Polaris 600 Switchback Assault User manual

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®

WARNING
Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.

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WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
•RANGER®utility vehicles
•RZR®sport vehicles
• VICTORY® motorcycles
• GEM® vehicles
We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle, making it the finest machine we've ever
produced.
For safe and enjoyable 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 Service Dealer® (MSD)
technician.
Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.

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POLARIS, PERC, SWITCHBACK and ASSAULT are registered trademarks of
POLARIS Industries Inc.
Copyright 2013 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in
this publication. Depictions and/or procedures in this publication are intended for
reference use only. No liability can be accepted for 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 instructions.
Printed in U.S.A.
2014 600 SWITCHBACK ASSAULT / 800 SWITCHBACK ASSAULT
Owner's Manual P/N 9924273

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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner's manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
This section describes safe vehicle operation and identifies warning
labels and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 48
This section includes suspension set-up information and explains how to
make additional suspension adjustments for the perfect riding
experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 52
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
This section defines your role, and your dealer's role, in your
snowmobile's regular maintenance.
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 106
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 112
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 113
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 127
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile when the snowmobile
is sold.
Some of the illustrations and photos used in this manual are general
representations. 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 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
to ensure warranty coverage.
Protect and preserve your right to ride by joining your local trail riding
clubs.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.

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INTRODUCTION
Preservation of the Environment
POLARIS is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection of our environment, including wildlife and vegetation.
Snowmobile clubs and other organizations are working together to
protect our environment. Please support their efforts and operate your
snowmobile with consideration for the protection and preservation of
our environment.
Noise Level
One of the most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
POLARIS snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may not
be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.
Air Pollution
POLARIS engineers continuously investigate ways to reduce emission
levels of two-stroke engines. We expect our efforts to lead to the
reduction of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.

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INTRODUCTION
Vehicle Identification Numbers
Record your snowmobile's identification numbers and key number in
the spaces provided. Remove the spare key and store it in a safe place.
Your key can be duplicated only by mating a POLARIS key blank with
one of your existing keys, so if both keys are lost, the ignition switch
must be replaced.
Vehicle Model Number: ___________________________________________________
Tunnel VIN (right side of tunnel): ____________________________________________
Engine Serial Number (on recoil housing): _____________________________________
Key Number: ____________________________________________________________
Tunnel VIN

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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and
symbols are used. Become familiar with their meanings before reading
the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.