Polaris 800 Switchback User Manual Page 1

2004RMK & SwitchbackSnowmobiles2004RMK & SwitchbackSnowmobilesOwner's Manualfor Vehicle Maintenanceand SafetyOwner's Manualfor Vehic

8SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these word

98MAINTENANCETrack MaintenanceIf the track needs adjustment (continued):8. Repeat measurement on the other side of the track. NOTE: Checkmore frequent

99MAINTENANCETrack MaintenanceTrack Insp ectio nUsing a hoist, safely lift and support therear of the snowmobile off the ground.Rotate the track by ha

100MAINTENANCESteering SystemSteering Inspectio n and AdjustmentEach week, or before a long ride, check fasteners and tighten ifnecessary. Specific fa

101MAINTENANCESteering SystemSki AlignmentWith the handlebars in a straight ahead position, and with vehicleweight compressing the suspension, measure

102MAINTENANCESteering SystemSki SkagsCheck skags weekly to maintain positive steering characteristics. Skagsmust be replaced when worn to half their

103MAINTENANCEHi-F ax WearCheck Hi-fax wear bymeasuring t he thickness atseveral points along the rail(A). Replace Hi-fax when athickness of 7/16″ is

104MAINTENANCEExtended StorageOff-season or extended storage of your snowmobile requires preventivemeasures to aid against deterioration and to prolon

105MAINTENANCEExtended StorageControls and LinkageAll bushings, spindle shafts, tie rod ends, and cables s hould receive alight coat of oil or grease.

106MAINTENANCEExtended StorageElectrical Conn ectio n sSeparate electrical connector blocks and clean corrosive build-up fromconnectors. Lubricate or

107MAINTENANCEBatteryBattery FluidA poorly maintained battery willdeteriorate rapidly. C heck the batteryfluid level often. The fluid level shouldbe k

9SAFETYOperator SafetyWARNINGDriving a snowmobile requires your full attention. DO NOTdrink alcohol or use drugs or medications before or whiledriving

108MAINTENANCEBatteryBattery ConnectionsKeep battery terminals and connections free of corrosion. Whencleaning is necessary, remove the corrosion with

109MAINTENANCEBattery Installation1. Place the battery in its holder. Attach the hold down strap.2. Install the battery vent line. It must be free fro

110POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2871098 Premium 2-Cycle Engine Oil (qt.)2871097 Premium 2-

111TROUBLESHOOTINGSuspension TroubleshootingProblem Solution (perform only one change at a time)Rear suspensionbottoms too easily- Verify sag dimensio

112TROUBLESHOOTINGBelt Wear/Burn TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM Drive at higher RPMs. Gear the machine down

113TROUBLESHOOTINGEngine TroubleshootingCAUTION: Unless you have experience and training in two-cycleengine repair, see your dealer if technical probl

114TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drivesystemBroken drive clutchcomponentsBearing failure/chaincase, jac

115TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turnsbut fails to startFaulty ignitionNo fuel to engineFlooded engine(no

116WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warrantyinfor

117WARRANTYLimited W arrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Pola

10SAFETYOperator SafetyStay Away F rom Movin g PartsBe alert when riding, and remain properly seated to stay clear of thetrack. Your snowmobile is pro

118WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND F

119WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if app

120WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that w

121WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

122INDEXAAccessories 39-42...Airbox 22...BBattery 106-108...Battery Connections 108...

123INDEXHHalogen Bulbs 90...Handlebar Adjustments 38...Handlebar with Riser Block 38...Handlebar, Standard 38...

124INDEXSSuspension 106...Suspension Maintenance 103...Suspension Performance Tips 34...Suspension Troubleshooting 111...

For your nearest Polaris dealer, call 1-800-POLARISor visit www.polarisindustries.comPolaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340Phone (763) 4

11SAFETYOperator SafetyRiding PositionOperating a snowmobile requires skill and balance for proper control.Rider positions may vary from person to per

12SAFETYOperator SafetyCargo OverloadToo much weight on the rear of the machine may reduce your ability tosteer. Do not exceed carrier and rack weight

13SAFETYOperator SafetyExcessive SpeedObserve all state and local laws governing snowmobile operation.They’ve been established for your protection.Alw

14SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles,posts, or other obstacles. Be especiallyalert if you’re snowmobiling after

15SAFETYOperator SafetyIce and Snow Build -upBefore driving, manually turn the skis to the left and right to be sureice and snow are not interfering w

16SAFETYOperator SafetyDriving in Hilly TerrainOperating in hilly terrain requires extreme caution to maintain balanceand avoid roll-over. If climbing

17SAFETYOperator SafetyDriving DownhillWhen riding downhill, shift your weight to the rear of the machine andreduce your speed to a minimum. Apply jus

Read, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the safety precau

18SAFETYOperator SafetyIntake SilencerDo not operate the engine with the intake silencer or filter removed.Damage to the engine may occur if the intak

19SAFETYOperator SafetyPowder Snow OperationMoveable hood closures are included on some Polaris snowmobiles.They are normally left open and are locate

20SAFETYOperator SafetyYour Polaris snowmobile is a well-engineered and well-constructedrecreational vehicle. Follow the recommended maintenance progr

21SAFETYOperator SafetyWindchill/Temperature Ch artsThe following information is provided to help you determine whentemperatures become dangerous for

22SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for yourprotection. Read and follow the instructions of the decal

23SAFETYSafety Decals and LocationsTrack/Seat WarningThe track/seat warning decal is on the rear ofthe tunnel:Stay clear of track. Do not sit on seatb

24SAFETYSafety Decals and LocationsOperation WarningAn operation warning decal is present on the console of all Polarissnowmobiles:S To avoid serious

25FEATURES AND CONTROLSControls1. Fuel Filler C ap (may include a fuel gauge)2. Ignition Switch3. Brake Lever4. Speedometer (may include indicator/war

26FEATURES AND CONTROLSControlsSome P olaris snowmobiles are equipped with special features.Controls for these features are illustrated on this page.

27FEATURES AND CONTROLSFeatures1. Hood2. Headlight3. Windshield4. Handlebar5. Seat6. Storage Compartment7. Taillights8. Snow Flap9. T rack10. Suspensi

1What’s the hottest thing on snow?A Polaris owner ’s Web site, designed just for YOU!S Technical tipsS New product introductionsS Event schedulesS Par

28FEATURES AND CONTROLSFeaturesDetonation Elimination Technology (D.E.T.)Some P olaris snowmobiles are equipped with adetonation sensor that monitors

29THE PERFECT FITFront Suspension AdjustmentsBreak in the suspension for approximately 150 miles (240 km) andre-grease all suspension parts before fin

30THE PERFECT FITFront Suspension AdjustmentsThe tension at which the shock coil spring i s set is called springpreload. For the best ride, the spring

31THE PERFECT FITFront Suspension AdjustmentsShock DampingAdjustments to the compressionstiffness of Indy Select orRydeFX SOLO shocks can bemade by tu

32THE PERFECT FITFront Suspension AdjustmentsAdjusting Front Shock Spring PreloadIncreasing spring preload will increaseski-to-ground pressure. Decrea

33THE PERFECT FITFront Suspension AdjustmentsShock ValvingRydeFX or RydeFX SOLO shocks can be revalved if spring preloadalone isn’t sufficient and fur

34THE PERFECT FITRear Suspension AdjustmentsRear SuspensionsRider weight, riding style, trail conditions, and vehicle speed all affectsuspension actio

35THE PERFECT FITRear Suspension AdjustmentsRear Suspension Initial Spring Preload Setting(Sag Method)To set up the rear suspension torsionspring prel

36THE PERFECT FITRear Suspension AdjustmentsRear Torsion Spring TensionTo adjust rear torsion spring t ension, rotate the t hree-position camusing the

37THE PERFECT FITRear Suspension AdjustmentsIndy Select Rear ShockSome snowmobiles are equipped with the Indy Select rear shock,which allows for adjus

2Copyright 2003 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

38THE PERFECT FITHandlebar AdjustmentsStandard HandlebarFollow these steps to adjust the handlebar for a personal fit.1. Remove the handlebar cover to

39THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile. Frommap light to electric start, Polaris has the accessori

40THE PERFECT FITAccessoriesTraction ProductsAnother way to tailor your machine is to install traction products. S eeyour dealer about installing stud

41THE PERFECT FITAccessoriesTraction ProductsA skag is a replaceable bar attached to the underside of the ski to assistin turning the snowmobile and t

42THE PERFECT FITAccessoriesWear StripsTo avoid excessive tunnel or cooler damage, wear strips must beinstalled whenever track studding is used. See y

43PRE-RIDE INSPECTIONSBefore Starting the EngineRead and Understand Your Owner’s ManualRead the Owner’s Manual completely and refer to it often. We’ve

44PRE-RIDE INSPECTIONSBefore Starting the EngineHydraulic BrakesProperly functioning brakesare critical to your safety.Always check the followingitems

45PRE-RIDE INSPECTIONSBefore Starting the EnginePark Brake Lever L o ckYour snowmobile may have a park brake lever l ock located over thebrake lever.

46PRE-RIDE INSPECTIONSBefore Starting the EngineCheck fo r Proper Operation of Steering SystemManually turn the skis completely to the right and to th

47PRE-RIDE INSPECTIONSStart the Engine and Checkn Engine Stop Switch: Check the auxiliary shut-off switch forproper operation. Push down to stop the e

3WELCOMEThank you for purchasing a Polaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of utili

48OPERATIONStarting the EngineStarting a Cold Engine (Manual Start)Do not depress the throttle until the engine starts.1. Turn key to ON.2. Pull kill

49OPERATIONStarting the EngineStarting a Cold Engine (Electric Start)Do not depress the throttleuntil the engine starts.1. Flip choke toggle toFULL ON

50OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-freemachine life as proper break-in of a new or rebuilt engin

51OPERATIONEngine Break-InOil In jectio n SystemAlways fill the oil reservoir when refueling. Fuel-to-oil mix ratios arecontrolled by the oil pump and

52OPERATIONTrack W arm- UpFollow these steps to ensure proper warm-upof the engine, drive train and track.1. Use an appropriate stand to securelysuppo

53OPERATIONFuelGasoline is highly flammable and explosive under certainconditions.S Always exercise extreme caution whenever handling gasoline.S Alway

54OPERATIONFuelThe fuel used in your Polaris engine is as important to engine life andperformance as the lubricant used.Your Polaris engine is designe

55OPERATIONFuelPremium Fuel SwitchIf you’re uncertain about the quality or octane rating of the fuel youuse, turn your key switch to ON/REG. The Premi

56OPERATIONOilLow Oil Indicator LightThe low oil indicator light will indicate when to add oil. See page 51for oil recommendations.When the low oil in

57OPERATIONOilLow Oil LevelAlways do a visual check of the oil level whenrefueling. When the oil reaches the low levelmark, add one U.S. quart of reco

4TABLE OF CONTENTSIntroduction 5...This section contains helpful i nformation for owners and drivers andillustrates t he lo

58OPERATIONCarburetionJetting GuidelinesChanges in altitude and temperature affect air density, which is theamount of oxygen available for combustion.

59OPERATIONEngine Stop SwitchPush down on the engine stopswitch (A) to stop the engine in anemergency. This will ground outthe ignition and bring the

60OPERATIONThrottle LeverIf the engine stops abruptly when the throttle lever is released:1. Turn the ignition switch to OFF.2. Visually inspect the t

61OPERATIONEmergency StoppingThe following chart lists methods for stopping the snowmobile in theevent of an emergency. Refer to page 59 for more info

62OPERATIONEmergency StartingYour machine is equipped with a tool kit containing essential tools foremergency use. Machines equipped with electric sta

63OPERATIONReverse OperationElectronic Reverse (PERCt)Electronic reverse will activate only if the engine is below 4000 RPM.If your machine is running

64OPERATIONDaily StorageAt the end of each ride, park the snowmobileon a level surface and support it at the rearwith an appropriate track stand. The

65MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, followrecommended regular maintenance

66MAINTENANCEMaintenance ChartThe following chart is a guide based on average riding conditions. Youmay need to increase frequency based on riding con

67MAINTENANCEMaintenance ChartItem Weekly orbeforelong trip150miles(240 km)500miles(800 km)1000miles(1600 km)SeePageTighten idler adjusting bolt jamnu

5INTRODUCTIONImportant Notes for Owners and Driversn After reading this manual, store it in the snowmobile forconvenient reference. It should remain w

68MAINTENANCEMaintenance LogPresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future

69MAINTENANCEMaintenance LogAdditional Services PerformedAuthorized Polaris Servicing DealerServicing TechnicianDate MileageType of ServiceAdditional

70MAINTENANCELubricationLubricate the suspension and steering components with PolarisPremium All-Season Grease at 500 miles (800 km) andannually or ev

71MAINTENANCELubricationThe suspension pivot shafts should be lubricated with Polaris P remiumAll Season Grease at 500 miles (800 km) initially, every

72MAINTENANCELubricationJackshaft Bearing GreasingLoosen the driven clutch retaining bolt and pullthe clutch outward to expose the bearing andgrease f

73MAINTENANCELubricationChaincase Oil LevelIt’s the operator’s responsibility to check and m aintain the properchaincase oil level.To check the oil le

74MAINTENANCEGeneral MaintenanceSpark PlugsIt’s very important to use the correct spark plug for your machine. Aspark plug with a heat range too high

75MAINTENANCEGeneral MaintenanceSpark PlugsSpark plug condition is indicative of engine operation. The spark plugfiring end condition should be read a

76MAINTENANCEGeneral MaintenanceIntake FilterThe intake foam filter limits snowingestion into the intake system.When operating in loose powdersnow, ch

77MAINTENANCEGeneral MaintenanceVariable Exhaust System (V.E.S.)Mainte nanc e of the V.E.S. is limited to a periodic inspection andclea ning of system

6INTRODUCTIONPreservation of the EnvironmentPolaris is committed to supporting an environmental educationcampaign. We encourage state and provincial g

78MAINTENANCEGeneral MaintenanceWater/Sediment Trap ServiceMost Polaris snowmobiles contain patented carburetor bowlwater/sediment traps located at th

79MAINTENANCEGeneral MaintenanceFuel Filter/Fuel LinesInspect the in-tank fuel filter (1) and fuellines regularly. Give special attention to thesystem

80MAINTENANCEGeneral MaintenanceGeneral Carburetor InformationThe number stamped in the end of the main jet indicates the jet size.The jet installed a

81MAINTENANCEGeneral MaintenanceExhaust SystemCheck the exhaust system for wear or damage at approximately 1000miles (1600 km). To inspect, allow the

82MAINTENANCEGeneral MaintenanceEngine Cooling - Liquid Cooled ModelsCoolant High Temperature Indicator LightThe high temperature indicator light is c

83MAINTENANCEGeneral MaintenanceEngine Cooling - Liquid Cooled ModelsBleeding the Cooling SystemIf the pressure cap needs replacement, contact your de

84MAINTENANCEGeneral MaintenanceDrive Chain TensionTo obtain correct chain tension:1. Rotate the driven clutchcounterclockwise to move all chainslack

85MAINTENANCEGeneral MaintenanceHydraulic Brake InspectionFrequently inspect the brakelever reserve. Firmlydepress the brake lever andmeasure the clea

86MAINTENANCEGeneral MaintenanceBrake ComponentsAir cooled model Liquid cooled model1. Brake Caliper2. Chaincase3. Brake Disc4. Backing Plate5. Brake

87MAINTENANCEGeneral MaintenanceBrake FluidThe brake fluid level can be seen through a plastic sight glass in thebrake reservoir. If the fluid is suff

7INTRODUCTIONVehicle Identification NumbersThe tunnel vehicle identification number (VIN) and engine serialnumber are important for model identificati

88MAINTENANCEGeneral MaintenanceBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action.Bleed the sy

89MAINTENANCEGeneral MaintenanceHeadlight AdjustmentThe headlight may be adjusted forvertical aim using the followingprocedure:1. Place the snowmobile

90MAINTENANCEGeneral MaintenanceNOTE: Avoid t ouching a halogen bulb with bare fingers. Oil fromskin leaves a residue, causing a hot spot that will sh

91MAINTENANCEGeneral MaintenanceClutch SystemPeriodically inspect the clutch sheaves for damage, wear , or beltresidue. To maintain optimum performanc

92MAINTENANCEGeneral MaintenancePeriodically check the condition and tension of the drive belt, andalways carry a spare belt. For improved drive-away

93MAINTENANCEGeneral MaintenanceDrive Belt Installation1. Drop the drive belt over thedrive clutch and pull back theslack (A). NOTE: To ensuresatisfac

94MAINTENANCEGeneral MaintenanceDrive Belt DeflectionMeasure belt deflection with bothclutches at rest and in their fullneutral position.Place a strai

95MAINTENANCEGeneral MaintenanceTorque StopYour snowmobile is equippedwith an engine torque stop (1).Periodically check the torquestop clearance. W it

96MAINTENANCEGeneral MaintenanceFor Your ProtectionFor added protection, carry the following items on your snowmobile atall times:SSpare Drive Belt SE

97MAINTENANCETrack MaintenanceTrack TensionTrack adjustment is critical for proper handling. Always maintaincorrect tension and alignment. Tension adj