2011-2012 Polaris 800 Switchback Assault Snowmobile Service & Repair Manual
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General Information
1.1
CHAPTER 1
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2010 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2011 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2011 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2011 800 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2011 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
2011 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
2011 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
2012 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
2012 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
2012 800 RUSH PRO-R LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
2012 600 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
2012 800 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
2012 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
2012 600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
2012 600 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
2012 600 PRO RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
2012 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
2012 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
2012 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
2013 600 INDY/INDY SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
2013 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
2013 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
2013 800 RUSH PRO-R LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
2013 600 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
2013 800 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
2013 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
2013 600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
2013 600 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
2013 600 PRO RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
2013 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60
2013 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.62
2013 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64
SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
TUNNEL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2010 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2011 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2012 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2013 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.69
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.70
GENERAL REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
FUEL / OIL PREMIX RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
FUEL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74
PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74
1.2
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
MODEL SPECIFICATIONS
2010 600 RUSH
Model Numbers:
S10BF6KSA / S10BF6KSL / S10BF6KEA
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4202-6044-OP6N
Displacement / # Cylinders 599cc / 2
Bore (inches/mm) 3.04 / 77.25
Stroke (inches/mm) 2.52 / 64
Piston to Cylinder
Clearance (inches/mm)
.0033-.0054 / 0.085-0.137
Installed Ring Gap
(inches / mm)
.014-.020 / 0.356 - 0.508
Operating RPM ±200 8250
Idle RPM 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Purple
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 4
Throttle Body Marking 1203978
Throttle Body Bore 46mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.95 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLACK
120 - 310
7043601
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Clutch Settings (Electric Start Models)
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLK/GRN
120 - 340
7042083
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 120 (304.8)
Pitch
Plies
2.86
2
Lug Height - Inches (cm) 1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
7/8 - 1-1/8(2.2 - 2.9cm)
1.3
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
NOTE: * = Rider weight in everyday clothing.
** = From full soft (CCW) position.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 459 / 208
Fuel (Gallons / Liters) 11 / 41.6
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System Capacity(Qts/ L) 5.25 / 5.0
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211122
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
23
39
72
Polaris Synthetic (80W)
9 / 266
PERC
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
Walker Evans Needle w/Remote
Reservoir
16 Click Compression Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
80 (14)
IFS Spring Installed
Length - Inches (cm)
Preload = 3.75 (9.5)
10.25 (26)
Front Vertical Travel
Inches (cm)
9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type Pro-Ride Progressive
Front Track Shock
(FTS)
Walker Evans w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 2
FTS Spring Rate
lbs/in (N/mm)
120 - 310 (21 - 54.25)
FTS Spring Installed
Length
Inches (cm)
Preload = .75 (1.9)
7.75 (19.7)
Rear Track Shock
(RTS)
Walker Evans Needle
w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 4
Standard RTS Spring
Rider Weight*
120 - 250lbs.
Rate lbs/in (N/mm)
PN: 7043572-385
190 (33.25)
LW RTS Spring
Rider Weight*
90 - 150lbs.
Rate lbs/in (N/mm)
PN: 7041575-385
120 (21)
HD RTS Spring
Rider Weight*
240 - 335+lbs.
Rate lbs/in. (N/mm)
PN: 7043585-385
260 (45.5)
RTS Spring
Rider / Weight Setting
Spring length set to rider weight
using adjustment gauge.
STD Gauge PN: 5253792
LW Gauge PN: 5253854
HD Gauge PN: 5253855
(STD gauge in tool kit. LW and HD
gauges are accessories and should
be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
Inches (cm)
14 (35.6)
1.4
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 600 RUSH
Model Numbers:
600 RUSH
S11BF6NSA / S11BF6NSL / S11BF6NSB / S11BF6NSM
600 RUSH LX
S11BD6NSL / S11BD6NSM
600 RUSH PRO-R
S11BP6NSA / S11BP6NSL / S11PB6NEL / S11BP6NSB
S11BP6NSM / S11BE6NSM
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4215-6044-OO6N
Displacement / # Cylinders 599cc / 2
Bore (inches/mm) 3.04 / 77.25
Stroke (inches/mm) 2.52 / 64
Piston to Cylinder
Clearance (inches/mm)
.0033-.0054 / 0.085-0.137
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM ±200 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Purple
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 4
Throttle Body Marking 1203978
Throttle Body Bore 46mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.95 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLACK
120 - 310
7043681
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Clutch Settings (Electric Start Models)
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLK/GRN
120 - 340
7042083
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 121 (307)
Pitch
Plies
2.52
2
Lug Height - Inches (cm)
RUSH
RUSH PRO-R
1.0 (2.54) (Hacksaw)
1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
1/2 - 1.0(1.3 - 2.54cm)
1.5
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
NOTE: * = Rider weight in everyday clothing.
** = From full soft (CCW) position.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 469 / 212
Fuel (Gallons / Liters) 11 / 41.6
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System Capacity(Qts/ L) 6 / 5.7
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211122
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
23
39
72
Polaris Synthetic (80W)
9 / 266
PERC
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle Piggyback
16 Click Compression Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
100 (17.5)
Spring Preload -
Inches (cm)
4.5 (11.4)
Travel-Inches (cm) 9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type PRO-RIDE Progressive
Front Track Shock
(FTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 2
FTS Spring Rate
lbs/in (N/mm)
120 - 310 (21 - 54.25)
FTS Spring Installed
Length-Inches (cm)
RUSH Preload
RUSH PRO-R Preload
7.5 (19.05)
1.0 (2.54)
1.0 (2.54)
Rear Track Shock
(RTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle
w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 4
Standard RTS Spring
Rider Weight*
120 - 250lbs.
Rate lbs/in (N/mm)
PN: 7043572-133
190 (33.25)
LW RTS Spring
Rider Weight*
90 - 150lbs.
Rate lbs/in (N/mm)
PN: 7041575-385
120 (21)
HD RTS Spring
Rider Weight*
240 - 335+lbs.
Rate lbs/in. (N/mm)
PN: 7043585-385
260 (45.5)
RTS Spring
Rider / Weight Setting
Spring length set to rider weight
using adjustment gauge.
STD Gauge PN: 5254748
LW Gauge PN: 5254749
HD Gauge PN: 5254750
(STD gauge in tool kit. LW and HD
gauges are accessories and should
be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
Inches (cm)
14 (35.6)
1.6
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 800 RUSH
Model Numbers:
800 RUSH
S11BF8GSA / S11BF8GSL / S11BF8GSB / S11BF8GSM
800 RUSH LX
S11BD8GSM
800 RUSH PRO-R
S11BP8GSA / S11BP8GSL / S11PB8GEL / S11BP8GSB
S11BP8GSM / S11BP8GEM / S11BE8GSM
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4139-8044-OO8G
Displacement / # Cylinders 794cc / 2
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70
Piston to Cylinder
Clearance (inches/mm)
.004-.0055 / 0.103-0.141
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM +0-300 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Orange
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 2
Throttle Body Marking 1204094
Throttle Body Bore 48mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.94 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-66
BLACK
120-310
7043681
BLU/BLK
123-203
7043064
64/42 - .36
5135401
22:36-70
600-1200
(2000-4000)
10-64
1200-1800
(4000-6000)
10-62
1800-2400
(6000-8000)
10-60
BLK/PUR
160-240
7043363
2400-3000
(8000-10,000)
BLACK
140-330
7043829
20:38-70
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 465 / 211
Fuel (Gallons / Liters) 11 / 41.6
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System
Capacity(Qts/ L)
6 / 5.7
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211115
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
22
36
70
Polaris Synthetic (80W)
9 / 266
PERC
1.7
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
NOTE: * = Rider weight in everyday clothing.
** = From full soft (CCW) position.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 121 (307)
Pitch
Plies
2.52
2
Lug Height - Inches (cm)
RUSH
RUSH PRO-R
1.0 (2.54) (Hacksaw)
1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
1/2 - 1.0(1.3 - 2.54cm)
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle Piggyback
16 Click Compression Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
100 (17.5)
Spring Preload -
Inches (cm)
4.5 (11.4)
Travel-Inches (cm) 9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type PRO-RIDE Progressive
Front Track Shock
(FTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 2
FTS Spring Rate
lbs/in (N/mm)
120 - 310 (21 - 54.25)
FTS Spring Installed
Length-Inches (cm)
RUSH Preload
RUSH PRO-R Preload
7.5 (19.05)
1.0 (2.54)
1.0 (2.54)
Rear Track Shock
(RTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle
w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 4
Standard RTS Spring
Rider Weight*
120 - 250lbs.
Rate lbs/in (N/mm)
PN: 7043572-133
190 (33.25)
LW RTS Spring
Rider Weight*
90 - 150lbs.
Rate lbs/in (N/mm)
PN: 7041575-385
120 (21)
HD RTS Spring
Rider Weight*
240 - 335+lbs.
Rate lbs/in. (N/mm)
PN: 7043585-385
260 (45.5)
RTS Spring
Rider / Weight Setting
Spring length set to rider weight
using adjustment gauge.
STD Gauge PN: 5254748
LW Gauge PN: 5254749
HD Gauge PN: 5254750
(STD gauge in tool kit. LW and HD
gauges are accessories and should
be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
Inches (cm)
14 (35.6)
1.8
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 800 Switchback Assault
Model Numbers:
800 Switchback Assault 1.3
S11CW8GSA / S11CW8GSB / S11CW8GEA
S11CW8GEB
800 Switchback Assault 2.0
S11CW8GST
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4229-8044-OO8G
Displacement / # Cylinders 794cc / 2
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70
Piston to Cylinder
Clearance (inches/mm)
.004-.0055 / 0.103-0.141
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM +0-300 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Orange
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 2
Throttle Body Marking 1204094
Throttle Body Bore 48mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.94 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
800 Switchback Assault 1.3 Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-66
BLACK
120-310
7043681
BLU/BLK
123-203
7043064
64/42 - .36
5135401
23:39 - 72
600-1200
(2000-4000)
10-64
1200-1800
(4000-6000)
10-62
1800-2400
(6000-8000)
10-60
BLK/PUR
160-240
7043363
21:40 - 72
2400-3000
(8000-10,000)
BLACK
140-330
7043829
20:42 - 72
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
800 Switchback Assault 2.0 Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-66
BLACK
120-310
7043681
BLU/BLK
123-203
7043064
64/42 - .36
5135401
20:42 - 72
600-1200
(2000-4000)
10-64
1200-1800
(4000-6000)
10-62
1800-2400
(6000-8000)
10-60
BLK/PUR
160-240
7043363
2400-3000
(8000-10,000)
BLACK
140-330
7043829
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 144 (365.76)
Pitch
Plies
2.52
2
Lug Height - Inches (cm)
1.3
2.0
1.352 (3.43) (Cobra)
2.0 (5.08) (Series 4)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
3/8 - 1/2(1 - 1.3cm)
1.9
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 126 / 320
Height (in/cm) 48 / 121.9
Estimated Dry Weight (lb/kg) 457 / 212.7
Fuel (Gallons / Liters) 11.5 / 43.5
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System
Capacity(Qts/ L)
6.0/5.7
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211115
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
23
39
72
Polaris Synthetic (80W)
9 / 266
PERC
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
Walker Evans Needle Piggyback
16 Click Compression
Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
100 (17.5)
IFS Spring Installed
Length - Inches (cm)
10.0 (25.4)
Front Vertical Travel
Inches (cm)
9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type Switchback 144 Tipped
Front Track Shock
(FTS)
Walker Evans Piggyback
16 Click Compression
Adjustable
Factory Setting** = 8
FTS Spring Rate
lbs/in (N/mm)
170 (21 - 54.25)
FTS Spring Installed
Length
Inches (cm)
7.25 (18.4)
Rear Track Shock
(RTS)
Walker Evans
w/Remote Reservoir
16 Click Compression
Adjustable
Factory Setting** = 8
Torsion Springs
.359/77°
LH=7041629-329
RH=7041630-329
Rear Travel
Inches (cm)
14.5 (36.8)
1.10
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 800 RMK 155
Model Numbers:
S11CM8GSA / S11CM8GSL / S11CM8GEA
S11CM8GSB / S11CM8GSM
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4229-8044-OO8G
Displacement / # Cylinders 794cc / 2
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70
Piston to Cylinder
Clearance (inches/mm)
.0040-.0055 / 0.103-0.141
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM +0-300 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Orange
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 2
Throttle Body Marking 1204094
Throttle Body Bore 48mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.94 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-68
BLACK
140-330
7043829
BLACK
155-222
7043063
56/42 - .36
5135403
20:42 - 72
600-1200
(2000-4000)
10-66
1200-1800
(4000-6000)
10-64
1800-2400
(6000-8000)
10-62
2400-3000
(8000-10,000)
10-60
BLK/PUR
160-240
7043363
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
General
Width (in/cm) 46.5 / 118.1
Length (in/cm) 129 / 327.7
Height (in/cm) 51 / 129.5
Estimated Dry Weight (lb/kg) 440 / 199.6
Fuel (Gallons / Liters) 11.5 / 43.5
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System
Capacity(Qts/ L)
5.3/5.0
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211115
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
20
42
72
Polaris Synthetic (80W)
9 / 266
PERC
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2011-2012 Polaris 800 Switchback Assault Snowmobile Service & Repair Manual
This service and repair manual for the 2011-2012 Polaris 800 Switchback Assault snowmobile provides comprehensive technical information for maintaining and repairing all major components of this high-performance machine. It includes step-by-step repair instructions, troubleshooting procedures, and detailed maintenance schedules to ensure reliable operation in demanding conditions.
Covering key systems such as the engine, suspension, drivetrain, brakes, and electrical components, the manual features factory-approved wiring diagrams, torque specifications, and diagnostic guides specific to the 800 Switchback Assault model. Whether addressing routine maintenance or tackling more complex mechanical issues, it offers the precision required for accurate repairs.
Formatted for easy access in a digital format, the manual is designed for use on computers or mobile devices, making it practical for both shop environments and on-trail repairs. This essential service and repair manual is ideal for technicians and experienced snowmobile owners looking to keep their Polaris 800 Switchback Assault in peak condition.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
