Snowmobile Polaris 600 Switchback / 800 Switchback (2013 year). Manual - part 23

92

MAINTENANCE

Cooling System

Engine Overheating

The over-temperature indicator on the 
instrument cluster will illuminate when the 
engine is overheating. The indicator will 
flash when engine temperature reaches 
critical levels. 

Illuminated Indicator

Take action to cool the engine:

• Drive in loose snow.
• View the coolant level. Do not open the 

pressure cap while the engine is hot. 
Add coolant if the level is low.

• Stop the engine and allow it to cool down.

If you must continue to operate while the indicator light is illuminated, 
drive slowly and stop the engine frequently to allow it to cool down.

Flashing Indicator

If the indicator flashes, continued operation could result in serious 
engine damage. The system will automatically reduce engine power and 
create a misfire condition. Stop the engine immediately. Allow the 
engine to cool down.

If engine overheating seems to be caused by something other than poor 
cooling conditions, see your dealer for service.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, 
drain the system completely every two years and add a fresh mixture of 
antifreeze and distilled water. This service must be performed when the 
engine is cold. Ask your POLARIS dealer to check the coolant when he 
performs the fall tune-up on your snowmobile.

93

MAINTENANCE

Cooling System

Bleeding the Cooling System 

CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the 
cooling system or remove the pressure cap when the engine is warm or hot.

Use of a non-standard pressure cap will not allow the recovery system to 
function properly. If the pressure cap needs replacement, contact your 
dealer for the correct part.

NOTICE: Severe engine damage may occur if the cooling system becomes 

restricted or plugged or contains trapped air pockets.

Peform this procedure in a well-ventilated area. Use the recommended 
coolant. See page 91.

1. Open the side panels and remove the hood.

2. Close the side panels.

WARNING! Never operate a snowmobile with the side panels open or removed. 

3. Position the vehicle with the right ski and control arms elevated at a 

45-degree angle.

4. Fill the coolant bottle to the COLD FILL mark.

5. Using an 8mm wrench, loosen the air bleed screw located on the top 

of the coolant outlet elbow. Use a shop towel to catch any coolant 
that leaks from the bleeder. Tighten the screw after a steady stream 
of coolant flows from the bleeder.

6. Fill the coolant bottle to the COLD FILL mark.

7. Install the coolant bottle cap to the first lock. Do not tighten to the 

fully seated position.

8. Lock the parking brake.

9. Start the engine and run at a fast idle for several minutes, until the 

heaters are warm to the touch. Loosen the bleed screw occasionally 
to purge any trapped air.

10. When all heater extrusions are warm to the touch, stop the engine.

11. Allow the engine and cooling system to cool.

12. Fill the coolant bottle to the COLD FILL mark.

13. Carefully lower the front end of the snowmobile.

14. Secure the bleed screw and reinstall the pressure cap.

15. Open the side panels and reinstall the hood. Close the side panels.

94

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000 
miles (3200 km). Always allow the engine and exhaust system to cool 
completely before inspecting. 

CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for 
the exhaust system to cool. Never perform this procedure with the engine 
running.

1. Open the side panels and remove the hood. See page 85.

2. Inspect the muffler and pipes for cracks or damage.

3. Check for weak or missing retaining springs or damper/support 

grommets.

4. Check for loose clamps on the pipe covers.

5. Reinstall the hood and side panels.

95

MAINTENANCE

Drive Chain Tension

Check drive chain tension at the intervals outlined in the maintenance 
charts beginning on page 81 and before each long trip. 

1. Remove the side panels.

2. Rotate the driven clutch coun-

ter-clockwise to move all 
chain slack to the tensioner 
side. Lock the brake lever 
lock, or have an assistant hold 
the brake lever firmly.

3. Loosen the adjuster bolt jam 

nut.

4. Finger tighten the adjuster bolt 

until it can no longer be 
adjusted by hand, then back 
off 1/4 turn.

5. Tighten the jam nut while 

holding the adjuster bolt. 
Torque to 21 ft. lbs. (28 Nm).

6. Reinstall the side panels.

7. Release the brake lever lock.

Jam 

Nut

Adjuster 

Bolt