2005 Polaris Fusion 900 Service & Repair Manual

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS rT_h_ro_u_g_h_o_u_t _th_e_se....,...in_st_r_uc_t_io_n_ s_ , '_'m_p_o_r_ta_n_t _in_f_or_m_a_t_io_n_i_ s _b_ro_u_g_h_t _to_y _o_u_r_a_tt_e_nt_io_n_by_th_e_f_o_ll_o_ w _in_g_s y _m_b_O_I_S: _____ ---, " NOTE: CAUTION: .... DANGER .... WARNING • A NOTE provides key information to clarify instructions. A CAUTION indicates special precautions that must be taken to avoid personal injur~. or snowmobile or pnJperty damaJ;te. Failure to follow DANGER instructions will result in severe injury or death to the operator , bystander or person inspecting or servicing the snowmobile . Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servic~ng the snowmobile. CAUTION: I A CAUTION indicates special precautions that must be taken to avoid personal injury, or snowmobile or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc. Ammco, Registered Trademark of Ammco Tools, Inc. Torx, Registered Trademark of Textron Hilliard, Trademark of the Hilliard Corporation Willwood, Trademark of the Willwood Corporation )

, - PDLARIS. The Way Out. 2005 PERFORMANCE MANUAL TABLE OF CONTENTS Foreword This manual is designed primarily for use by certified Polaris snowmobile service technicians in a properly equipped shop. Persons using this manual should have a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. The technician should read the text and be fa- miliar with service procedures before starting the work. Certain procedures require the use of special too ls. Use only the proper tools, as specified. Cleanliness of parts and tools as well as the work area is of primary impor- tance. All references to left and right side of the vehicle are from th e operator's perspective when seated in anorrnal riding position. This manual includes 2005 Model Year information, along with service specifications. A table of contents is placed at the beginning of each chapter, and an alphabetic index is provided at the end of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area. At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice . Comments or suggestions about this manual may be directed to: Polaris Sales Inc. Snow Engineering Publications Department 2100 Hwy 55 Medina, Minnesota 55340. 2005 PERFORMANCE MANUAL (PN9919303) Copyright 2004 Polaris Sales Inc. Printed in U.S.A. .----- SPECIFICATIONS GENERAL MAINTENANCE FUEL DELIVERY ENGINE CLUTCHING FINAL DRIVE BRAKE SYSTEM STEERING FRONT SUSPENSION REAR SUSPENSION CHASSIS / HOOD ELECTRICAL SYSTEM WIRING DIAGRAMS i • /I

INTRODUCTION NOTES ,J ) ., ii

SPECIFICATIONS 500 XC SP ......... . . . . . • . . . . . . . . . . • • . . . . . . . . • . . . . . .. 1.2 - 1.3 600 XC SP ........ . ... .. .. ... . .... .. ..... .... ... ..... 1.4 - 1.5 700 XC SP ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.6 - 1.7 800 XC SP ... . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.8 - 1.9 900 FUSION .... . ..... .. .... ... .... . .... ... ..... . .... 1.10 - 1.11 )

==================================SPECIFICATIONS NOTES 1.1

SPECIFICATIONS'================================== MODEL: '" . . . . . . . . . .. 500 XC SP MODEL NUMBER: .... S05NE(P)SCS(A,B) ENGINE MODEL: ..... S2715-5044-PISC ENGINE CARBURETION Engine Ty pe Liberty ~ Type TM38 Engine Di splacement cc 500 Main Jet 410 Bore in 1 mm 2.78/70.5 Pilot Jet 45 Stroke in 1 nun 2.52/64 Jet Needle 9DFH6-57/2 Cylinders 2 Needle Jet P-8 Pi ston 1 Cy linder Clearance .0045" - .0059" Throttle Gap UnderCutaway 0.079"/2.0mm in / mm 0.115 - 0.149mm in / mm Piston Ring End Gap in / mm .014" - .020" Cutaway 1.5 0.356 - 0.508 Pi ston Marking N/A Valve Seat 1.5 Piston Ring Marking N/A Starter Jet 145 Operating RPM ±200 8250-8500 Fuel Screw 3.0 Idle RPM ±200 1500 Pilot Air Jet N/A Engagement RPM ±300 4200 Air Screw 1.25 Exhaust Va lve Spring PinklYellow Fuel Octane 87 min non-oxygentaed AMBIENT TEMPERATURE Altitude Below · 30 0 P _3D· 10 -10°F -10°'0 +lU~F +1O°to +30°F +30°10 +SO" F Above +50°F Be low _34°C .34°10 -23" C _23° to _12°C - Irlo -J"C _I °to +lOcC Above+l00C ) 440 430 4 10 390 380 360 0-600 (0-2000) " " .2 #2 N2 .2 600-1 200 420 400 390 370 350 340 (2000-4000) N3 '2 .2 .2 '2 " 1200- 1800 390 380 360 340 330 31 0 (4000-6000) '2 '2 " " " " Meiers 1000-2400 370 350 340 320 300 290 (FecI) (6000-'000) '2 '2 .2 " " " 2400 - 3000 340 330 310 300 28() 260 (RooO- U)(X 1O) '2 " " " " #I 3000 - 3700 320 300 290 270 25 0 240 (100lU-12000) '2 " " " " " naIVE CLUTCH DRIVEN CLlrreH Altitude Sh ift GUlch (1ulch Dri ven ctUlinC:I"C W(., 'i~1 sp.rn,:: SI )rin(! if eli). GClI.rin· 0-900 10- 56 Bushed 56/42-36 ER 22:40 - 74 (0-3000) MeIers 900· 1800 10- 54 Bushed 56/42-36 ER 22:40 - 74 (3000-6000) (Feet) BlaCk/Gr een 7043051{ 1800-2700 10 Bushed 56/ 42 -36 ER 2 1:40- 74 . (6000-9000) 2700-3700 10MB Bu~hed 56/42 - 36 ER 21:40- 74 ..L9000-12(00) 1.2

==================================SPECIFIC ATIONS DRlVE CLUTCH CHAINCASE Type P-85 Center Distance 7.92" Shift Weights 10-56 Bushed Gearing: Cha in 22:40- 74 Drive Spring Black/Green Reverse Electroni c Reverse DRIVElS (:LUTCH Brake Pads 2202202 Type Team Roller Reverse Spring Red/Black Brake Type Type 81 Helix Angle 56/42-36 ER CAPACITIES BELT Fuel Tank 11.8 gal / 44.7 I Belt Part Number 3211080 Oil Tank 3.25 qt s. / 3.1 I Belt Width (Projected) 1.438" Coolant 5.6 qt s. / 5.3 I Side Angle (Overall) 28° Chain Case Oil 9 oz. / 266 ml Outside Diameter 46.625" SLEP'DIMENSION Center Distance 11.50" Unit Length I Height I 113 / 46 / 48 Width in / cm. 287 / 117 / 122 FRON'}; ' St:JSPENS[ON REAR SUSPENSION Type Edge Type Edge / M-10 IFS Shocks M10/STD 7043082 FlO 7042211 Stock FTS STD / F/O 7041975 M-10 7042224 Stock IFS Spring Rate MI0/STD 68/160 F/O 90/180 M-lO/STD (lnst. length) FTS Spring Rate STD / FlO 160NAR IFS Spring Pre-Load 10.56" M-lO 160 F/O .625" Front Vertical Travel 10.28"126cm. STD / F/O N/A (eyelet to re- FTS Pre- Load tainer) 3. 50" TRACK M-lO .90" Width 15" STD 7042129 Stock RTS F/O 7042212 Length 121" M-10 7042216 Lug Height STD/F/O .91 " 1 1.25" Torsion Spr in g .375(sq.) M-lO 1. 0" M-1O RTS Springs 704193517041936 Track Tension See page 3.10 Optional Torsion Springs found on page 11.7- 11.8 ELECfRICAL Flywheell.D. 4010677 Spark Plug / Gap RN57YCC / .70mm/. 025" CD! Marking 4010829 Voltage Regulator N/A Alternator Output 280w Magneto Pulses 6 Ignition Timing(see conver- 25 ° @2500RPM Electric Start STD / M- 10 Accessory sian chart on page 13.4) FlO / M-lO FlO Standard 1.3

SPECIFICATIONS'================================== MODEL: .............. 600 XC SP MODEL NUMBER: .... S05N(A,E,P)6E(E,S)(A,B) ENGINE MODEL: ..... S2761-6044-PI6E ENGINE CARBURETION Engine Type Liberty ~ Ty pe Mikuni TM3 8 Engine Di splaceme nt cc 's 599 Main Jet 440 Bore in / mm 3.04" / 72.25mm Pi lot Jet 45 Stroke in / mm 2.52" / 64mm Jet Needle 9DFH7-60 / 3 Cylinders 2 Needle Jet P-8 Pi ston / Cylinder Clearence .0045 - .0059" Throttle Gap UnderCutaway 0.079" in / mm . 11 5 - .1 49 mm in / mm 2.0mm Pi ston Ring End Gap .014"- .020" Cutaway 2.5 in / mm .356 - .508mm Piston Marking 3021308 Valve Seat 1.5 Pi ston Ring Marking N/A Starter Jet 140 Operating RPM ±200 8100 Fuel Screw 2.5 Turns Idle RPM ±200 1200 Pilot Air Jet N/A Engagement RPM ±300 4000 Ai r Screw 1.0 Turns Exhaust Valve Spring GreenfYellow Fuel Octane (R+M/2) 87 Oct. NonOxy / 89 Oct. Ox y AMBIENT TEMPERATURE Altitude 8elow ·30°F _30" 10 - 10 "F _10 0 10 +10"F +1Q0 to +3QoF +30"10 +50°F Above +50 °F Below _ 34°C -34"10 -23 "G _23" to -12 "G -12"lo-l "G ·Pla +10°C Above +l Q"C 0- 600 480 460 440 420 400 390 (0-2000) #4 #4 #3 #3 #3 #2 600-1200 450 430 410 400 380 360 (2000-4000) #4 #4 #4 #3 #2 #2 1200- 1800 420 400 390 370 350 330 (4 000-6000) #4 #4 .3 #2 '2 #2 Meters 1800-2400 (Feet) (6000-8000) 400 380 360 340 330 310 #4 #3 .2 #2 '2 '2 2400-3000 370 3S0 330 320 300 280 (8000- 10000) #3 #2 #2 #2 #2 .2 3000-3700 340 330 310 290 270 260 (10000-12000) .2 #2 #2 #2 H1 ., DRIVE CLUTCH DRIVEN CLUTCH Altitude Shift Clutch Clutch Driven Chalncae8 Weight Spdng S",klQ Helix Gearing 0-900 10-58 58-42 -.36 ER 23 -39: 74 P (0·3000) Meiers 900-1800 10-56 58-42- .36 ER 23 -39 : 74P (3000·6000) (Feet) Dark Blue/White Red I Blue 1800·2700 10-54 58 - 42-. 36 ER 22- 39 . 74P (6000·9000) 1~700-370~) 9OQ().12000 10 58-42- .36 ER 22-39 : 74P 1.4

2005 Polaris Fusion 900 Service & Repair Manual

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