Polaris 2007 ATV Sawtooth User Manual

7SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow theseinstructions and procedures, which are outlined in further d

ACB97MAINTENANCEAdjustmentsAir Filter Service1. Remove the seat.2. Release the clips and remove the airbox cover (A).3. Loosen the clamp and remove th

98MAINTENANCECleaning and StorageSee page 107 for the part numbers of Polaris products.Washing t h e VehicleKeeping your ATV clean will not only impro

99MAINTENANCECleaning and StorageWashing t h e VehicleIf a high pressure water system i s used for cleaning (notrecommended), exercise extreme caution

100MAINTENANCECleaning and StorageChrome Wheel Care (if equipped)Proper maintenance will protect chrome wheels from corrosion,preserve wheel life and

101MAINTENANCECleaning and StorageStorage TipsSee page 107 for the part numbers of Polaris products.CAUTIONStarting the engine during the storage peri

102MAINTENANCECleaning and StorageStorage TipsFluid LevelsInspect fluid levels and change fluids if necessary.S TransmissionS Brake FluidEngine Foggin

103MAINTENANCECleaning and StorageTransporting an ATVFollow these procedures whentransporting an ATV.1. Turn off the engine andremove the key to preve

104SPECIFICATIONSCapacitiesGross Vehicle Weight 765 lbs. (348 kg)Dry Weight 425 lbs. (193 kg)Fuel Capacity 2.75 gal. (10.4 l)Engine Oil Capacity 41 oz

105SPECIFICATIONSDrive SystemDrive System Type Constant Variable Transmission (CVT)Shift Type Side Lever F/N/RFront Drive (ratio) N/AFront Tires 21x7-

106SPECIFICATIONSJetting ChartALTITUDEAMBIENT TEMPERATUREMeters (Feet)Below 40° F(Below 5° C)+40°F and above(+5°C and above)0-1800 (0-6000) 102 981800

8SAFETYOperator SafetyS Always travel slowly and use extra caution when operating on unfa-miliar terrain. Be alert to changing terrain conditions.S Ne

107POLARIS PRODUCTSPart No. DescriptionEngine Lubricant2870791 Fogging Oil (12 oz. Aerosol)2874865 Performance Synthetic 4-Stroke (PS-4) 0W 50 Oil (qt

108TROUBLESHOOTINGContact your P olaris dealer for service if you’re unable to identifysolutions using the following charts.Engine Doesn’t Turn OverPo

109TROUBLESHOOTINGEngine BackfiresPossible Cause SolutionWeak spark from spark plugs Inspect, clean and/or replace spark plugsIncorrect spark plug gap

110TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut o f fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line In

111WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITEDWARRANTY on all components of the Polaris A

112WARRANTYWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIEDWARR

113WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

114WARRANTYU.S.A. EPA Emissions Limited W arrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limitedwarranty is in add

115MAINTENANCE LOGUse the following chart to record periodic maintenance.DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

116MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

9SAFETYOperator SafetyS Always use proper procedures if you stall or roll backwards whileclimbing a hill. To avoid stalling, maintain a steady speed w

117MAINTENANCE LOGDATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS

118INDEXAAdjustments 87-97...Age Restrictions 5...Air Filter 97...BBattery 81-86...Batter

119INDEXMMain Switch 34...Maintenance Chart 63-66...Maintenance Log 115-117...Making Turns 49...Master Cyl

10SAFETYOperator SafetyS Never modify an ATV through improper installation or use of acces-sories.S Never exceed the stated load capacity for your ATV

<11SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without properinstruction.WHAT CANHAPPENThe risk of an accident is greatlyincreas

12SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CANHAPPENCarrying a passenger greatly reducesthe operator’s ability

13SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating an ATV on pavedsurfaces, including sidewalks,paths, parking lots, anddriveways.WHAT CANHAPPENA

14SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating this ATV without wearing anapproved helmet, eye protection andprotective clothing.WHAT CANHAPP

5040010203015SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV atexcessive speeds.WHAT CANHAPPENExcessive speed increasesthe operator’s ch

16SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CANHAPPENPoor main

17SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDFailure to use extra caution whenoperating the ATV on unfamiliarterrain.WHAT CANHAPPENUnfamiliar terrain

>25_18SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT urning improperly.WHAT CANHAPPENImproper turns could cause loss ofcontrol and lead to a collisi

<25_19SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating on frozen bodies of water.WHAT CANHAPPENSevere injury or death can result ifthe ATV and

5040010203020SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDT raveling downhill improperly.WHAT CANHAPPENImproperly descending a hill couldcause loss of

21SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly crossing hills and turningon hills.WHAT CANHAPPENImproperly crossing orturning as hills could

22SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDStalling, rolling backwards or improperlydismounting while climbing a hill.WHAT CANHAPPENThe vehicle cou

23SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CANHAPPENOperating over obstacles couldcause loss of control or

24SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV through deep orfast-flowing water.WHAT CANHAPPENT ires may float, causing loss of trac

25SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDImproperly operating in reverse.WHAT CANHAPPENThe ATV could collide with anobstacle or person, resulting

26SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOperating the ATV with impropermodifications.WHAT CANHAPPENImproper installation of accessories ormodifi

A card containing important ATV safety information should be attachedto the owner’s manual on the next page. If you cannot locate this card,or if it h

2/31/32/31/327SAFETYOperator SafetyWARNINGPOTENTIAL HAZARDOverloading the ATV or carrying/towingcargo improperly.WHAT CANHAPPENOverloading and towing

28SAFETYOperator SafetyWARNINGOperating the ATV on streets or roads, especially in darkness,could result in an accident and serious injury or death.Yo

1229SAFETYSafety Decals and LocationsWarning decals have been placed on the ATV for your protection. Readand follow the instructions of the decals and

46537730SAFETYSafety Decals and LocationsGeneral Warning (3)WARNINGImproper ATV use can result in SEVERE INJURY or DEATHALWAYS USE AN APPROVED HELMET

31SAFETYSafety Decals and LocationsNo Passenger Warning (4)WARNINGNEVER ride as a passenger. Passengers can cause a loss of control, resultingin SEVER

32SAFETYSafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requiresspecial protective clothing for comfort and to reduce th

33SAFETYFuel SafetyWARNINGGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasol

34FEATURES AND CONTROLSElectrical Switches1. Light Switch/Hi-Lo Beam Control - The lights won’t t urn onunless the main key switch is on.2. Engine Sto

35FEATURES AND CONTROLSElectrical SwitchesWARNINGActivating the override switch while the throttle is open can causeloss of control, resulting in seve

36FEATURES AND CONTROLSThrottle LeverPress the throttle lever (1) towardthe handlebar to increase enginespeed and vehicle movement.Engine speed return

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

37FEATURES AND CONTROLSBrakesMaster Cylind erCheck the brake fluid level inthe master cylinder before eachuse of t he ATV. The mastercylinder (A) is l

38FEATURES AND CONTROLSBrakesWARNINGApplying only one brake could cause loss of control and result inserious injury or death. Always apply both brakes

39FEATURES AND CONTROLSBrakesFoot BrakeThe foot brake (1) is amechanical rear wheel brake.The foot brake is located onthe inside of the rightfootrest.

1240FEATURES AND CONTROLSParking BrakeWARNINGOperating the ATV while the parking brake is engaged couldresult in an accident and serious injury or dea

AB41FEATURES AND CONTROLSChokeThe choke assists in starting a cold engine. See page 46 for correctchoke and throttle settings during starting.Fuel Fil

42FEATURES AND CONTROLSAutomatic Transmission Gear SelectorThe transmission gear selector (A)is located on the right side of thevehicle.F: Forward Gea

43FEATURES AND CONTROLSKick-Start LeverIf the battery becomes too weak to start the engine, use the kick-startlever to start the engine until the batt

44OPERATIONBreak-In PeriodThe break-in period for your new Polaris 4-cycle ATV is defined as thefirst ten hours of operation, or the time it takes to

45OPERATIONPre-Ride InspectionWARNINGIf a proper inspection is not done before each use, severe injuryor death could result. Always inspect the vehicl

46OPERATIONCold Weather Operation for 4-Cycle EnginesInternal engine condensation increases as outside temperaturesdecrease. If the vehicle is used ye

2Copyright 2006 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47OPERATIONStarting the Engine6. Squeeze the left brake lever.NOTE: The starter will not engage unless the rear brake is applied.Always squeeze and ho

48OPERATIONDriving SafelyDriving Procedures1. Sit upright. Keep your feet on the footrests. Keep both hands on thehandlebars.2. Start the engine and a

49OPERATIONDriving SafelyMaking Tu rns1. To make a turn, steer in the direction of the turn, leaning yourupper body to the inside of t he turn while s

2/31/350OPERATIONDriving SafelyHauling Cargo and TowingYour ATV has been designed to carry or tow a certain amount of load.Always read and understand

51OPERATIONDriving SafelyHauling Cargo and TowingWARNINGHauling cargo improperly can alter vehicle handling and maycause loss of control or brake inst

52OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever driving on slippery or loose surfaces such as wet trails,gravel, snow or ice, follow the

<25_53OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow theseprecautions:1. Drive straight uphill.2. Avoid steep hills (25_ ma

54OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow these precautions:1. Drive straight downhill.2. Shift your weight rearward

55OPERATIONDriving SafelySidehillingWARNINGImproperly crossing hills or turning on hills can result in loss ofcontrol or vehicle overturn, resulting i

8 ft. (2.4 m)56OPERATIONDriving SafelyTurning Around on a HillWARNINGImproper hill climbing procedures could cause loss of control oroverturn and resu

3TABLE OF CO NTENTSKNOW YOUR VEHICLE 4...SAFETY 5...FEATURES AND CONTROLS 34...OPERATION

57OPERATIONDriving SafelyK -Turn/Turning Around on a Hill1. Squeeze the front (right) brake lever to stop the vehicle.2. Keep your weight uphill.3. Lo

A58OPERATIONDriving SafelyDriving Through WaterFollow these procedures when operating through water:1. Check water depthsand current beforecrossing.2.

59OPERATIONDriving SafelyDriving Over Obstacles1. Always check for obstacles before operating in a new area.2. Be alert. Watch the terrain. Use extra

60OPERATIONDriving SafelyDriving in ReverseFollow these precautionswhen operating in reverse:1. Avoid backingdownhill.2. Always check forobstacles or

61OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline. If it’s unavoidable, follow theseprecautions:1. Turn the engine off.1. Place t

62EMISSION CONTROL SYSTEMSNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing somay affect compliance with U

63MAINTENANCEPeriodic Maintenance ChartCareful periodic maintenance will help keep your vehicle in the safest,most reliable condition. Inspection, adj

64MAINTENANCEPeriodic Maintenance ChartPerform all services at whichever maintenance interval is reached first.Item Maintenance Interval(whichever com

65MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Generallubrication50 H 3M

66MAINTENANCEPeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Miles(Km)"Wiring 100 H 12 M 1000 (16

4KNOW YOUR VEHICLEAs the operator of the vehicle, you are responsible for your personalsafety, the safety of others, and the protection of our environ

67MAINTENANCELubrication GuideCheck and lubricate all components at the intervals outlined in thePeriodic Maintenance Chart beginning on page 63. Item

68MAINTENANCEEngine OilAlways check and change the engine oil at the intervals outlined in thePeriodic Maintenance Chart beginning on page 63. Always

69MAINTENANCEEngine Oil CheckMaintain the oil level at the center of the sight glass. Do not overfill.1. Position the vehicle on a levelsurface.2. Vie

70MAINTENANCEOil and Filter ChangeCAUTIONIf the ATV is left without oil in the system for extended periods,the oil pump may lose its prime, which coul

71MAINTENANCEOil and Filter Change7. Reinstall the drain plug.Torque to 11 ft. lbs. (15 Nm).8. Place shop towels beneaththe oil filter. Using an oilfi

AB72MAINTENANCEGearcase Specification ChartGearcase Lubricant Capacity Drain/CheckPlug TorqueFill PlugTorqueTransmission Premium AGL SyntheticGearcase

73MAINTENANCERear Gearcase OilAlways check and change the rear gearcase oil at the intervals outlinedin the Periodic Maintenance Chart beginning on pa

AB74MAINTENANCELightsWARNINGPoor lighting while driving can result in severe injury or death.Headlight and taillight lenses become dirty during normal

75MAINTENANCELightsTaillig ht/Brakelight Lamp ReplacementIf the taillight/brakelight does not work the lamp m ay need to bereplaced.1. Remove the tail

A76MAINTENANCESpark PlugsSpark Plug RecommendaitonsRefer to the specifications section beginning on page 104 for spark plugand gap specifications.Plug

5SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can resultin serious injury or death.A Polaris ATV is not a toy a

77MAINTENANCESpark PlugsSpark Plug ConditionNormal PlugThe normal insulator tip is gray, t an or light brown. There will be fewcombustion deposits. Th

78MAINTENANCEVehicle ImmersionCAUTIONIf your vehicle becomes immersed, major engine damage canresult if the machine is not thoroughly inspected. Take

79MAINTENANCESpark Arrestor Clean-OutWARNINGDo not perform clean-out immediately after the engine has beenrun, as the exhaust system becomes very hot.

80MAINTENANCEConstant Variable Transmission (CVT) SystemWARNINGFailure to comply with the instructions in this warning can result insevere injury or d

81MAINTENANCEBatteryYour ATV may have either a sealed battery, which requires littlemaintenance, or a conventional battery. A sealed battery can beide

82MAINTENANCEBatteryWARNINGImproperly connecting or disconnecting battery cables can resultin an explosion and cause serious injury or death. Whenremo

83MAINTENANCEBatteryBattery InstallationUsing a new battery that has not been fully charged can damage thebattery and result in a shorter life. It can

84MAINTENANCEBatteryBattery StorageWhenever the vehicle is not used for a period of three months or more,remove the battery from the vehicle, ensure t

85MAINTENANCEBatteryBattery Charging (Conventional Battery)1. Remove the battery from the vehicle to prevent damage fromleaking or spilled electrolyte

86MAINTENANCEBatteryBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after theend of charging.State ofCharg

6SAFETYOperator SafetySignal Words and SymbolsThe following signal words and s ymbols appear throughout thismanual and on your ATV. Your safety is inv

87MAINTENANCEAdjustmentsBrakes (Front)The front brakes are hydraulic disc brakes. These brakes areself-adjusting.The following checks are recommended

88MAINTENANCEAdjustmentsBrake Lever Travel (Rear)Service the brakes whenbrake lever travel reaches21/2″ (65 mm). Alwaysservice the brakes when thereis

89MAINTENANCEAdjustmentsWARNINGSevere injury or death can result from improper toe alignment andadjustment. Do not attempt to adjust tie rod alignment

90MAINTENANCEAdjustmentsSteering AssemblyThe steering assembly of the ATV should be checked periodically forloose nuts and bolts. If loose nuts and bo

91MAINTENANCEAdjustmentsWARNINGImproper adjustment of the handlebars or incorrect torquing ofthe adjuster block tightening bolts can cause limited ste

92MAINTENANCEAdjustmentsCarburetorIMPORTANT: Your Polaris ATV is calibrated at the factory foroptimal performance at altitudes ranging from zero to 6,

93MAINTENANCEAdjustmentsThrottle Cable FreeplayThe throttle cable adjuster is located at the right handlebar.1. Slide the boots (A) off the inline cab

94MAINTENANCEAdjustmentsWARNINGOperating your ATV with worn tires, improperly inflated tires,non-standard tires or improperly installed tires will aff

95MAINTENANCEAdjustmentsWARNINGImproperly installed wheels can adversely affect tire wear andvehicle handling, which can result in serious injury or d

96MAINTENANCEAdjustmentsFront Wheel Hub TighteningFront wheel bearing tightness and spindle nut retention are criticalcomponent operations. All servic