe adjustment Headlight aim " Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service J Have an authorized Polaris dealer perform these
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    Lubrication Guide MAINTENANCE AND LUBRICATION Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Items not listed in
  • 2006 Polaris Sawtooth | Owners Manual - Page 73
    MAINTENANCE AND LUBRICATION Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Always change the oil filter whenever changing oil. Performance Synthetic 4-Stroke (PS-4) Oil Polaris recommends the use of Performance
  • 2006 Polaris Sawtooth | Owners Manual - Page 74
    Engine Oil Check MAINTENANCE AND LUBRICATION Maintain the oil level at the center of the sight glass. Do not overfill. 1. Position the vehicle on a level B surface. 2. View the oil level through the sight glass (A) on the right side of the vehicle. NOTE: A rising oil level between checks in cool
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    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. Do not allow the vehicle to be
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    Oil and Filter Change MAINTENANCE AND LUBRICATION 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
  • 2006 Polaris Sawtooth | Owners Manual - Page 77
    MAINTENANCE AND LUBRICATION Gearcase Specification Chart Gearcase Transmission Rear Gearcase Lubricant Premium AGL Synthetic Gearcase Lubricant Premium ATV Angle Drive Fluid 18.6 oz. (550 ml) 4 oz. (120 ml) Capacity Drain/Check Plug Torque 18 ft. lbs. (24 Nm) 18 ft. lbs. (24 Nm) Fill Plug Torque N/A
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    Rear Gearcase Oil MAINTENANCE AND LUBRICATION Always check and change the rear gearcase oil at the intervals outlined in the 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.
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    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. Headlight Lamp Replacement To access the assembly from the front, remove the front cover and
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    Lights MAINTENANCE AND LUBRICATION 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. Apply
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    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion
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    . A 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the transmission, follow the procedure on
  • 2006 Polaris Sawtooth | Owners Manual - Page 83
    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
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    procedures. See your dealer as outlined in the owner's manual. This CVT system is intended for use on Polaris products when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on service as soon as possible. 81
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    not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 83 before installing the battery. 1. Ensure that the battery is fully charged. 2. Set the battery in the battery holder. 3. Connect and
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    or less until the battery voltage is 12.8 or greater. NOTE: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. WARNING An overheated battery may explode, causing severe
  • 2006 Polaris Sawtooth | Owners Manual - Page 87
    MAINTENANCE AND LUBRICATION Battery NOTE: Battery Charging Always verify battery condition before and 1-2 hours after the end of charging. Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) State of Charge 100% 12.8-13.0 volts None, check at
  • 2006 Polaris Sawtooth | Owners Manual - Page 88
    Adjustments Brakes (Front) MAINTENANCE AND LUBRICATION The front brakes are hydraulic disc brakes. These brakes are self-adjusting. The following checks are recommended to keep the hydraulic brake system in good operating condition. Check more often if brakes are used heavily under normal
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    , turn the adjuster nuts (A) at the rear brake drum. .40″-.80″ (10-20 mm) A Brake Lever Travel (Rear) Service the brakes when brake lever travel reaches 2 1/2″ (65 mm). Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting. 2 1/2″ (65 mm
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    the front rim (C). Rear measurement should be 1/16″ - 1/8″ (2-3 mm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. 87
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    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. Rear Spring The rear shock absorber spring is adjusted by
  • 2006 Polaris Sawtooth | Owners Manual - Page 92
    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. Handlebars The handlebars can be adjusted for rider preference. 1. Remove the handlebar cover. 2. Loosen (do not remove) the four handlebar bolts
  • 2006 Polaris Sawtooth | Owners Manual - Page 93
    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
  • 2006 Polaris Sawtooth | Owners Manual - Page 94
    Adjustments MAINTENANCE AND LUBRICATION 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
  • 2006 Polaris Sawtooth | Owners Manual - Page 95
    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. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace
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    wear and vehicle handling, which can result in serious injury or death. 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. 2. Lock the parking
  • 2006 Polaris Sawtooth | Owners Manual - Page 97
    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 tire pressure as outlined in this owner's manual. When replacing a tire always use original equipment size and type. 94
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    Adjustments MAINTENANCE AND LUBRICATION 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
  • 2006 Polaris Sawtooth | Owners Manual - Page 99
    MAINTENANCE AND LUBRICATION Cleaning and Storage Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. See page 103 for the part numbers of Polaris
  • 2006 Polaris Sawtooth | Owners Manual - Page 100
    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. 2. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse
  • 2006 Polaris Sawtooth | Owners Manual - Page 101
    in the maintenance section of the service or owner's manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports
  • 2006 Polaris Sawtooth | Owners Manual - Page 102
    tie the frame of the ATV to the transporting unit securely using suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting the unit. 5. Place the transmission in gear and lock the parking brake. 99
  • 2006 Polaris Sawtooth | Owners Manual - Page 103
    SPECIFICATIONS Capacities 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
  • 2006 Polaris Sawtooth | Owners Manual - 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
  • 2006 Polaris Sawtooth | Owners Manual - Page 105
    SPECIFICATIONS Jetting Chart ALTITUDE Meters (Feet) 0-1800 (0-6000) 1800-3700 (6000-12000)* AMBIENT TEMPERATURE Below 40° F (Below 5° C) 108 92.5 +40°F and above (+5°C and above) 108 90 *Change to a #40 pilot jet if operating the ATV at these higher elevations. Clutching Chart Altitude Meters (
  • 2006 Polaris Sawtooth | Owners Manual - Page 106
    POLARIS PRODUCTS Part No. 2870791 2874865 2874866 2873602 2873603 2871653 2872276 2870465 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872889 2871326 2870652 2870990 2872893 2871956 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil
  • 2006 Polaris Sawtooth | Owners Manual - Page 107
    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
  • 2006 Polaris Sawtooth | Owners Manual - Page 108
    plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure TROUBLESHOOTING Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris
  • 2006 Polaris Sawtooth | Owners Manual - Page 109
    TROUBLESHOOTING Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plugs Worn or
  • 2006 Polaris Sawtooth | Owners Manual - Page 110
    preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not
  • 2006 Polaris Sawtooth | Owners Manual - Page 111
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2006 Polaris Sawtooth | Owners Manual - Page 112
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2006 Polaris Sawtooth | Owners Manual - Page 113
    WARRANTY U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at
  • 2006 Polaris Sawtooth | Owners Manual - Page 114
    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 111
  • 2006 Polaris Sawtooth | Owners Manual - Page 115
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 112
  • 2006 Polaris Sawtooth | Owners Manual - Page 116
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 113
  • 2006 Polaris Sawtooth | Owners Manual - Page 117
    60 Driving Uphill ...55 K K-Turn ...58-59 Key Switch ...36 Kick-Start Lever ...45 L Light Switch ...36 Lights ...76-77 Lubrication Guide ...69 E Electrical Switches ...36-37 Emission Control Systems ...64 Emissions Warranty ...110 Engine Fogging ...98 M Main Switch ...36 Maintenance Log ...111
  • 2006 Polaris Sawtooth | Owners Manual - Page 118
    38 Tire Tread Depth ...94 Toe Alignment ...87 Towing ...52-53 Transmission Gear Selector ...44 Transmission Oil ...74 Transporting an ATV ...99 Troubleshooting ...104-106 Turning Around on a Hill ...58-59 P Parking Brake ...42 Parking on an Incline ...63 Periodic Maintenance Chart ...65-68 Polaris
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