Owners Manual
Page 1
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
Page 21
...; Remove the key from the ignition when you 're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under normal riding conditions. SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may injure your vehicle. Allow even more distance when driving on the rider's body position for a snowmobile...
...; Remove the key from the ignition when you 're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under normal riding conditions. SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may injure your vehicle. Allow even more distance when driving on the rider's body position for a snowmobile...
Owners Manual
Page 50
...Battery: The wire leading from the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Diagnostic Codes Component Throttle Position Sensor Condition Voltage Too High Voltage Too Low Abnormal Rate of Change... 4 Vehicle Speed Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Engine Temperature Sensor 84 105 108 110 Alternator Power Supply Potential (DC Chassis Voltage) Exhaust Temperature Sensor 167 173 48 FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that ...
...Battery: The wire leading from the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Diagnostic Codes Component Throttle Position Sensor Condition Voltage Too High Voltage Too Low Abnormal Rate of Change... 4 Vehicle Speed Sensor Intake Air Temperature Sensor Barometric Pressure Sensor Engine Temperature Sensor 84 105 108 110 Alternator Power Supply Potential (DC Chassis Voltage) Exhaust Temperature Sensor 167 173 48 FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that ...
Owners Manual
Page 51
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
Page 69
...) is released, it automatically returns to crank the engine. OPERATION Ignition Switch The ignition switch has three positions. The IDD screen will continue to stop switch to draw a small amount of inactivity, but the IDD will turn off Vehicle / IDD power on the battery while the engine is running, but turn the key to START to the RUN position. When the key is used. 67 OFF RUN START Vehicle / IDD power off after...
...) is released, it automatically returns to crank the engine. OPERATION Ignition Switch The ignition switch has three positions. The IDD screen will continue to stop switch to draw a small amount of inactivity, but the IDD will turn off Vehicle / IDD power on the battery while the engine is running, but turn the key to START to the RUN position. When the key is used. 67 OFF RUN START Vehicle / IDD power off after...
Owners Manual
Page 82
OPERATION Emergency Stopping The following chart lists methods for more information about the engine stop switch and throttle safety switch. See page 76 for stopping the snowmobile in the event of an emergency. 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
OPERATION Emergency Stopping The following chart lists methods for more information about the engine stop switch and throttle safety switch. See page 76 for stopping the snowmobile in the event of an emergency. 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
Page 83
... a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Always remove the drive belt from a disabled snowmobile before towing, and have no braking power and can result in the towed object. Towing For your safety, do not attempt to maintain control of the snowmobile. Remove the key and cover the snowmobile...
... a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Always remove the drive belt from a disabled snowmobile before towing, and have no braking power and can result in the towed object. Towing For your safety, do not attempt to maintain control of the snowmobile. Remove the key and cover the snowmobile...
Owners Manual
Page 84
... maintain, replace, or repair the emission control devices or systems on , you must not be necessary. Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of the tunnel or the engine recoil cover. The ECI label is available to your qualified service technician. The ECI label should review the limitations of sale with a check engine light and it...
... maintain, replace, or repair the emission control devices or systems on , you must not be necessary. Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of the tunnel or the engine recoil cover. The ECI label is available to your qualified service technician. The ECI label should review the limitations of sale with a check engine light and it...
Owners Manual
Page 98
... under the seat. Lift the front of the vehicle slightly if necessary. 2. Reinstall the side panel. Reinstall the side panel. 10. Reinstall the side panel. 12. Steam and hot liquids will cause burns to the maximum mark. 7. NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. 1. Reinstall the bleed screw into the manifold. 6. Loosen the...
... under the seat. Lift the front of the vehicle slightly if necessary. 2. Reinstall the side panel. Reinstall the side panel. 10. Reinstall the side panel. 12. Steam and hot liquids will cause burns to the maximum mark. 7. NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or engine damage may result. 1. Reinstall the bleed screw into the manifold. 6. Loosen the...
Owners Manual
Page 103
... operate properly, replace the entire taillight assembly. 101 Secure the foam shield. If fingers do touch a lamp, clean it counter-clockwise to the back of the headlight. 3. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Taillight/Brake Light Replacement The taillight assembly is not serviceable. Oil from the...
... operate properly, replace the entire taillight assembly. 101 Secure the foam shield. If fingers do touch a lamp, clean it counter-clockwise to the back of the headlight. 3. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Taillight/Brake Light Replacement The taillight assembly is not serviceable. Oil from the...
Owners Manual
Page 104
KEY ON power supplies battery voltage to operate, a fuse may have a battery/electric start wire harness. If the fuse is located in the ON position, check for a blown fuse. If the IDD does not turn on when the key is in the hood harness. Never replace a fuse with a fuse of the blown fuse. Constant Power Fuse Models equipped with a new fuse having the same amperage rating of a higher amperage rating. This fuse protects KEY ON power at the ignition switch. Locate...
KEY ON power supplies battery voltage to operate, a fuse may have a battery/electric start wire harness. If the fuse is located in the ON position, check for a blown fuse. If the IDD does not turn on when the key is in the hood harness. Never replace a fuse with a fuse of the blown fuse. Constant Power Fuse Models equipped with a new fuse having the same amperage rating of a higher amperage rating. This fuse protects KEY ON power at the ignition switch. Locate...
Owners Manual
Page 120
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 Drive Clutch Type Driven Clutch Type 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...
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 Drive Clutch Type Driven Clutch Type 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...
Owners Manual
Page 121
SPECIFICATIONS 600 SWITCHBACK ASSAULT 2.0 Clutching (Non-Electric Start) 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. 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-58 (1321588) 10-56 (1321684) 10 AL (1321531...
SPECIFICATIONS 600 SWITCHBACK ASSAULT 2.0 Clutching (Non-Electric Start) 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. 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-58 (1321588) 10-56 (1321684) 10 AL (1321531...
Owners Manual
Page 122
SPECIFICATIONS 600 SWITCHBACK ASSAULT 1.3 Clutching (Non-Electric Start) 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. 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-58 (1321588) 10-56 (1321684) 10 AL (1321531...
SPECIFICATIONS 600 SWITCHBACK ASSAULT 1.3 Clutching (Non-Electric Start) 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. 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-58 (1321588) 10-56 (1321684) 10 AL (1321531...
Owners Manual
Page 123
SPECIFICATIONS 600 SWITCHBACK ASSAULT 1.75 Clutching (Electric Start) 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. 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-58 (1321588) 10-56 (1321684) 10 AL (1321531) Black/Green (7042083) RED/BLK (7043058) 56/42/36 LWER (5135403) 21:41 72 Pitch 20:41 72 Pitch 121
SPECIFICATIONS 600 SWITCHBACK ASSAULT 1.75 Clutching (Electric Start) 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. 10-64 (1321585) 10-62 (1321586) 10-60 (1321587) 10-58 (1321588) 10-56 (1321684) 10 AL (1321531) Black/Green (7042083) RED/BLK (7043058) 56/42/36 LWER (5135403) 21:41 72 Pitch 20:41 72 Pitch 121
Owners Manual
Page 135
... residence. Outside the country where your product was purchased: If you are traveling within the country where your product was purchased, warranty and service bulletin repairs may also be required to obtain documentation from POLARIS in order to perform the warranty repair. When requesting warranty service you use any authorized POLARIS dealer that you receive safety information and notices regarding your vehicle.
... residence. Outside the country where your product was purchased: If you are traveling within the country where your product was purchased, warranty and service bulletin repairs may also be required to obtain documentation from POLARIS in order to perform the warranty repair. When requesting warranty service you use any authorized POLARIS dealer that you receive safety information and notices regarding your vehicle.
Owners Manual
Page 137
... in addition to the POLARIS standard Limited Warranty for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following...
... in addition to the POLARIS standard Limited Warranty for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector *As related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following...
Owners Manual
Page 142
... 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
Page 143
... 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
Page 144
... 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...