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Polaris 800 switchback assault, Owner'S Manual

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72

MAINTENANCE

Lubrication

Rear Suspension

Lubricate the suspension pivot shafts with POLARIS Premium All Sea-
son Grease at the intervals outlined in the Periodic Maintenance Table 
beginning on page 68 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 sus-
pension. Lubricate where indicated in the illustration below. For more 
information about suspension lubrication and adjustments, see your 
POLARIS dealer.

X

X

X

Summary of Contents for 800 switchback assault

Page 1: ...l for Maintenance and Safety 800 SwitchBack Assault Modifications to this snowmobile are not recommended and may result in voided warranty coverage Please read the warranty section of this manual care...

Page 2: ...ns 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 th...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9923248 Rev 01 Printed in USA 9923248 PMS...

Page 5: ...sign and development of your POLARIS vehicle making it the finest machine we ve ever pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations i...

Page 6: ...result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted...

Page 7: ...ontrols and features The Perfect Fit 42 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experi ence Pre Ride Inspe...

Page 8: ...4...

Page 9: ...are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary t...

Page 10: ...at snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE stan dards Our muffler systems are designed to reduce noise levels and must not be altered...

Page 11: ...a POLARIS key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN ri...

Page 12: ...eir meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death o...

Page 13: ...in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as di...

Page 14: ...off the igni tion open the side panels or hood make the adjustment secure shields and guards secure the side panels and hood and then restart the engine to check its operation WARNING Serious injury c...

Page 15: ...will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterpro...

Page 16: ...f it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the condi tions you may encounter Such equipment may include but is...

Page 17: ...and speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds y...

Page 18: ...f a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first ver...

Page 19: ...ow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow co...

Page 20: ...rating on slippery surfaces Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is...

Page 21: ...causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low an...

Page 22: ...mplex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather D...

Page 23: ...ell as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of...

Page 24: ...93 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min...

Page 25: ...chase a replacement Replacement safety labels are pro vided by POLARIS at no charge The part number is printed on the label Clutch Warning This warning label is found on the oil bottle WARNING Do not...

Page 26: ...even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse on...

Page 27: ...rom seat back may result in severe injury or death Hot Surface Warning The hot surface warning is on the rear center of the tunnel WARNING Hot Surface Do Not Touch Burns may result Entire top of tunne...

Page 28: ...nfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Nev...

Page 29: ...in 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...

Page 30: ...11 2 1 3 4 10 9 1 Nosepan 2 Skis 3 Front Bumper 4 Hood 5 Headlight 6 Windshield accessory 7 Handlebar 8 Operator Seat 9 Taillight 10 Rear Bumper 11 Snow Flap 12 Suspension 13 Track 14 Side Panel 15 S...

Page 31: ...rake 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 Headlight Dimmer Switch 12 MOD...

Page 32: ...accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmo bile Use of unapproved parts and accessories may result in Non compl...

Page 33: ...ust be connected Whenever in doubt of your fuel purchase use the 10 ETHANOL 24 OHM resistor as a safeguard The resistor is installed into the wiring harness on the left side of the snowmobile just abo...

Page 34: ...ases this is temporary and the operator does not need to take any action The engine will return to its normal performance automatically If severe detonation occurs the check engine light will begin to...

Page 35: ...on ethanol fuel resistor installed Verify correct fuel resistor for fuel type in tank Low fuel no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel fil...

Page 36: ...ET switch on the left handlebar or console NOTICE Certain products will damage the lens and other plastic sur faces Do not use alcohol to clean the instrument cluster Immediately clean off any gasolin...

Page 37: ...indicator flashes continued operation could result in serious engine damage Stop the engine immediately Low Oil Indicator The low oil indicator light may flicker at times due to oil movement in the bo...

Page 38: ...ttable trip meters 2 total engine hours of operation fuel level engine tempera ture and diagnostic display mode Setting changes must be made with the engine running or with the vehi cle powered by an...

Page 39: ...a displays either vehicle speed or engine speed To change the display see page 36 3 Odometer Engine Hour Display This area displays the odometer Trip A Trip B and engine hours To change the display se...

Page 40: ...plays first make sure the information dis play area is set to display either engine speed or vehicle speed 2 Press and hold the mode button on the instrument cluster or the mode switch on the left han...

Page 41: ...To reset a trip meter press and hold the SELECT button or the SET switch until the meter resets to zero Playback Function The playback function allows the rider to record and play back engine speed v...

Page 42: ...are changed The new settings will remain until changed by the operator Change Method 1 1 Press and release the MODE button or MODE switch until engine temperature displays 2 Press and hold the MODE b...

Page 43: ...ve codes 1 Do not stop the engine 2 With the brake engaged press and release the SELECT button or SET switch to toggle to the diagnostic display mode When a code is active the diagnostic display mode...

Page 44: ...o the electronic control unit is shorted to a wire at battery voltage Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Cha...

Page 45: ...G Maximum Detonation Correction Limit Reached 1352 0 Knock Above Critical Level 16 Knock Level Cylinder 2 PTO Maximum Detonation Correction Limit Reached 1353 0 Knock Above Critical Level 16 Sensor Su...

Page 46: ...distance between the ground and the rear bumper at the exact loca tion used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measure ment Y from X Sag...

Page 47: ...Different rate torsion springs are available if a firmer ride is desired Contact your dealer for more information The following information is provided only as a guideline to be used for initial suspe...

Page 48: ...y To stop bottoming of the front or rear sus pension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top of the clicker then test ride Repeat the adjustment until bottoming s...

Page 49: ...t ments can be made to the independent front suspension and front track shock preload When adjusting the front suspension be sure the springs on both sides of the vehicle are at the same adjustment Fo...

Page 50: ...7 Steering System 51 Recoil Rope 51 Coolant Level 78 Chaincase Oil Level 73 Injection Oil Level 59 Parking Brake Lock Brake Lever Brake System 49 50 82 Auxiliary Shut Off Switch Engine Stop Switch 52...

Page 51: ...ems Check the follow ing items on a weekly basis or before any long trip Item See Page Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness 93 Check rear idler adju...

Page 52: ...Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience n Throttle Lever The throttle and brake are the primary controls of your...

Page 53: ...tes low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 84 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed che...

Page 54: ...place Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service b...

Page 55: ...njury or death Always inspect the track for damage before using the vehicle WARNING Use of traction products such as studs increases the possibility of track damage and or failure Driving at high spee...

Page 56: ...ch down to stop the engine Pull it up to allow restarting n Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF n Tether Switch if equipped If your snowmobile has a te...

Page 57: ...le no more than 1 4I open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rop...

Page 58: ...umbers of POLARIS products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could...

Page 59: ...our vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snow mobile Oil Injection System Always check and fill...

Page 60: ...ate stand to securely support the rear of the snow mobile at the rear bumper The track should be about 4I 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress...

Page 61: ...n or near the area where refu eling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the...

Page 62: ...d exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non ethanol fuel sometimes labeled non oxygenated POLARIS reco...

Page 63: ...indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can...

Page 64: ...e safety switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately...

Page 65: ...the throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized POLARIS dealer for servic...

Page 66: ...dle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Electro...

Page 67: ...ansmission is in reverse The maximum engine RPM will be 6000 when in reverse TIP If the engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the s...

Page 68: ...See page 60 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 Inter...

Page 69: ...w hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the...

Page 70: ...e with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specificat...

Page 71: ...rvals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered owner If during the course of the warranty perio...

Page 72: ...Lubricate Item See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 86 I I I Drive Belt Condition 87 I I I I Clutches...

Page 73: ...I I I I Brake System 49 82 I Brake Fluid 83 R FUEL MANAGEMENT Idle RPM I I I Throttle Lever 61 I I I I I Oil Pump Lever synchronize I I I Throttle Position Sensor I I I Fuel Lines 75 I I I I Fuel Filt...

Page 74: ...steners I I I I I Steering Fasteners I I I I C Suspension Shock Oil R Cooling Fins and Shroud I I I I Skags Wear Bars 97 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 81 I I I I I H...

Page 75: ...lace before starting the engine To open a side panel rotate the two 1 4 turn fasteners at the upper edges of the side panel Release the side panel strap at the lower edge of the panel To remove an ope...

Page 76: ...nance Table beginning on page 68 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 li...

Page 77: ...overflow 4 Wipe the fill area with a clean cloth 5 Reinstall the fill plug Torque to 6 10 ft lbs 8 13 Nm Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain plug R...

Page 78: ...ry 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 directio...

Page 79: ...or quality fuel will shorten the life of the fuel filter and result in poor engine performance Always store fuel in clean fuel containers If low fuel pressure or reduced engine performance occurs betw...

Page 80: ...ange the spark plugs every 2000 2500 miles 3200 4000 km Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Always carry spar...

Page 81: ...Reverse the procedure for spark plug installation Torque to specifi cation 5 Reinstall the spark plug cap Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There wil...

Page 82: ...See page 100 for POLARIS products Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system n Coolant Level The engine...

Page 83: ...ine frequently to allow it to cool down Flashing Indicator If the indicator flashes continued operation could result in serious engine damage The system will automatically reduce engine power and crea...

Page 84: ...this time 5 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed scre...

Page 85: ...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 side pa...

Page 86: ...ng brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner tha...

Page 87: ...ke fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature o...

Page 88: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16I 6 8 cm below the lip of the reservoir open ing Reinstall the gasket and cover 3 Slip a rubber tube over the ball of...

Page 89: ...the headlight assembly 2 Remove the wire harness connector from the back of the headlight 3 Grasp the bulb housing and turn it counter clockwise to remove the bulb 4 Apply dielectric grease to the so...

Page 90: ...pairs have been made All clutch maintenance and repairs must be performed by an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the wa...

Page 91: ...cracks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 105 Always carry a spare drive belt Store the spare belt in the belt clip locat...

Page 92: ...and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 inches 3 2 cm Drive Belt Adjustment 1 Loosen the 7 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch...

Page 93: ...ion key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Remove the left side panel 5 Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagem...

Page 94: ...install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as out lined in the belt removal p...

Page 95: ...l needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear WARNING Operating with...

Page 96: ...ion and alignment TIP Tension 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 Pla...

Page 97: ...e equal adjust ment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Start the engine and slowly rotate the tr...

Page 98: ...Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails X are evenly spaced on each side If the track...

Page 99: ...95 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...

Page 100: ...dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measure...

Page 101: ...f their orig inal 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...

Page 102: ...ntive measures to aid against deterioration and to prolong the useful life of many components See page 100 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with...

Page 103: ...f more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium Carbon Clean or a fuel conditioner stabilizer to the...

Page 104: ...le Engine Oil 4 ltr Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 l 2872951 Synthetic Chaincase Lubricant 12 oz 355 ml Grease Specialized Lubricants 2871312 Grease Gun Kit Premium A...

Page 105: ...drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount bro ken or...

Page 106: ...OUR DEALER Poor low RPM performance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel...

Page 107: ...operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Plugged fuel filter or tank pick up sock SEE YOUR D...

Page 108: ...on page 42 Too little weight transfer when climbing Refer to the suspension adjustment and set up information beginning on page 42 Machine darts from side to side Check ski alignment see page 96 Make...

Page 109: ...oid riding in high ambient temperatures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the snowmobile in extremel...

Page 110: ...ontained in this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the fol lowi...

Page 111: ...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 mode...

Page 112: ...al damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for...

Page 113: ...present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility POLARIS recommends that you use your original selling dealer...

Page 114: ...coverage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress...

Page 115: ...any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was...

Page 116: ...u receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above...

Page 117: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 118: ...by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine...

Page 119: ...r each time your snow mobile 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...

Page 120: ...116 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 121: ...117 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 122: ...nation Technology 30 31 Diagnostic Display Codes 40 41 Diagnostic Display Mode 39 Disabled Operators 12 D Display Standard Metric 38 Drive Belt Adjustment 88 Break In 55 Condition 87 Deflection 88 Ins...

Page 123: ...nance Program 67 Maintenance Recommendations 9 Maneuverability 18 Metric Standard Display 38 N Noise 6 O Odometer Engine Hour Display Area 37 Oil Change Chaincase 73 Oil Filter 74 Oil Injection System...

Page 124: ...n 12 Suspension Adjustments 42 45 Suspension Inspection Pre Ride 47 Suspension Lubrication Rear 72 Switches Engine Stop Switch 60 Mode Select Buttons 32 Mode Set Switch 32 Throttle Safety Switch 60 T...

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