Polaris 600 Switchback Assault Owner's Manual
Polaris 600 Switchback Assault Owner's Manual

Polaris 600 Switchback Assault Owner's Manual

Polaris snowmobile owner's manual
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PMS 419
IMPORTANT NOTICE TO OWNER
Modifications to this snowmobile are not recommended
and may result in voided warranty coverage.
Please read the warranty section of this manual carefully.
600 Switchback Assault®
800 Switchback Assault®
Snowmobile Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 600 Switchback Assault

  • Page 1 IMPORTANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully. 600 Switchback Assault® 800 Switchback Assault® Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2014 600 SWITCHBACK ASSAULT / 800 SWITCHBACK ASSAULT Owner's Manual P/N 9924273...
  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ......5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.
  • Page 7: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations.
  • Page 8: Preservation Of The Environment

    INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment.
  • Page 9: Vehicle Identification Numbers

    INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
  • Page 10: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 11: Operator Safety

    SAFETY Operator Safety Follow the recommended maintenance program beginning on page 73 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger.
  • Page 12: Riding Position

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. WARNING! Serious injuries may result if NO STEP hands, feet, or clothing become entangled in the track.
  • Page 13: Riding Apparel

    SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • Page 14: Disabled Operators

    SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Preparation For your safety, always ride in a group of other snowmobilers.
  • Page 15: Rider Capacity

    SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a passenger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits.
  • Page 16: Driver Awareness

    SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.
  • Page 17 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.
  • Page 18: Ice And Snow Build-Up

    SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.
  • Page 19: Driving Downhill

    SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely downhill.
  • Page 20: Drive Belt

    SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. NOTICE: Operation of the engine with the belt removed may result in injury or damage to the engine.
  • Page 21: Driving Responsibly

    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
  • Page 22 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) Wind Actual Thermometer Reading (°F) Speed -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature (°F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63...
  • Page 23: Clutch Warning

    SAFETY Safety Labels and Locations Warning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile.
  • Page 24: Reverse Warning

    SAFETY Safety Labels and Locations Reverse “No Passenger” Warning Warning “No Passenger” Warning Snowmobiles designed for a single rider only have a NO PASSENGER warning label on the console: WARNING This vehicle is designed for operator only. NO PASSENGER Reverse Warning The reverse warning label is located on the console: WARNING Reverse operation, even at low speeds, can cause loss of control...
  • Page 25: Hot Surface Warning

    SAFETY Safety Labels and Locations Track Warning Hot Surface Track Warning The track warning label is on the Warning rear tunnel: WARNING Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.
  • Page 26: Operation Warning

    SAFETY Safety Labels and Locations Operation Warning The operation warning label is also located on the console. Operation Warning WARNING • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact a POLARIS dealer for a replacement.
  • Page 27 SAFETY Safety Labels and Locations Operation Warning • When operating with a passenger (on approved models only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle. • When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced.
  • Page 28: Features

    FEATURES 1. Nosepan 8. Operator Seat 2. Skis 9. Taillight 3. Front Bumper 10. Rear Bumper 4. Hood 11. Snow Flap 5. Headlight 12. Suspension 6. Windshield (accessory) 13. Track 7. Handlebar 14. Side Panel 15. Side Panel Fasteners...
  • Page 29: Features

    FEATURES 1. Fuel Filler Cap 12 11 2. Electronic Reverse Button 3. Brake Lever 4. Parking Brake Lock 5. Instrument Cluster 6. Ignition Switch 7. Engine Stop Switch 8. Throttle Control 9. Recoil Starter Handle 10. Handlebar Grip Warmer Switch 11.
  • Page 30: Features

    FEATURES Storage Bag/Tool Kit Storage Bag A storage bag and tool kit is located under the left side panel between the oil bottle and console. Adjustable Headlights Move the headlight adjuster to the left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam downward.
  • Page 31: Features

    FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gasolines, the fuel type designation setting must be changed to “Eth” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel purchase, use the “Eth”...
  • Page 32: Features

    FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engine performance and RPM when the DET system is activated.
  • Page 33: Features

    FEATURES Detonation Elimination Technology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethanol fuel Verify correct fuel resistor for fuel type resistor installed in tank Low fuel/no fuel in tank...
  • Page 34: Features

    FEATURES Instrument Cluster Rider Information Center Check Engine High Beam Indicator Indicator Over- Park Brake Temperature Indicator Indicator Reverse Low Oil Indicator Indicator SELECT MODE Button Button The instrument cluster contains Mode/Set Switch indicator lights and the rider information center. The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the...
  • Page 35: Features

    FEATURES Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer. See page 46 for diagnostic code definitions. Over-Temperature Indicator This indicator illuminates to alert the operator that the engine is overheating.
  • Page 36: Features

    FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic display mode. Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector.
  • Page 37: Features

    FEATURES Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 36. 2.
  • Page 38: Features

    FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).
  • Page 39: Features

    FEATURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip B meter and engine hours meter. The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled by the vehicle on a trip if the meter is reset before each trip.
  • Page 40: Features

    FEATURES Instrument Cluster Rider Information Center Standard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Change Method 1 1.
  • Page 41: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended.
  • Page 42: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System Perform all tasks in the order shown if you wish to activate and use the optional security system. TASK 1: Activate the security system See your authorized POLARIS dealer to have the optional security system feature activated in the electronic control unit (ECU).
  • Page 43: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System TASK 3: Unlock the System 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit.
  • Page 44: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed.
  • Page 45: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit.
  • Page 46: Features

    FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning on page 40.
  • Page 47: Features

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a diagnostic code is active. Do not stop the engine if you want to view the active code (failure code).
  • Page 48: Features

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • Page 49: Features

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions. Diagnostic Codes Component Condition ECU Memory Checksum/CRC Error Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Knock Sensor 1 Voltage Too Low Ignition Coil Primary Driver 1 (MAG)
  • Page 50: The Perfect Fit

    THE PERFECT FIT Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension.
  • Page 51: Suspension Adjustments

    THE PERFECT FIT Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate Soft torsion springs are available if a firmer (long end of cam to front) ride is desired.
  • Page 52: Experience

    THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload Factory settings, combined with user adjustments to the rear track shock spring, should be all that’s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is torsion spring preload.
  • Page 53: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Handlebar Angle 1. Loosen the four bolts on the Loosen top of the adjuster block. If Bolts necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired angle. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the...
  • Page 54: Pre-Ride Inspections

    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Item See Page Drive Belt Condition Steering System Recoil Rope Coolant Level Chaincase Oil Level Injection Oil Level Parking Brake Lock/Brake Lever/Brake System...
  • Page 55: Item See Page

    PRE-RIDE INSPECTIONS Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip. Item See Page Check suspension mounting bolts for tightness.
  • Page 56: Before Starting The Engine

    PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.
  • Page 57 PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2” (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.
  • Page 58: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.
  • Page 59: Steering System

    PRE-RIDE INSPECTIONS Before Starting the Engine Steering System WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering.
  • Page 60: Start The Engine And Check

    PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 54.
  • Page 61: Operation

    OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2.
  • Page 62: Break-In Period

    OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel and fill the oil reservoir as outlined below. Oil added to the fuel and oil injection systems will provide the necessary engine lubrication.
  • Page 63: Oil Injection System

    OPERATION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds to reduce friction on all close- fitting machined parts, allowing them to break in slowly without damage.
  • Page 64: Slide Rail And Track Cooling

    OPERATION Track Warm-Up WARNING! A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging.
  • Page 65 OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. •...
  • Page 66: Fuel Recommendation

    OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol. Never use E85 fuel in your snowmobile.
  • Page 67: Low Oil Level

    OPERATION Low Oil Level Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 60 for oil recommendations. “Add” Mark 1. Immediately stop the engine if the low oil indicator light comes on. 2.
  • Page 68 OPERATION Engine Stop Switch Push down on the engine stop switch (X) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.
  • Page 69: Throttle Lever

    OPERATION Throttle Lever WARNING! An improperly functioning throttle lever may cause erratic snowmobile behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1.
  • Page 70 OPERATION Electronic Reverse (PERC) WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed.
  • Page 71 OPERATION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation.
  • Page 72: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch...
  • Page 73: Daily Storage

    OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) off the ground. Remove the key and cover the snowmobile.
  • Page 74: Maintenance

    MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hangtag.
  • Page 75 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 127. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km).
  • Page 76: Coolant Level

    MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS dealer. Item Frequency Page...
  • Page 77 MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System 55, 88 Brake Fluid FUEL MANAGEMENT...
  • Page 78: Chaincase Oil Level

    MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques See your dealer every 1000 mi. (1600 km) for inspection Rear Suspension Fasteners Steering Fasteners...
  • Page 79 MAINTENANCE Hood/Side Panel The hood and side panels of the snowmobile protect the operator from moving parts. Strap Never operate a snowmobile with the hood or side panels open or removed. Always ensure that the hood and side panels are securely in place before starting the engine.
  • Page 80: Rear Suspension

    MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 74 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km). Lack of lubrication will adversely affect your ride and the life of the suspension.
  • Page 81: Chaincase Oil

    MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 73. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube.
  • Page 82: Oil Filter

    MAINTENANCE Lubrication Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).
  • Page 83: Intake Filters

    MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer.
  • Page 84: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs at the intervals outlined in the Periodic Maintenance Table beginning on page 73.
  • Page 85: Spark Plug Inspection

    MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
  • Page 86: Cooling System

    MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required.
  • Page 87: Engine Overheating

    MAINTENANCE Cooling System Engine Overheating The over-temperature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels. Illuminated Indicator Take action to cool the engine: • Drive in loose snow. •...
  • Page 88: Bleeding The Cooling System

    MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.
  • Page 89: Exhaust System

    MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool.
  • Page 90: Hydraulic Brake Inspection

    MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 55. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads.
  • Page 91: Brake Fluid

    MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid.
  • Page 92: Bleeding The Hydraulic Brake System

    MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.
  • Page 93: Headlight Lamp Replacement

    MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.
  • Page 94: Clutch System

    MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the snowmobile until repairs have been made.
  • Page 95: Drive Belt Condition

    MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.
  • Page 96: Drive Belt Deflection

    MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm).
  • Page 97: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counter- clockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.
  • Page 98: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period.
  • Page 99: Track Inspection

    MAINTENANCE Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground.
  • Page 100: Track Tension

    MAINTENANCE Track Maintenance WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.
  • Page 101 MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7.
  • Page 102: Track Alignment

    MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground.
  • Page 103: Steering Inspection

    MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary.
  • Page 104: Ski Alignment

    MAINTENANCE Steering System Ski Alignment WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer. 1. Place the handlebars in a straight-ahead position. 2.
  • Page 105: Ski Skags

    MAINTENANCE Steering System Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
  • Page 106: Transporting The Snowmobile

    MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your snowmobile in peak operating condition. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly. 2.
  • Page 107: Electrical Connections

    MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 74. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual.
  • Page 108: Specifications

    SPECIFICATIONS 600 SWITCHBACK ASSAULT Capacities and Dimensions Body Style PRO-RIDE Rider Capacity Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (43.5 l) Fuel Tank Capacity 11.5 gal. (41.6 l) Gearcase Oil Capacity Oil Capacity 3.8 qts. (3.6 l)
  • Page 109 SPECIFICATIONS 600 SWITCHBACK ASSAULT 2.0 Clutching (Non-Electric Start) ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters Gearing/ Shift Weight Spring Spring Helix (Feet) Pitch *Shaded cells indicate factory settings. (58/42/.45) 0-600 10-64 120/310 Black 130/180 P2 Tab 20:42...
  • Page 110 SPECIFICATIONS 600 SWITCHBACK ASSAULT 1.3 Clutching (Non-Electric Start) ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters Gearing/ Shift Weight Spring Spring Helix (Feet) Pitch *Shaded cells indicate factory settings. (58/42/.45) 0-600 10-64 120/310 Black 130/180 P2 Tab 22:40...
  • Page 111 SPECIFICATIONS 800 SWITCHBACK ASSAULT Capacities and Dimensions Body Style PRO-RIDE Rider Capacity Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel Tank Capacity 11.5 gal. (43.5 l) Gearcase Oil Capacity Oil Capacity 3.8 qts. (3.6 l) Height 48 inches (122 cm) Length...
  • Page 112 SPECIFICATIONS 800 SWITCHBACK ASSAULT 2.0 Clutching Chart ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters Gearing/ Shift Weight Spring Spring Helix (Feet) Pitch *Shaded cells indicate factory settings. (64/42/.36) 20:42 0-600 10-66 120/310 Black LH BLUE/BLACK 21:41 (INTL) (0-2000) (1321584) (7043681)
  • Page 113 SPECIFICATIONS 800 SWITCHBACK ASSAULT 1.3 Clutching Chart ALTITUDE Chaincase Drive Clutch Drive Clutch Driven Clutch Driven Meters Gearing/ Shift Weight Spring Spring Helix (Feet) Pitch *Shaded cells indicate factory settings. (64/42/.36) 0-600 10-66 120/310 Black LH BLUE/BLACK 23:39 (0-2000) (1321584) (7043681) Team (7043064) 72 Pitch...
  • Page 114: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES 2-Cycle Engine Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 2877884 VES 2-Cycle Engine Oil (2.5 gal./9.5 l) Chaincase Lubricants 2873105 SCL - Synthetic Chaincase Lubricant (qt./.95 l)
  • Page 115: Troubleshooting

    TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding • SEE YOUR DEALER. ating RPM during Driven clutch mal- •...
  • Page 116 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch • SEE YOUR DEALER. system components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 117 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition • Install new spark plug(s). If engine to start still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine •...
  • Page 118: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension • Refer to the suspension adjustment and set-up information bottoms too easily beginning on page 48. • Revalve rear track shock (see your dealer). Rides too stiff in rear • Refer to the suspension adjustment and set-up information beginning on page 48.
  • Page 119: Drive Belt Troubleshooting

    TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the snowmobile in extremely cold weather and warm it up.
  • Page 120: Warranty

    WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
  • Page 121 WARRANTY Service and Warranty Information POLARIS Anti-Theft System The POLARIS anti-theft system (PATS) monitoring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration POLARIS snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call POLARIS Customer Service.
  • Page 122: Limited Warranty

    WARRANTY Limited Warranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. Warranty period will vary regionally. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.
  • Page 123: Engine Oil

    WARRANTY Limitations of warranties and remedies ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
  • Page 124 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty.
  • Page 125 Vehicles importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS Industries in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country.
  • Page 126 WARRANTY How to Get Service If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 127 U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S.
  • Page 128 WARRANTY U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement 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.
  • Page 129: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 130 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 131 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 132: Index

    INDEX Accessories ....28 Drive Belt Break-In ....61 Air Pollution .
  • Page 133 INDEX Handlebar Adjustments... 51 Operation Warning ... 24-25 Handlebar Angle ....51 Operator Safety .
  • Page 134 INDEX Spring Preload ....48, 50 Tool Kit ..... . . 28 Standard/Metric Display .
  • Page 135 PMS 419 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924273 Rev 01 Printed in USA *9924273...

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