2014 Polaris 800 Switchback Assault Owners Manual
2014 Polaris 800 Switchback Assault Manual
2014 Polaris 800 Switchback Assault manual content summary:
- 2014 Polaris 800 Switchback Assault | Owners Manual - Page 1
PMS 419 Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully. IMPORTANT NOTICE TO OWNER 600 Switchback Assault® 800 Switchback Assault® Snowmobile Owner's Manual for Maintenance and Safety - 2014 Polaris 800 Switchback Assault | Owners Manual - 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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 3
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 4
omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 5
identification numbers that should be recorded in the owner's manual. Safety ...8 This section describes safe vehicle operation and identifies in your snowmobile's regular maintenance. Specifications ...POLARIS Products...Troubleshooting ...Warranty ...Maintenance Log ...Index ... 106 112 113 118 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 6
4 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 7
when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 8
of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 9
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 10
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 11
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 12
warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. NO STEP Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, open the side panels - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 13
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. - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 14
bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular telephone. Always carry the owner's manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well Spare Drive Belt Extra Set of - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 15
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 16
if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party. Always check with local authorities - 2014 Polaris 800 Switchback Assault | Owners Manual - 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. You - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 18
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. If difficulty - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 19
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 20
removed. NOTICE: Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 21
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. - 2014 Polaris 800 Switchback Assault | Owners Manual - 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 Speed 40 in MPH Calm 5 10 15 20 25 30 35 40 45 50 55 60 40 36 34 32 30 29 28 28 27 26 26 25 25 Actual Thermometer - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 23
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. guard removed. Never run engine with drive belt removed. Never service clutches yourself. See your dealer. Pressure Cap Warning This warning - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 24
backing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse: • Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 25
SAFETY Safety Labels and Locations Track Warning The track warning label is on the 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. Hot Surface Warning Track Warning Hot Surface Warning - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 26
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. • This vehicle is capable of high speeds. Buried objects or uneven terrain can - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 27
stop. • To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. • Repeated stops from high speed may cause fading or sudden loss of braking ability. • Parking brake may relax - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 28
FEATURES 7 8 9 10 11 6 5 4 3 2 12 13 14 15 1 1. 2. 3. 4. 5. 6. 7. Nosepan Skis Front Bumper Hood Headlight Windshield (accessory) Handlebar 8. 9. 10. 11. 12. 13. 14. 15. Operator Seat Taillight Rear Bumper Snow Flap Suspension Track Side Panel Side Panel Fasteners 26 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 29
FEATURES 5 6 4 3 7 8 2 9 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fuel Filler Cap Electronic Reverse Button Brake Lever Parking Brake Lock Instrument Cluster Ignition Switch Engine Stop Switch Throttle Control Recoil Starter Handle Handlebar Grip Warmer Switch 11. Headlight Dimmer Switch 12. MODE/SET - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 30
: brakes, clutches, fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved POLARIS parts. Please see your POLARIS dealer for service. 28 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 31
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, - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 32
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 33
of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Cause of DET Activation Poor quality fuel with recommended fuel Replace with recommended fuel See your POLARIS dealer for service Do not add deicers or additives that contain any form of alcohol instructions. 31 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 34
FEATURES Instrument Cluster Rider Information Center Check Engine Indicator OverTemperature Indicator High Beam Indicator Park Brake Indicator Low Oil Indicator MODE Button SELECT Button Mode/Set Switch Reverse Indicator The instrument cluster contains indicator lights and the rider information - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 35
the lights are set to high beam. Parking Brake Indicator This indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use. See page 56. Reverse Indicator This indicator flashes when the transmission is in reverse. See page 69. 33 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 36
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. - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 37
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. Speed Display - The speed - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 38
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). 1. To - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 39
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 40
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 41
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 42
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 43
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 44
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. If - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 45
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 46
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 47
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 48
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 49
FEATURES 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) - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 50
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. - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 51
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 torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 52
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 53
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 54
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 Drive Belt Condition Steering System Recoil Rope Coolant Level Chaincase Oil Level Injection Oil Level - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 55
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 Check suspension mounting bolts for tightness. Check rear - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 56
and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. Throttle Safety Switch Test the throttle safety switch system before the - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 57
indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 90 or see your dealer for service. ) 1.3 cm 1/2" ( Lever Feel If the brake lever feels "spongy" when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 89 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 58
is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer. Lock Release To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position. WARNING! If the - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 59
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. If difficulty - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 60
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 61
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. Pull the engine stop switch up to the - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 62
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 63
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 64
before operating the snowmobile. Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be about 4 inches (10 cm) off the ground. 2. Start the engine and allow - 2014 Polaris 800 Switchback Assault | Owners Manual - 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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 66
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. - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 67
OPERATION Oil 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. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. View the oil level in the - 2014 Polaris 800 Switchback Assault | Owners Manual - 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. x Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 69
may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized POLARIS dealer for service. If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from - 2014 Polaris 800 Switchback Assault | Owners Manual - 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. • Shift to or from - 2014 Polaris 800 Switchback Assault | Owners Manual - 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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 72
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 Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch ( - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 73
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 74
and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups - 2014 Polaris 800 Switchback Assault | Owners Manual - 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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 76
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 77
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 78
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques Rear Suspension Fasteners Steering Fasteners Suspension Shock Oil Cooling Fins - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 79
, pull the panel outward to release the tabs at the lower edge of the panel. 1/4-Turn Fasteners Strap Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer. 77 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 80
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). - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 81
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. See page 112 for the part - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 82
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). TIP: The direction of the arrows indicates - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 83
performance. Always store fuel in clean fuel containers. If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals, the filter may need replacement. See your dealer. Inspect the fuel lines regularly for signs of deterioration or damage. Always - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 84
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 85
be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. TIP: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 86
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 87
coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 88
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. - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 89
remove the hood. See page 77. 2. Inspect the muffler and pipes for cracks or damage. 3. Check for weak or missing retaining springs or damper/support grommets. 4. Check for loose clamps on the pipe covers. Drive Chain Tension Check drive chain tension weekly and before each long trip. 1. Remove the - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 90
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 91
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 92
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 93
MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin 6. Secure the foam shield. Taillight/Brake Light Replacement The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly. 91 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 94
be damaged if lubricated. Do not lubricate clutch bushings. Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment. 92 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 95
for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 117. Always carry a spare drive belt. Store the spare belt in the belt clip located under the left side of the hood. For - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 96
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). 2 1 Drive Belt - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 97
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 counterclockwise 1/4 turn by hand to ensure - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 98
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 99
Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand ! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 100
adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off. 2. Lift the rear of the snowmobile and safely support it off the ground. 3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of - 2014 Polaris 800 Switchback Assault | Owners Manual - 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 98. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. Adjusting Screw - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 102
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. 2. Start the engine and apply a small amount of throttle until the track turns - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 103
MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary. X X X X 101 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 104
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 105
when worn to half their original diameter. TIP: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 106
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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 107
driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the fogging oil. Follow the engine fogging instructions provided on the container. Always add Carbon Clean or supported off the ground to allow the track to hang freely - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 108
SPECIFICATIONS 600 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 Clutch Type Reverse Transmission - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 109
SPECIFICATIONS 600 SWITCHBACK ASSAULT 2.0 Clutching (Non-Electric Start) ALTITUDE Meters (Feet) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 110
SPECIFICATIONS 600 SWITCHBACK ASSAULT 1.3 Clutching (Non-Electric Start) ALTITUDE Meters (Feet) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 111
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 Clutch Type Reverse Transmission - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 112
SPECIFICATIONS 800 SWITCHBACK ASSAULT 2.0 Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch 20:42 21:41 (INTL) 72 Pitch 20:42 21:41 (INTL) 72 Pitch 20:42 21:41 (INTL) 72 Pitch 20:42 21:41 (INTL) 72 Pitch 20 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 113
SPECIFICATIONS 800 SWITCHBACK ASSAULT 1.3 Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 114
POLARIS PRODUCTS Part No. 2870791 2877882 2877953 2877883 2877884 2873105 2873106 2871312 2871322 2871423 2871329 2871534 2871323 2871326 2870652 2872189 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) VES 2-Cycle Engine Oil (qt./.95 l) VES 2-Cycle Engine - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 115
TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Harsh drive clutch engagement Probable Cause Solution Drive clutch - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 116
TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 117
TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable or pump. Add isopropyl alcohol to the fuel system. • SEE YOUR DEALER. • This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER. • Replace the plug(s). • SEE YOUR DEALER. • - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 118
TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension bottoms too easily Rides too stiff in rear Solution • Refer to the suspension adjustment and set-up information beginning on page 48. • Revalve - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 119
Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Driving at low RPM Insufficient warm-up Solutions • Drive at higher RPMs. Gear the machine down. Check belt deflection. • Warm - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 120
of purchase 5. Details of trouble experienced 6. Length of time and conditions of operation 7. Previous correspondence Use the page provided near the front of your Owner's Manual to record the identification numbers of your snowmobile and its engine. POLARIS Customer Service United States: 1-888-704 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 121
1. POLARIS snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call POLARIS Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2. 3. POLARIS warranty will - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 122
preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 123
offered by POLARIS. These warranties can be, but are not limited to: • Two-year extended engine coverage • Two-year powertrain coverage • Extended service contract If you selected any type of extended warranty coverage as part of a POLARIS retail program, please contact any authorized POLARIS dealer - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 124
to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 125
must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle. Outside the Country where your vehicle - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 126
it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment outside of the country - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 127
WARRANTY 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 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 128
responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 129
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 (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 130
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 128 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 131
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 129 - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 132
Linkage - Storage ...105 Coolant...84 Coolant Level...84 Cooling System ...84-86 Cooling System, Bleeding ...86 Cooling System, Flushing ...85 Customer Service...118 F Fasteners, Hood and Side Panel ...57 Fluid Change Chaincase...79 Coolant ...85 Fluid Level Brake Fluid ...89 Chaincase...79 Coolant - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 133
INDEX H Handlebar Adjustments...Handlebar Angle ...Headlight Adjustment ...Headlight Lamp Replacement ...Hood Fasteners ...Hood/Side Panel Access ...Hot Surface Warning ...51 51 28 91 57 77 23 O Operation Warning ...24-25 Operator Safety ...8-20 Overheating, Engine ...85 P Parking Brake Lever Lock - 2014 Polaris 800 Switchback Assault | Owners Manual - Page 134
Safety...10 Track Warm-Up...62 Track Warning...23 Transporting the Snowmobile ...104 Troubleshooting, Drive Belt ...117 Troubleshooting, Engine ...113-115 Troubleshooting, Suspension...116 Tune-Up...104 V Vehicle Identification Numbers...7 T Taillight/Brakelight Replacement . . Throttle Lever - 2014 Polaris 800 Switchback Assault | Owners Manual - 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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PMS 419
Modifications to this snowmobile are not recommended
and may result in voided warranty coverage.
Please read the warranty section of this manual carefully.
IMPORTANT NOTICE TO OWNER
Snowmobile Owner's Manual
for Maintenance and Safety
800 Switchback Assault®
600 Switchback Assault®