Polaris 2006 Sawtooth Owner'S Manual Download Page 80

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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. Apply dielectric grease to the socket and install a new lamp.
5. Test the taillight/brakelight for proper operation.
6. Reinstall the lens cover.

Summary of Contents for 2006 Sawtooth

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Page 3: ...ed 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 The engine exhaust from this product contains chemicals kno...

Page 4: ...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...

Page 5: ...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...

Page 6: ...NTIFICATION 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...

Page 7: ...4...

Page 8: ...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...

Page 9: ...vailable to you and your eligible family members 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...

Page 10: ...ut 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...

Page 11: ...leted a certified safe ty 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 hi...

Page 12: ...ascend a hill Never climb hills with excessive ly 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 h...

Page 13: ...s be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control S Avoid operating the ATV through deep...

Page 14: ...ned 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...

Page 15: ...se and the operating techniques described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTEN...

Page 16: ...D 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 WARNING POTENTIAL HAZARD Carryin...

Page 17: ...loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING POTENTIAL HAZARD Operating...

Page 18: ...ID THE HAZARD 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 WARNING POTENTIAL HAZARD Oper...

Page 19: ...t 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 WARNING POTENTIAL HAZARD Attempting whe...

Page 20: ...ance 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...

Page 21: ...ert to changing terrain conditions WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough sl...

Page 22: ...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 steep hill...

Page 23: ...loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill...

Page 24: ...raveling 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 hil...

Page 25: ...t 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 crossin...

Page 26: ...ake 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 ro...

Page 27: ...es 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 WH...

Page 28: ...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 mai...

Page 29: ...nd check for obstacles or people behind the ATV When it s safe to proceed back slowly WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN...

Page 30: ...ling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Pol...

Page 31: ...andling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce...

Page 32: ...serious 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 da...

Page 33: ...nings 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...

Page 34: ...ARNING S Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed S Do not modify engine or clutch Doing so can cause part failure possible imbal...

Page 35: ...y on rough or hilly 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 WARNING...

Page 36: ...LWAYS 7172560 WARNING H MANUFACTURED IN TAIWAN DATE VIN THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI NiEST PAS DESTIN...

Page 37: ...stitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protecti...

Page 38: ...o not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run i...

Page 39: ...an emergency To stop the engine press the lower end of the rocker switch down to the OFF position Before starting the engine press the upper end of the switch down to the ON position 3 Main Key Switch...

Page 40: ...vere 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 To gain additio...

Page 41: ...rly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for...

Page 42: ...rvoir is level 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...

Page 43: ...r can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always test front brake lever travel and master cylinder fluid level before riding...

Page 44: ...TE If the rear wheels slide while using the foot brake reduce brake pedal pressure to brake the rear wheels without skidding WARNING Aggressively applying the rear brake when backing down a hill may c...

Page 45: ...rake lever 1 2 Push the park brake lock 2 down This will prevent the lever from returning to the released position 3 To release the parking brake lock squeeze and release the brake lever The parking b...

Page 46: ...the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to the specifications section beginning on page 100 for tank capacity Fuel Valve The fu...

Page 47: ...Gear N Neutral R Reverse Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehi...

Page 48: ...ake sure the stop switch and main key switch are on 3 Place your foot on the kick start Thrust your heel downward to crank the engine NOTE If the engine is cold use the choke as outlined on page 48 4...

Page 49: ...periods during the first three hours of use CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Never substitute or mix oil brands 1 Fill the fuel tank with gasoline...

Page 50: ...n Tires Inspect condition and pressure 94 Wheels fasteners Inspect ensure fastener tightness 93 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 71 Coolant level i...

Page 51: ...st contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface 2 Turn t...

Page 52: ...starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts 9 If the engine slows or stops position the choke lever half way...

Page 53: ...gine 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 throttle lever toward the handlebar to begin driving...

Page 54: ...e 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 faster speeds WARNING Turning at sha...

Page 55: ...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 low as possible When operating over rough or hilly terrain redu...

Page 56: ...e unstable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered secur...

Page 57: ...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 WARNING Failure to exercise care when operating...

Page 58: ...begins rolling downhill never apply engine power Never apply the rear brakes while rolling backwards 2 Gradually squeeze the right hand brake lever to engage the front brakes When fully stopped apply...

Page 59: ...rear brake lever slightly to aid in slowing Do not apply the front brakes 6 Avoid hills with excessively slippery or loose surfaces 7 Avoid going down a hill at an angle which can cause the vehicle t...

Page 60: ...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 or loose surfaces 2 Avoid c...

Page 61: ...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...

Page 62: ...uphill 6 Staying uphill of the vehicle turn the handlebars full left 7 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it...

Page 63: ...apply them lightly several times to allow friction to dry out the pads After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 65 The follow...

Page 64: ...e 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...

Page 65: ...erse always come to a complete stop and check for obstacles or people behind the vehicle When it s safe to proceed back slowly Avoid backing on inclines Avoid turning at sharp angles Do not use the ov...

Page 66: ...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 th...

Page 67: ...low by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this veh...

Page 68: ...ons Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be insp...

Page 69: ...if applicable Daily Check level daily change coolant every 2 years Headlamp tail lamp Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as nee...

Page 70: ...strength seasonally pressure test system yearly Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at one month Oil filter change 100 H 6 M 1000 1600 Replace with oil change J E Valv...

Page 71: ...1000 1600 Inspect clean replace worn parts J Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed J Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 300...

Page 72: ...ed in the chart should be lubricated at the General Lubrication interval Item Lube Method Engine Oil PS 4 0W50 See page 70 Brakes DOT 3 fluid only See page 39 Transmission Premium AGL Synthetic Gearca...

Page 73: ...l for this engine PS 4 is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 103 for the part numbers of Polaris...

Page 74: ...evel through the sight glass A on the right side of the vehicle NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crank...

Page 75: ...r change can be completed without interruption 2 Position the vehicle on a level surface 3 Clean the area around the drain plug on the bottom of the engine crankcase 4 Run the engine for two to three...

Page 76: ...the gasket is in good condition 11 Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn 12 Remove the oil fill plug and add t...

Page 77: ...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 vehi...

Page 78: ...vehicle on a level surface 2 Remove the check plug A and view the oil level 3 Remove the fill plug B Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification 5 Reinstall th...

Page 79: ...ps until they ve cooled sufficiently Headlight Lamp Replacement To access the assembly from the front remove the front cover and unplug the wiring harness Remove the headlight assembly from the vehicl...

Page 80: ...t 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 dielectric grease to the so...

Page 81: ...ght brown There 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...

Page 82: ...irbox for any water and dry it if water is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw A 6 Turn the engine over several times using the electric start...

Page 83: ...eed these warnings could result in serious injury or death Periodically clean the spark arrestor to remove accumulated carbon 1 Remove the three screws A and remove the arrestor from the end of the mu...

Page 84: ...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 Alw...

Page 85: ...tery cable next 5 Lift the battery out of the battery compartment Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has...

Page 86: ...ready filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintain...

Page 87: ...tandard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 mont...

Page 88: ...over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill 1 Always keep brake fluid at...

Page 89: ...o adjust rear brake freeplay turn the adjuster nuts A at the rear brake drum Brake Lever Travel Rear Service the brakes when brake lever travel reaches 2 1 2 65 mm Always service the brakes when there...

Page 90: ...n be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands A in front of the vehicle perpendicular to the rear ti...

Page 91: ...d 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...

Page 92: ...edures 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 3 Adju...

Page 93: ...ailable from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when require...

Page 94: ...uster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth several times 3 Tighten the locknut and slide the boots...

Page 95: ...r 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...

Page 96: ...sition the vehicle on a level surface 2 Lock the parking brake 3 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotatio...

Page 97: ...rating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 mm...

Page 98: ...n 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 5 Reinstall the pre filter over the main filter Replace the...

Page 99: ...nd 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 i...

Page 100: ...ast seals Fuel Stabilizer Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and p...

Page 101: ...riod Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricat...

Page 102: ...uring transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly and securely 4 Always tie the frame of the ATV to the transporting unit securely using suit...

Page 103: ...Turn Radius 65 in 165 cm unloaded Ground Clearance 5 7 in 14 5 cm Length 70 in 178 cm Width 42 in 106 7 cm Height 42 in 106 7 cm Seat Height 32 in 81 3 cm Wheel Base 45 in 114 3 cm Engine Cooling Engi...

Page 104: ...travel Rear Suspension Mono Shock Swing Arm w 6 5 in 16 5 cm travel Shock Adjustment CAM Front Brake Hydraulic Disc Rear Brake Mechanical Drum Foot Brake Mechanical Drum Rear Brake Park Brake Mechanic...

Page 105: ...Below 5 C 40 F and above 5 C and above 0 1800 0 6000 108 108 1800 3700 6000 12000 92 5 90 Change to a 40 pilot jet if operating the ATV at these higher elevations Clutching Chart Altitude Meters Feet...

Page 106: ...id 8 oz 2872276 Premium ATV Angle Drive Fluid 2 5 gal 2870465 Pump for Gallon Jug Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz...

Page 107: ...in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if n...

Page 108: ...o specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fue...

Page 109: ...s See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to...

Page 110: ...MEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improp...

Page 111: ...ESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warra...

Page 112: ...ized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer wi...

Page 113: ...of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABIL...

Page 114: ...111 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 115: ...112 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 116: ...113 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 117: ...ippery Surfaces 54 Driving Over Obstacles 61 Driving Procedures 50 Driving Safely 50 63 Driving Through Water 60 Driving Uphill 55 E Electrical Switches 36 37 Emission Control Systems 64 Emissions War...

Page 118: ...park Arrestor Clean Out 80 Spark Plugs 78 Specifications 100 102 S Start Button 36 Starting the Engine 48 49 Steering Assembly 88 Stop Switch 36 Storage Tips 97 98 T Taillight Brakelight Lamp Replacem...

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