Polaris 800 switchback assault User manual

PMS 419
SnowmobileOwner'sManual
forMaintenanceandSafety
800SwitchBack
Assault
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

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.

The text is printed on 100% recycled
with 40% post-consumer waste (PCW).

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone]
Part No. 9923248 Rev 01
Printed in USA
*9923248 *
PMS 419

1
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.polarisindustries.com for the latest news, new product introduc-
tions, 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)
•RANGER®utility vehicles
• Victory Motorcycles®
• Low emission vehicles (LEVs)
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 pro-
duced.
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 ser-
vice needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and acces-
sories, available through our online store at www.purepolaris.com. Have
your accessories and clothing delivered right to your door!

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POLARIS, THE WAY OUT, SWITCHBACK and ASSAULT are registered trademarks
of POLARIS Industries Inc.
Copyright 2010 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 discrep-
ancies may 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 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.
2011 800 SWITCHBACK ASSAULT Owner's Manual
P/N 9923248

3
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 . . . . . . . . . . . . . . . . . . . . . . . . . 42
This section includes suspension set-up information and explains how to
make additional suspension adjustments for the perfect riding experi-
ence.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 46
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
This section defines your role, and your dealer's role, in your snowmo-
bile's regular maintenance.
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 100
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 101
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 115
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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5
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient ref-
erence. It should remain with the snowmobile when the snowmobile is
sold.
Some of the illustrations and photos used in this manual are general rep-
resentations. 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 cam-
paign. We encourage state and provincial governments across the snow-
belt 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 pro-
tect 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 stan-
dards. 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 manufac-
turing 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 reduc-
tion 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.