Owners Manual
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600 SWITCHBACK ASSAULT 800 SWITCHBACK ASSAULT Snowmobile Owner's Manual for Maintenance and Safety
600 SWITCHBACK ASSAULT 800 SWITCHBACK ASSAULT Snowmobile Owner's Manual for Maintenance and Safety
Owners Manual
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... vehicle and the information presented in part, is based on the latest product information at the time of publication. Printed in English. No liability can be accepted for reference use only. All information contained within , whether whole or in this publication. Depictions and/or procedures in this publication are in U.S.A. 2016 600/800 SWITCHBACK ASSAULT Owner's Manual P/N 9925995 2 POLARIS...
... vehicle and the information presented in part, is based on the latest product information at the time of publication. Printed in English. No liability can be accepted for reference use only. All information contained within , whether whole or in this publication. Depictions and/or procedures in this publication are in U.S.A. 2016 600/800 SWITCHBACK ASSAULT Owner's Manual P/N 9925995 2 POLARIS...
Owners Manual
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... by dimming your headlights and reducing your vehicle. Check to avoid accidents. • Remove the key from flying snow and debris. Allow even more distance when driving on the rider's body position for proper balance in darkness or other low visibility conditions. Drive defensively to see if they take a snowmobile safety course. SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and...
... by dimming your headlights and reducing your vehicle. Check to avoid accidents. • Remove the key from flying snow and debris. Allow even more distance when driving on the rider's body position for proper balance in darkness or other low visibility conditions. Drive defensively to see if they take a snowmobile safety course. SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and...
Owners Manual
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Short-to-Ground: The wire is shorted to a wire at battery voltage. Shorted Load: The wires leading to the item listed in the chart. Short-to-Battery: The wire leading from the item listed in the chart (injector, fuel pump, etc.), or the item has failed. FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that...
Short-to-Ground: The wire is shorted to a wire at battery voltage. Shorted Load: The wires leading to the item listed in the chart. Short-to-Battery: The wire leading from the item listed in the chart (injector, fuel pump, etc.), or the item has failed. FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that...
Owners Manual
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FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Code Definitions. Diagnostic Codes Component ECU Memory Injector 1 (MAG) (Port Injector) Injector 2 (PTO) (Port Injector) Knock Sensor 1 Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Knock Level Cylinder 1 (MAG) Condition Checksum/CRC Error Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Open/Grounded Driver Circuit Short to B+ Fuel Type Selected Voltage Too High Voltage Too Low Signal Out Of Range 3509 3510 3598 520194...
FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Code Definitions. Diagnostic Codes Component ECU Memory Injector 1 (MAG) (Port Injector) Injector 2 (PTO) (Port Injector) Knock Sensor 1 Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Knock Level Cylinder 1 (MAG) Condition Checksum/CRC Error Driver Circuit Open/Grounded Driver Circuit Short to B+ Driver Circuit Open/Grounded Driver Circuit Short to B+ Fuel Type Selected Voltage Too High Voltage Too Low Signal Out Of Range 3509 3510 3598 520194...
Owners Manual
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... electric start, turn the key to START to the RUN position. This feature is useful for accessing the IDD without starting the engine, but turn off Vehicle / IDD power on the battery while the engine is running, but the IDD will continue to draw a small amount of current from the battery until the key is released, it automatically returns to crank the engine. The IDD is not dependent on Activates starter motor...
... electric start, turn the key to START to the RUN position. This feature is useful for accessing the IDD without starting the engine, but turn off Vehicle / IDD power on the battery while the engine is running, but the IDD will continue to draw a small amount of current from the battery until the key is released, it automatically returns to crank the engine. The IDD is not dependent on Activates starter motor...
Owners Manual
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See page 76 for stopping the snowmobile in the event of an emergency. OPERATION Emergency Stopping The following chart lists methods for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (Option) WHAT IT DOES Interrupts ignition circuit Slows jackshaft Interrupts ignition circuit Interrupts ignition circuit Interrupts ignition circuit 80
See page 76 for stopping the snowmobile in the event of an emergency. OPERATION Emergency Stopping The following chart lists methods for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (Option) WHAT IT DOES Interrupts ignition circuit Slows jackshaft Interrupts ignition circuit Interrupts ignition circuit Interrupts ignition circuit 80
Owners Manual
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... to be used. Towing For your safety, do not attempt to maintain control of the snowmobile. DO NOT tow toboggans, sleds, saucers, or any possibility of contact between the snowmobile's track and a person riding in serious damage to the engine and drive system. WARNING! Always remove the drive belt from a disabled snowmobile before towing, and have no braking power and can result...
... to be used. Towing For your safety, do not attempt to maintain control of the snowmobile. DO NOT tow toboggans, sleds, saucers, or any possibility of contact between the snowmobile's track and a person riding in serious damage to the engine and drive system. WARNING! Always remove the drive belt from a disabled snowmobile before towing, and have no braking power and can result...
Owners Manual
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... the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang tag. Specifications and adjustments for engine tune-ups are located in making a purchasing decision. Reverse (if equipped) must take your owner's manual. Environmental Protection Agency regulations. People with a minimum octane level of the tunnel or the engine recoil cover. MAINTENANCE Emission Control Information Any qualified repair shop...
... the time of sale with an emission control information (ECI) label and a factory-installed emissions information hang tag. Specifications and adjustments for engine tune-ups are located in making a purchasing decision. Reverse (if equipped) must take your owner's manual. Environmental Protection Agency regulations. People with a minimum octane level of the tunnel or the engine recoil cover. MAINTENANCE Emission Control Information Any qualified repair shop...
Owners Manual
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... this time. 5. Lift the front of the vehicle slightly if necessary. 2. Elevate the front of the snowmobile slightly to function properly. Fill the coolant bottle with properly mixed coolant to purge any trapped air. 9. Reinstall the side panel. 12. Never bleed the cooling system or remove the pressure cap when the engine is cold before starting the engine. 8. Reinstall the bleed screw into the manifold...
... this time. 5. Lift the front of the vehicle slightly if necessary. 2. Elevate the front of the snowmobile slightly to function properly. Fill the coolant bottle with properly mixed coolant to purge any trapped air. 9. Reinstall the side panel. 12. Never bleed the cooling system or remove the pressure cap when the engine is cold before starting the engine. 8. Reinstall the bleed screw into the manifold...
Owners Manual
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... fingers. Taillight/Brake Light Replacement The taillight assembly is not serviceable. Headlight Lamp Replacement 1. Rotate the bulb 1/4 turn it . 5. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 3. Secure the foam shield. Oil from the back of the lamp. Peel back the foam shield covering the headlight assembly. 2. Grasp the bulb housing and turn clockwise to...
... fingers. Taillight/Brake Light Replacement The taillight assembly is not serviceable. Headlight Lamp Replacement 1. Rotate the bulb 1/4 turn it . 5. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 3. Secure the foam shield. Oil from the back of the lamp. Peel back the foam shield covering the headlight assembly. 2. Grasp the bulb housing and turn clockwise to...
Owners Manual
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... Power Fuse Models equipped with electric start or an IDD have caused the blown fuse, then replace the fuse. If the IDD does not turn on when the key is located in the ON position, check for a blown fuse. Locate and correct any damaged components before replacing the fuse. 102 The 2 amp constant power fuse is in the hood harness. This fuse protects KEY ON power at the ignition switch. KEY ON power supplies battery...
... Power Fuse Models equipped with electric start or an IDD have caused the blown fuse, then replace the fuse. If the IDD does not turn on when the key is located in the ON position, check for a blown fuse. Locate and correct any damaged components before replacing the fuse. 102 The 2 amp constant power fuse is in the hood harness. This fuse protects KEY ON power at the ignition switch. KEY ON power supplies battery...
Owners Manual
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SPECIFICATIONS 800 SWITCHBACK ASSAULT Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity Oil Capacity Height Length Designed Width Brake Type Drive Clutch Center Distance Drive Belt P/N Drive Clutch Driven Clutch Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Throttle Body Recommended Engine Oil Throttle Body Bore Size Idle RPM Rated Operating RPM Cooling Ignition Type Ignition Timing °BTDC Spark Plug / Gap Recommended Fuel Octane PRO-RIDE 1 5 qts. (4.7 l) 9 oz. (266...
SPECIFICATIONS 800 SWITCHBACK ASSAULT Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity Oil Capacity Height Length Designed Width Brake Type Drive Clutch Center Distance Drive Belt P/N Drive Clutch Driven Clutch Reverse Transmission Engine Displacement Cylinders Bore x Stroke (mm) Alternator Output Throttle Body Recommended Engine Oil Throttle Body Bore Size Idle RPM Rated Operating RPM Cooling Ignition Type Ignition Timing °BTDC Spark Plug / Gap Recommended Fuel Octane PRO-RIDE 1 5 qts. (4.7 l) 9 oz. (266...
Owners Manual
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SPECIFICATIONS 800 SWITCHBACK ASSAULT 2.0 Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 10-66 (1321584) 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-60 (1321587) 10...
SPECIFICATIONS 800 SWITCHBACK ASSAULT 2.0 Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 10-66 (1321584) 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-60 (1321587) 10...
Owners Manual
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... of purchase 5. Length of time and conditions of your POLARIS dealer for replacement parts, service or warranty. Model number 3. Your dealer is also familiar with POLARIS policies and procedures and will be happy to record the identification numbers of operation 7. Contact your snowmobile and its engine. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede...
... of purchase 5. Length of time and conditions of your POLARIS dealer for replacement parts, service or warranty. Model number 3. Your dealer is also familiar with POLARIS policies and procedures and will be happy to record the identification numbers of operation 7. Contact your snowmobile and its engine. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede...
Owners Manual
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... safety information and notices regarding your vehicle. Product importation rules vary considerably from POLARIS in order to register your product in your new country. You may be requested from a private party, to be authorized to perform the warranty repair. If you purchase from a private party: If you purchase a POLARIS product from any POLARIS Servicing Dealer to perform warranty service. WARRANTY How to Obtain Warranty Service...
... safety information and notices regarding your vehicle. Product importation rules vary considerably from POLARIS in order to register your product in your new country. You may be requested from a private party, to be authorized to perform the warranty repair. If you purchase from a private party: If you purchase a POLARIS product from any POLARIS Servicing Dealer to perform warranty service. WARRANTY How to Obtain Warranty Service...
Owners Manual
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...; Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for a period of 200 hours of engine operation; 4,000 kilometers (2,485 miles) of the vehicle owner...
...; Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for a period of 200 hours of engine operation; 4,000 kilometers (2,485 miles) of the vehicle owner...
Owners Manual
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... Clutch Safety ...18 Clutch System ...103-106 Clutch Warning ...21 Clutch/Drive System, Storage ...117 Clutching Charts ...119-121, 123 Cold Weather Drive-Away ...18 Constant Power Fuse ...102 Controls and Linkage, Storage ...117 Coolant...94 Coolant Level...94-95 Cooling System ...94-96 Cooling System, Bleeding ...96 Cooling System, Flushing ...95 Customer Service...129 F Fasteners, Hood and Side Panel ...65 Fluid Change Chaincase...89 Coolant ...95 Fluid Level Brake Fluid ...99 Chaincase...89 Coolant ...94-95 Fuel ...73 Fuel Filter...
... Clutch Safety ...18 Clutch System ...103-106 Clutch Warning ...21 Clutch/Drive System, Storage ...117 Clutching Charts ...119-121, 123 Cold Weather Drive-Away ...18 Constant Power Fuse ...102 Controls and Linkage, Storage ...117 Coolant...94 Coolant Level...94-95 Cooling System ...94-96 Cooling System, Bleeding ...96 Cooling System, Flushing ...95 Customer Service...129 F Fasteners, Hood and Side Panel ...65 Fluid Change Chaincase...89 Coolant ...95 Fluid Level Brake Fluid ...99 Chaincase...89 Coolant ...94-95 Fuel ...73 Fuel Filter...
Owners Manual
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... Headlight Lamp Replacement ...101 Hood Fasteners ...65 Hood/Side Panel Access ...87 Hot Surface Warning ...23 O Oil Lines ...90 Oil Recommendations ...70 Operating in Deep Snow...16 Operation Warning ...24-25 Operator Safety ...8-20 Overheating, Engine ...32-33 P Parking Brake Lever Lock ...64 Passenger Warning ...22 PERC Button Alignment ...57 Playback Function ...39 Polaris Products and Part Numbers 124 Preload, IFS Shock Spring ...55 Pre-Ride Checklist ...60 Pre-Ride Suspension...
... Headlight Lamp Replacement ...101 Hood Fasteners ...65 Hood/Side Panel Access ...87 Hot Surface Warning ...23 O Oil Lines ...90 Oil Recommendations ...70 Operating in Deep Snow...16 Operation Warning ...24-25 Operator Safety ...8-20 Overheating, Engine ...32-33 P Parking Brake Lever Lock ...64 Passenger Warning ...22 PERC Button Alignment ...57 Playback Function ...39 Polaris Products and Part Numbers 124 Preload, IFS Shock Spring ...55 Pre-Ride Checklist ...60 Pre-Ride Suspension...
Owners Manual
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... Throttle Safety Switch ...76 Throttle Safety Switch Inspection ...62 Tool Kit ...28 Torsion Spring Preload ...52 Towing...81 Track Alignment ...110 Inspection...107 Lubrication...107 Tension ...108-109 Track Care for Storage ...117 Track Inspection ...65 Track Maintenance ...107-110 Track Safety...10 Track Warm-Up...72 Track Warning...23 Transporting the Snowmobile ...116 Troubleshooting, Drive Belt ...128 Troubleshooting, Engine ...125-126 Troubleshooting, Suspension...127 Tune-Up...116 V Vehicle Identification...
... Throttle Safety Switch ...76 Throttle Safety Switch Inspection ...62 Tool Kit ...28 Torsion Spring Preload ...52 Towing...81 Track Alignment ...110 Inspection...107 Lubrication...107 Tension ...108-109 Track Care for Storage ...117 Track Inspection ...65 Track Maintenance ...107-110 Track Safety...10 Track Warm-Up...72 Track Warning...23 Transporting the Snowmobile ...116 Troubleshooting, Drive Belt ...128 Troubleshooting, Engine ...125-126 Troubleshooting, Suspension...127 Tune-Up...116 V Vehicle Identification...