POLARIS SAWTOOTH 200 ATV Full Service & Repair Manual 2006-2007

GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 1.1 MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL NUMBER AND ENGINE NUMER LOCATION . . . . . . . . . . . . . . . . . . . . . 1.2 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2006 PHOENIX 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2006 SAWTOOTH 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2006 PHOENIX 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL: 2006 SAWTOOTH 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MISCELLANIOUS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

GENERAL INFORMATION 1.2 MODEL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. ENGINE DESIGNATION NUMBERS ES20PFESingle, Air Cooled, SOHC 4 Stroke, Electric Start VIN IDENTIFICATION ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine, be sure to refer to the engine serial number. This information can be found stamped on the top LH side of the crankcase as shown below. UNIT SERIAL NUMBER AND ENGINE NUMER LOCATION The machine serial number (1) and engine serial number (2) are important for vehicle identification. The machine serial number (VIN) is stamped on the LH lower front of the frame. } Machine Model Number Identification } } Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option A 0 6 P B 2 0 A A } 4 X A P B 2 0 A * 6 P 0 0 0 0 0 0 } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier } Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 1 2

GENERAL INFORMATION 1.3 GENERAL SPECIFICATIONS MODEL..................2006 PHOENIX 200 MODEL NUMBER.............A06PB20AA ENGINE MODEL...................ES20PFE MODEL..............2006 SAWTOOTH 200 MODEL NUMBER..............A06SB20AA ENGINE MODEL....................ES20PFE Category Dimension Length 65 in. / 165.1 cm Width 42 in. / 106.7 cm Height 42 in. / 106.7 cm Wheel Base 45 in. / 114.3 cm Ground Clearance 5.7 in. / 14.5 cm Dry Weight 395 lbs. / 179.2 kg Gross Vehicle Weight 720 lbs. / 326 kg Oil Capacity 1.26qt / 1.2L Front Rack Capacity n/a Rear Rack Capacity 70 lbs. / 31.7 kg Towing Capacity 300 lbs. / 136 kg Hitch Tongue Weight 30 lbs. / 13.6 kg Body Style Youth / Sport Category Dimension Length 65 in. / 165.1 cm Width 42 in. / 106.7 cm Height 42 in. / 106.7 cm Wheel Base 45 in. / 114.3 cm Ground Clearance 5.7 in. / 14.5 cm Dry Weight 425 lbs. / 192.8 kg Gross Vehicle Weight 765 lbs. / 348 kg Oil Capacity 1.26qt / 1.2L Front Rack Capacity 45 lbs. / 20.4 kg Rear Rack Capacity 70 lbs. / 31.7 kg Towing Capacity 300 lbs. / 136 kg Hitch Tongue Weight 30 lbs. / 13.6 kg Body Style Youth / Utility

GENERAL INFORMATION 1.4 MODEL: 2006 PHOENIX 200 MODEL #: A06PB20AA, AB, AC / EA, EB ENGINE MODEL: ES20PFE JETTING CHART CLUTCH CHART Engine Platform Aeon 4 stroke, Single Cylinder Engine Model Number ES20PFE Engine Displacement 196cc Number of Cylinders 1 Bore & Stroke (mm) 65 x 59 mm Compression Ratio 9.2:1 Compression Pressure 160-190 psi Engine Idle Speed 1500 ± 100 Rpm Cooling System/Capacity Oil/ Air Overheat Warning n/a Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 1.26qt (1.2L) Exhaust System USFS Approved Carburetion Carburetor model Keihin VM 22mm Main Jet 108 Pilot Jet 35 Jet Needle 2MKNN - 4 clip Needle Jet n/a Pilot/Air Screw 1 Turn Out (Initial setting, varies by ATV) Float Height Parallel To Float Bowl Fuel Delivery Gravity Feed System Fuel Capacity / Requirement 2.5 gal. (9.5 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 210 w @ 5000 RPM Voltage Regulator 3-Phase Lights: High Beam 35 watts Low Beam 35 watts Brake 21 watts Tail 5 watts Ignition System CDI Ignition Ignition Timing 32° ± 2° BTDC @ 3000 RPM Spark plug / Gap NGK CR6HSA .024 - .028 in./ .6-.7 mm Battery / Model / Amp Hr Maintenance-Free - 12 Amp Hr Circuit Breakers Harness 15 amp Starting Electric / Kick Start Backup Indicator Panel Neutral / Reverse Drivetrain Transmission Type Inline F/N/R Transmission Capacity 18.6 oz. (550 ml) Rear Gearcase Capacity 4 oz. (120 ml) Drive Type Shaft Clutch Type CVT Non EBS Belt 0452496 Steering / Suspension Front Suspension / Shock Dual A-arm / Coil over Shocks Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Mono Shock Swingarm / Coil over shock Rear Travel 6.5 in. / 16.5 cm Ground Clearance 5.7 in. / 14.5 cm Shock Preload Adjustment Front / Rear Front - Cam Rear - Cam Turning Radius 64 in. / 106.7 cm unloaded Toe Out 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Tire/Rim Size - Front 21 x 7 - 10 / 4-156 Tire/Rim Size - Rear 20 x 10 - 9 / 4-110 Air Press. F/R Tires 4 psi Front / 3 psi Rear Brake - Front Dual Hydraulic Disc Brake - Rear Single Drum Brake Fluid Polaris DOT 3 Brake Fluid Altitude ambient temperature Below 40° F Below 5° C Above +40° F Above +5° C Meters (Feet) 0-1800 (0-6000) 108 (0452555) 108 (0452555) above 1800 (above 6000) 92.5 (3131616) 90 (3131617) Altitude Shift Weight Meters (Feet) 0-1800 (0-6000) 6 @ 14.5 grams (0452471) 1800-3700 (6000 - 12000) 6 @ 11grams (0453091)

GENERAL INFORMATION 1.5 MODEL: 2006 SAWTOOTH 200 MODEL NUMBER: A06SB20AA,AB / ED,EE ENGINE MODEL: ES20PFE JETTING CHART CLUTCH CHART Engine Platform Aeon 4 stroke, Single Cylinder Engine Model Number ES20PFE Engine Displacement 196cc Number of Cylinders 1 Bore & Stroke (mm) 65 x 59 mm Compression Ratio 9.2:1 Compression Pressure 160-190 psi Engine Idle Speed 1500 ± 100 Rpm Cooling System/Capacity Oil/ Air Overheat Warning n/a Lubrication Wet Sump Oil Requirements Polaris 0W-50 / 1.26qt (1.2L) Exhaust System USFS Approved Carburetion Carburetor model Keihin VM 22mm Main Jet 108 Pilot Jet 35 Jet Needle 2MKNN - 4 clip Needle Jet n/a Pilot/Air Screw 1 Turn Out (Initial setting, varies by ATV) Float Height Parallel To Float Bowl Fuel Delivery Gravity Feed System Fuel Capacity / Requirement 2.75 gal. (10.4 L) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 210 w @ 5000 RPM Voltage Regulator 3-Phase Lights: High Beam 35 watts Low Beam 35 watts Brake 21 watts Tail 5 watts Ignition System CDI Ignition Ignition Timing 32° ± 2° BTDC @ 3000 RPM Spark plug / Gap NGK CR6HSA .024 - .028 in./ .6-.7 mm Battery / Model / Amp Hr Maintenance-Free - 12 Amp Hr Circuit Breakers Harness 15 amp Starting Electric / Kick Start Backup Indicator Panel Neutral / Reverse Drivetrain Transmission Type Inline F/N/R Transmission Capacity 18.6 oz. (550 ml) Rear Gearcase Capacity 4 oz. (120 ml) Drive Type Shaft Clutch Type CVT Non EBS Belt 0452496 Steering / Suspension Front Suspension / Shock Dual A-arm / Coil over Shocks Front Travel 7 in. / 17.8 cm Rear Suspension Style / Shock Mono Shock Swingarm / Coil over shock Rear Travel 6.5 in. / 16.5 cm Ground Clearance 5.7 in. / 14.5 cm Shock Preload Adjustment Front / Rear Front - Cam Rear - Cam Turning Radius 64 in. / 106.7 cm unloaded Toe Out 0 - 1/16 in / .0 - .159 mm Wheels / Brakes Tire/Rim Size - Front 21 x 7 - 10 / 4-156 Tire/Rim Size - Rear 21 x 10 - 10 / 4-110 Air Press. F/R Tires 4 psi Front / 3 psi Rear Brake - Front Dual Hydraulic Disc Brake - Rear Single Drum Brake Fluid Polaris DOT 3 Brake Fluid Altitude ambient temperature Below 40° F Below 5° C Above +40° F Above +5° C Meters (Feet) 0-1800 (0-6000) 108 (0452555) 108 (0452555) above 1800 (above 6000) 92.5 (3131616) 90 (3131617) Altitude Shift Weight Meters (Feet) 0-1800 (0-6000) 6 @ 14.5 grams (0452471) 1800-3700 (6000 - 12000) 6 @ 11grams (0453091)

GENERAL INFORMATION 1.6 MISCELLANIOUS INFORMATION PUBLICATION NUMBERS NOTE: When ordering service parts be sure to use the correct parts manual. NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from www.purepolaris.com. REPLACEMENT KEYS Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the original. Should both keys become lost, ignition switch replacement is required. Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2006 Phoenix 200 A06PB20AA, AB, AC 9920243 9920244 9920245 2006 Sawtooth 200 A06SB20AA, AB 9920278 9920279 9920280 Key Blank 0453013

GENERAL INFORMATION 1.7 SPECIAL TOOLS NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog. PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN 2870872 Shock Spanner Wrench 2, 5 PV-39951-A or 8712500 Tachometer 2,9 2200634 Valve Seat Reconditioning Kit 3 2870390 Piston Support Block 3 PA-47308 Flywheel Puller 3 2871293-B Crankshaft Slotted Nut Socket 3 PA-47344 Balance Shaft Slotted Nut Socket 3 2870386 Piston Pin Puller 3 PA-47361 Carburetor Adjustment Screwdriver 4 2870975 Mity Vac™ Pressure Test Tool 4 2872314 Carburetor Float Adjustment Tool 4 2870623 Shock Absorber Spring Compression Tool 5 2870871 Ball Joint Replacement Tool 5 PA-47309 Transmission Output Shaft Collar Tool 8 2870630 Timing Light 9 2870836 Battery Hydrometer 9 PV-43568 Fluke™77 Digital Multimeter 9 PV-39991 Peak Reading Adaptor 9

GENERAL INFORMATION 1.8 SPECIAL TOOLS Special Tools may be required to service this ATV. Some of the tools listed are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Standard Tools and Engine Tools 2871293 - B - Crankshaft Slotted Nut Socket PA - 47344 - Balance Shaft Slotted Nut Socket PA-47308 - Flywheel Puller 2870975 - Mity VacTM 2870773 - C - Clip Install Tool 2870390 - Piston Support Block 2870569 - Crankshaft True Kit PV - 35667 - A - Cylinder Leakdown Tester PU - 45432 - Caliper or A Basic Caliper Suspension Tools 2870871 - ATV Ball Joint Tool Kit

GENERAL INFORMATION 1.9 2870623 - Shock Spring Compressor Standard Tools and Engine Tools 2870303- Hone Kit 2870305 - Stone Replacement Kit 2870588 - Hone Oil (12 OZ.) 2200634 - Valve Seat Reconditioning Kit 2870459 - Dial Indicator Transmission Tools PA - 47309 - Transmission Output Shaft Collar Tool PA- 47360 - Rear Gearcase Input Shaft Collar Tool Electrical Tools PV-43568 - FlukeTM 77 Multimeter PV-39617 - Current Clamp 2870836 - Battery Hydrometer 8712500 PV-39951-A Tachometer Tachometer

GENERAL INFORMATION 1.10 STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

POLARIS SAWTOOTH 200 ATV Full Service & Repair Manual 2006-2007

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