Polaris Sawtooth User manual

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.
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING

1
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.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory 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 Factory 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!

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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

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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...................................

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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.
Vehicle Model Number:
Frame VIN (1):
Engine Serial Number (2):
1
2

6
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
RiderCoursesm available 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 to take the ATV RiderCoursesm.Youwerealso
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
RiderCoursesm by calling ATV Enrollment Express at [phone]
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.

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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
Acaution indicates a situation that may result in damage to the
vehicle.
NOTE:
Anote will alert you to important information or instructions.

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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.
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever 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 RiderCoursesm. Contact ATV
Enrollment Express at [phone] or visit www.atvsafety.org for
information on enrollment in the ATV RiderCoursesm.
SNever allow anyone under 16 years of age to operate this ATV.
SNever permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
SAlways avoid operating an ATV on paved surfaces, including side-
walks, driveways, parking lots, and streets.
SNever operate an ATV on a public street, road or highway, including
a dirt or gravel road.
SNever 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.
SNever consume alcohol or drugs before or while operating an ATV.
SNever operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
SNever attempt wheelies, jumps or other stunts.
SAlways 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.
SAlways keep both hands on the handlebars and both feet on the foot-
rests of the ATV during operation.

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SAFETY
Operator Safety
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
SNever operate on excessively rough, slippery, or loose terrain.
SAlways follow proper turning procedures as described in this manu-
al. Practice turning at low speeds before attempting to turn at faster
speeds. Do not turn at excessive speeds.
SAlways have the ATV inspected by an authorized Polaris dealer if
it’s been involved in an accident.
SNever operate on hills too steep for the ATV or for your abilities.
Practice on smaller hills before attempting larger hills.
SAlways follow proper procedures for climbing hills. Check the ter-
rain carefully before 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 high speed.
SAlways 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 pos-
sible.
SAlways 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 the ATV
around on any hill until you’ve mastered (on level ground) the turn-
ing technique outlined in this manual. Avoid crossing the side of a
steep hill when possible.

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SAFETY
Operator Safety
SAlways 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.
Turn the ATV around and remount following the procedure de-
scribed in this manual.
SAlways 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.
SAlways 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.
SAvoid operating the ATV through deep or fast-flowing water. If it’s
unavoidable, travel slowly, balance your weight carefully, avoid sud-
den movements, and maintain a slow and steady forward motion. Do
not make sudden turns or stops, and do not make sudden throttle
changes.
SWet 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.
SAlways 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.
SAlways use the size and type of tires specified for your ATV, and
always maintain tire pressure as recommended.

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SAFETY
Operator Safety
SNever modify an ATV through improper installation or use of acces-
sories.
SNever 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.
SAlways remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION 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.

<
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SAFETY
Operator Safety
WARNING
POTENTIAL HAZARD
Operating this ATV without proper
instruction.
WHAT CAN HAPPEN
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 HAZARD
Beginning and inexperienced operators should complete the ATV
RiderCoursesm offered by Polaris through the SVIA. They should
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 RiderCoursesm contact ATV
Enrollment Express at [phone] or visit www.atvsafety.org
WARNING
POTENTIAL HAZARD
Failure to follow the age
recommendations for this ATV.
WHAT CAN HAPPEN
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 HAZARD
No one under the age of 16 should operate a Polaris ATV.

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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. 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
Carrying a passenger on one of the
racks.
WHAT CAN HAPPEN
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 HAZARD
Never allow passengers to ride on one of the racks.

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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 result in 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 this ATV on
public streets, roads or
highways.
WHAT CAN HAPPEN
The ATV could collide
with another vehicle.
HOW TO AVOID THE HAZARD
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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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.
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 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
Operating the ATV after consuming
alcohol or drugs.
WHAT CAN HAPPEN
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 HAZARD
Never consume alcohol or drugs before or while operating an
ATV.

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40
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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.
WARNING
POTENTIAL HAZARD
Attempting wheelies, jumps and
other stunts.
WHAT CAN HAPPEN
Attempting stunts increases the
chance of an accident, including an
overturn.
HOW TO AVOID THE HAZARD
Never attempt wheelies, jumps, or
other stunts. Avoid exhibition driving.

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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.
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 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 HAZARD
Always keep both hands on the handlebars and both feet on the
footrests of the ATV during operation.