Polaris 900 Fusion 2006 Manuals

Manuals and User Guides for Polaris 900 Fusion 2006. We have 2 Polaris 900 Fusion 2006 manuals available for free PDF download: Manual, Owner's Manual

Polaris 900 Fusion 2006 Manual

Polaris 900 Fusion 2006 Manual (300 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 13.2 MB

Table of Contents

Table of Contents

1
- 340 Classic
  2
- Chapter 1
  2
- 550 Classic
  6
- 700 Classic
  10
- 500 Indy
  12
- Supersport
  14
- 340 Indy Touring
  16
- Trail Touring
  18
- 600 Edge Touring
  20
- 700 Touring
  22
- Widetrak Lx
  24
- 500 XC Sp
  26
- 600 Ho Standard Fusion
  28
- 600 Ho Dragon Fusion
  30
- 700 Fusion
  32
- 600 Ho Switchback
  36
- 900 Switchback
  38
- Trail Rmk
  40
- 600 Ho Rmk
  42
- 700 Rmk
  44
Specifications Notes

49
- Chapter 2 General
  50
- How to Use this Manual
  50
  - Locating Information
    50
  - Explination Method of this Manual
    50
- Snowmobile Model Number Designation
  51
  - Example
    51
- Tunnel Decal
  51
  - Tunnel Decal Located on the Right Hand Side of the Sled
    51
- Publication Part Numbers
  52
  - 2006 Part Numbers
    52
- Vin (Vehicle Identification Number)
  52
  - Vin Explination
    52
- General Reference
  54
  - Standard Bolt Specifications
    54
  - Sae Tap Drill Sizes
    55
  - Metric Tap Drill Sizes
    55
  - Mesurement Conversion Chart
    56
  - Piston Wash / Spark Plug Reading
    57
- Gasoline Information
  57
  - Gasoline Volatility
    57
  - Stroke Gasoline / Oil Pre MIX
    58
- Special Tools
  59
General

63
- Chapter 3 Polaris Recommended Program
  65
- Maintenance Program
  65
- Inspectons
  67
  - Cylinder Head Inspection
    67
  - Cylinder Measurement
    68
  - Cylinder Honing
    68
  - Honing Procedure
    69
  - Honing to over Size (340/550/500 Fuji Engines Only)
    69
  - Cleaning the Cylinder after Honing
    69
  - Piston Inspection
    69
  - Piston Ring Installed Gap
    70
  - Coolant Level
    70
  - Recommended Coolant
    70
  - Cooling System Bleeding
    70
  - Bearing Fit
    71
  - Main Bearing
    72
  - Connecting Rod (Big End) Bearing
    72
  - Wrist Pin Bearing
    72
  - Crankshaft Indexing
    73
  - Checking Crankshaft Index
    73
  - Crankshaft Truing
    73
  - Crankshaft Runout Inspection
    74
  - Oil Pump Bleeding
    75
  - Fitting Types
    75
  - Verifying Check Valve Operation
    75
  - Oil / Fuel Filter
    76
  - Brake Lever Travel
    76
  - Brake Fluid
    76
  - Brake Fluid Bleeding
    77
  - Exhaust System
    78
  - Exhaust Removal
    78
  - Exhaust Installation
    78
  - Belt Deflection
    79
  - Measuring Belt Deflection
    79
- Lubrication
  79
  - Grease Points
    79
  - Jackshaft Bearing
    79
  - Driveshaft Bearing
    80
  - Rear Suspension
    80
  - Chaincase
    80
  - Steering U Joint
    80
- Adjustment
  81
  - Chaincase Drive Tension
    81
  - Track Alignment
    82
  - Track Lubrication
    82
  - Track Tension
    83
  - Oil Pump Adjustment
    84
  - Headlight Adjustment
    84
  - Handlebar Adjustment
    85
  - Handlebar Riding Position Adjustment (Rider Select Only)
    85
  - Throttle Lever Free Play
    86
  - Torque Stop
    86
- Cleaning
  86
Table of Contents

89
- Chapter 4 Warnings
  90
- General Information
  90
  - Service Precautions
    90
  - Gasoline Votalitiy
    91
  - Stroke Gasoline / Oil Pre MIX
    91
- Fuel Delivery System (Carbureted)
  91
  - Carbureted System Overview
    91
- Fuel Pump (Non-Injected Units)
  92
  - Fuel Pump Overview
    92
  - Maintenance
    93
  - Operation
    93
  - Cleaning
    93
  - Inspection
    93
- Mikuni Jet Needle
  93
  - Overview
    93
- Mikuni Tm 38
  94
  - Carburetor Overview
    94
- Mikuni Carburetor
  95
  - Function
    95
  - Float System
    95
  - Fuel Metering
    96
  - Fuel Delivery
    96
  - Pilot Jet
    96
  - Pilot Air Screw
    96
  - Main Jet
    96
  - Jetting Guidelines
    97
  - Piston Valve or Throttle Valve
    97
  - Jet Needle / Needle Jet
    97
  - Jet Needle
    97
  - Needle Jet
    98
  - Throttle Opening Vs Fuel Flow
    98
- Mikuni Tm38 Flat Slide Service
  99
  - Disassembly
    99
  - Assembly
    100
- Carburetor Syncronization
  101
  - Throttle Valve Syncronization
    101
- Throttle Position Sensor
  102
  - Setting the Tps
    102
- Carburetor Cable Adjustments
  103
  - Choke Adjustment
    103
  - Throttle Lever Freeplay
    103
- Carburetor Component Part Numbers
  104
  - Mikuni Pilot Jets
    104
  - Mikuni Main Jets
    104
  - Mikuni Jet Needles
    104
  - Mikuni Starter Jets
    104
  - Mikuni Pilot Air Jets
    105
  - Mikuni Piston Valves
    105
Cleanfire Fuel

107
- Chapter 5 Warnings
  108
- Fuel Delivery System (Cleanfiret)
  108
  - Cleanfire System Overview
    108
- General Information
  108
  - Gasoline Voltality
    108
  - Stroke Gasoline / Oil Pre MIX
    108
- Fuel Rail
  109
  - Fuel Rail/Injector Removal
    109
  - Fuel Rail/Injector Installation
    109
  - Fuel Rail Bleeding
    110
- Pump Flange Assembly
  109
  - Fuel Pump
    109
  - Fuel Level
    109
- Injector
  110
  - Injector Replacement
    110
- Throttle Body
  110
  - Setting the Throttle Body Tps
    110
  - Setting the Base Line Voltage
    110
  - Setting the Idle Voltage
    112
  - Throttle Body Removal
    112
- Fuel Filter
  112
  - Fuel Filter Removal
    112
  - Fuel Filter Installation
    112
Table of Contents

113
- Chapter 6
  114
- Exhaust Valve Removal
  114
- General Engine Information
  114
- Exhaust Valve Installation
  115
- Reed Valve Disassembly
  115
- Exhaust Valve Springs
  116
- Reed Valve Assembly
  116
- Thermostat Replacement
  116
- Water Temperature Sensor Replacement
  116
- 700/900 Engine
  117
- 700/900 Engine Rebuilding
  123
  - 700/900 Disassembly
    123
  - 700/900 Torque Patterns
    124
  - 700/900 Assembly
    124
  - 700/900 Water/Oil Pump Cross Shaft Disassembly
    124
  - 700/900 Water/Oil Pump Cross Shaft Assembly
    126
  - 700/900 Recoil/Stator Disassembly
    126
  - 700/900 Recoil/Stator Assembly
    126
- 500/600 Ho Engine
  127
  - 500/600 Ho Torque Specifications
    127
  - 600 Ho Iq Engine Removal
    127
  - 600 Iq Engine Installation
    131
- 500/600 Ho Engine Rebuilding
  134
- 340/550 Fuji Engine/500 Liberty
  138
  - 340/550 Fuji/500 Liberty Engine Removal/Installation
    138
- 340/550 Engine Rebuilding
  139
  - 340/550 Engine Disassembly
    140
  - 340/550 Engine Assembly
    140
- 500 Fuji
  141
  - Disassembly
    141
  - Assembly
    142
Table of Contents

145
- Chapter 7 Clutch Tools
  147
- Special Clutch Tools
  147
- Drive Belt
  148
  - Belt Inspection
    148
  - Belt Diagnosis
    148
  - Drive Belt Removal with Team Clutch
    149
  - Belt Installation (Team Driven Clutch)
    149
  - Drive Belt Removal with Polaris Driven Clutch
    150
  - Belt Installation (Polaris Driven Clutch)
    150
- Drive System Terminology
  151
  - System Overview
    151
  - Drive Spring
    151
  - Clutch Weight
    151
  - Neutral Speed
    151
  - Engagement Rpm
    151
  - Shift out Overrev
    151
  - Shift out Rpm
    151
  - Driven Spring
    151
  - Back-Shifting
    152
  - Final Gearing
    152
  - 1:1 Shift Ratio
    152
  - Low / High Ratio Lines
    152
  - Driven Helix / Ramp
    152
- Centrifugal Drive System
  153
  - Theory of Operation
    153
- Drive Clutch
  153
  - Operation
    153
  - Drive Clutch Identification
    154
  - Drive Clutch Removal
    154
  - Drive Clutch Components
    155
  - Drive Clutch Disassembly
    157
  - Clutch Assembly
    157
  - Drive Clutch Spider Removal/Installation
    158
  - Roller Removal
    158
  - Roller Installation
    159
  - Spider Indexing
    159
  - Spring Free Length
    160
  - Drive Clutch Weights
    162
  - Drive Clutch Installation
    163
- Driven Clutch
  164
  - Driven Clutch Overview
    164
  - Driven Clutch Types
    164
  - Driven Clutch Removal
    164
  - Driven Clutch Installation
    164
  - Team Ramps Explained
    165
  - Polaris P-85 Helix
    167
- Drive System Adjustments
  169
  - Clutch Alignment
    169
  - Clutch Alignment Inspection
    169
  - Clutch Alignment Adjustment
    169
  - Clutch Offset
    169
  - Off Set Adjustment
    169
Table of Contents

173
- Chapter 8
  178
- Gears
  178
- Gears and Chains
  178
- Chain Case
  179
  - Exploded View
    179
  - 8.37 Chaincase Removal
    180
  - 8.37 Chaincase Installation
    181
  - 7.92 Chaincase Removal
    181
  - 7.92 Chaincase Assembly
    181
  - Chaincase Seal/Bearing Replacement
    182
- Drive Chain
  179
- Drive Train
  183
  - Jackshaft Exploded View
    183
  - Jackshaft Removal
    184
  - Jackshaft Installation
    184
- Driveshaft
  185
  - Drive Shaft Removal
    185
- Widetrak Transmission
  186
  - Removal
    186
  - Inspection
    187
  - Low/Reverse Shaft Disassembly
    189
  - Shift Fork Disassembly
    189
  - Transmission Assembly
    190
  - Transmission Installation
    190
Final Drive

193
- Chapter 9
  194
- Compensating Port
  194
- General Guidelines
  194
- Hydraulic Brake System
  194
- Overview
  194
- Brake Fluid Replacement & Bleeding
  195
- Brake Line Replacement
  195
- Brake Light Switch Replacement
  196
- Caliper
  196
  - Caliper Removal
    196
  - Caliper Replacement
    197
  - Caliper Assembly
    197
  - Brake Pad Replacement
    197
  - Brake Disc Replacement
    197
- Widetrak Brake Caliper
  197
  - Removal
    197
  - Assembly
    198
  - Installation
    198
Front Suspension/

199
- Chapter 10
  200
- Fusion/Iq Rmk
  200
- Edge Rmk
  201
- 42.5 Edge
  202
- Widetrak
  203
- Front Suspension Adjustment Procedures
  204
  - Set up and Adjustments
    204
  - Ifs Shock Springs
    205
  - Springs
    206
  - Compression Damping Adjustable Shocks
    206
- Shock Information
  207
  - Ifs Shock Specifications
    207
  - Ifs Shock Production Valving
    208
- Iq Front Suspension
  210
  - Spindle Removal
    212
  - Spindle Assembly
    212
  - Lower Spherical Bearing Replacement
    212
  - Upper / Lower Control Arm Removal
    212
  - Upper / Lower Control Arm Installation
    212
- Steering
  212
  - Inspection
    212
  - Alingment Bar Specifications
    213
  - Camber Definition
    213
  - Rod End Procedure
    213
  - Rod End Engagement
    213
- Camber &Toe Specifications
  213
- Alignment Adjustments
  214
  - Edge Set up Width
    214
  - Edge Camber Adjustment
    214
  - Iq Camber Adjustment
    215
  - Handlebar Centering
    215
  - Toe Adjustment
    215
- Ski Stance
  216
  - Adjustment (Rmk Only)
    216
Chapter 11 Rear Suspension

217
- Rear Suspension Operation
  218
  - Operation
    218
  - Weight Transfer
    218
  - Suspension Coupling
    218
  - Rear Torsion Spring Tension Adjustment
    219
- Rear Suspension Specifications
  218
- Rear Suspension Adjustments and Settings
  219
- M-10 Suspension
  226
  - M-10 Overview
    226
  - M-10 Adjustments
    226
  - M-10 Terminology
    226
  - M-10 Adjustments
    227
  - M-10 Fra Initial Set up Reference
    227
  - M-10 Rear Spring Preload
    228
  - Ski Pressure
    228
- Rail Slider
  229
  - Rail Slide Wear Limit
    229
  - Rail Slide Removal
    229
  - Rail Slider Break
    229
- Rear Suspension Removal / Installation
  229
  - Rear Suspension Removal
    229
  - Rear Suspension Installation
    229
- Shock Information
  230
- Valving Specifications
  231
  - Rear Suspension Front Track Shock (Fts) Stock Valving
    231
  - Rear Suspension Rear Track Shock (Rts) Stock Valving
    233
- Shock Valve Part Numbers
  236
  - Ryde Fxt Shock Valve Part Numbers
    237
  - Foxt Shock Valve Part Numbers
    237
  - Shock Valving Arrangement
    238
- Shock Maintenance
  239
  - Ryde Fx Mono-Tube Shock Disassembly
    240
  - Ryde Fx Mono-Tube Shock Assembly
    241
  - Fox Ps-5 Assembly
    242
- Special Tools
  239
  - Shock Rebuilding Tools
    239
- Rear Suspension Troubleshooting
  243
Chapter 12 Chassis / Hood

245
- Bumper
  246
  - Iq Front Bumper Removal / Installation
    246
- Headlight
  246
  - Iq Headlight Removal / Installation
    246
- Hood
  246
- Hood Repair
  246
- Instrument / Mfd
  246
  - Edge Instrument Removal / Installation
    246
  - Iq Mfd Removal / Installation
    246
- Removal / Installation
  246
- Coolant/Oil Tank
  247
  - Coolant Tank Removal
    247
  - Coolant Tank Installation
    247
- Fuel Clips
  247
  - Fuel Clip Removal
    247
  - Fuel Clip Installation
    247
- Oil Tank
  247
  - Oil Tank Removal
    247
  - Oil Tank Installation
    247
- Seat and Fuel Tank
  248
  - Fusion Seat and Base Removal/Installation
    248
  - Iq Rmk Seat Removal/Installation
    248
  - Iq Rmk Seat Base Removal/Installation
    249
  - Iq Fuel Tank Removal
    249
  - Iq Fuel Tank Installation
    249
  - Edge Seat Removal / Installation
    250
  - Seat Cover Replacement
    250
  - Iq Seat Cover Replacement
    250
- Air Intake Removal
  250
  - Edge Air Box Removal
    250
  - Edge Air Box Installation
    251
  - Iq 700/900 Air Intake Removal
    251
  - Iq 700/900 Air Intake Installation
    251
  - Iq Carbureted Air Intake Removal
    251
- Console
  250
  - Iq Console Removal / Installation
    250
  - Edge Console Removal / Installation
    250
- Tail Light
  250
  - Tail Light Assembly Replacement
    250
- Handlebar Cover
  252
  - Handle Bar Cover Removal/Instaltion
    252
- Skis
  252
  - Ski Removal
    252
  - Ski Installation
    252
- Decals
  253
  - Decal Removal
    253
  - Decal Installation
    254
- Nosepan
  253
  - Replacement
    253
Chapter 13 Electrical

257
- Ignition Timing (Carbureted Units)
  259
  - Ignition Timing
    259
- Multimeter
  259
- Battery
  261
  - Preparing a New Battery for Service
    261
  - Battery Testing
    261
  - Open Circuit Voltage Testing (Ocv)
    261
  - Load Test
    261
  - Refilling a Low Battery
    261
  - Off Season Storage
    262
  - Charging Procedure
    262
- Starter System
  262
  - Dynamic Testing of the Electric Starter System
    262
  - Starter Motor Static Testing
    264
  - Starter Housing and Field Coil Inspection
    264
  - Armature Testing
    264
  - Starter Assembly
    265
  - Starter Solinoid Bench Test
    265
  - Starter Installation
    265
- Voltage
  265
  - Unregulated Voltage
    265
  - Regulated Voltage
    266
  - Short Circuit Current (Ac Amp Test)
    266
- Alternators
  266
- Electrical Testing
  267
- Troubleshooting Charts
  270
  - No Spark
    270
- Tps Tool Set up
  272
  - Tps Set
    272
  - Tps Adjustment
    272
- Clean Fire Electrical
  273
  - Iq Throttle Position Sensor
    273
  - Iq Temperature Light
    273
  - Lamp Circuit Test
    273
  - Thermistor Sensor Test
    273
  - Iq Detonation Elimination Sensor (Det)
    274
  - Det Troubleshooting
    275
  - Effect of Det
    275
  - Sensor Fail Safe
    275
  - Iq Temerature Sensor
    275
  - Exhaust Temperature Sensor
    275
  - Intake Air Temperature Sensor
    276
  - Barometric Pressure Sensor
    276
  - Crankshaft Position Sensor (Cps)
    276
  - Speed Sensor
    277
  - Ecu Plug #1
    278
  - Ecu Plug #2
    279
  - Stator
    280
  - Ignition Coil
    281
  - Exhaust Valve Solinoid
    281
  - Regulator Rectifier
    283
  - Capacitor
    284
  - Chassis Relay
    284
  - Chassis Ground
    284
- General Electrical Items
  285
  - Oil Level Sender
    285
- Polaris Electronic Reverse Control (Perc)
  286
  - Operation
    286
  - Reverse Operation
    286
  - Forward Operation
    286
  - Altitude Setting
    286
  - Perc Notes
    286
- Digital Wrench
  287
  - Connections
    287

Polaris 900 Fusion 2006 Owner's Manual

Polaris 900 Fusion 2006 Owner's Manual (139 pages)

Polaris 2006 Snowmobile Owner's Manual

Brand: Polaris | Category: Offroad Vehicle | Size: 10.92 MB

Table of Contents

Table of Contents

6
- Introduction
  7
  - Preservation of the Environment
    8
  - Vehicle Identification Numbers
    9
- Safety
  10
  - Operator Safety
    11
  - Riding Position
    13
  - Survival Preparation
    13
  - Riding Apparel
    14
  - Disabled Operators
    14
  - Rider Capacity
    15
    
    Excessive Speed
    15
    
    Driver Awareness
    16
    
    Driving Downhill
    18
  - Ice and Snow Build-Up
    18
    
    Driving on Slippery Surfaces
    18
    
    Driving in Hilly Terrain
    19
    
    Drive Belt
    20
  - Intake Silencer
    20
  - Cold Weather Drive-Away
    20
  - Inadequate Snow Conditions
    21
  - Driving Responsibly
    22
  - Safety Decals and Locations
    24
    
    Clutch Cover Warning
    24
    
    Pressure Cap Warning
    24
    
    Track Warning
    25
    
    Reverse Warning
    26
    
    Operation Warning
    26
- Features
  28
  - Features
    29
  - Features
    30
  - Features
    31
  - Seat Storage Compartment
    31
    
    Adjustable Headlights
    31
    
    Access Panel
    31
    
    Features
    32
    
    Features
    33
    
    MFD Component Identification
    33
    
    Digital Display Identification
    33
    
    Features
    34
  - Mfd Settings
    34
    
    Speedometer/Tachometer
    34
    
    Features
    35
- Features
  36
  - Features
    38
  - Features
    39
  - Features
    40
  - Mfd Battery Replacement
    40
    
    Features
    41
    
    Gauge Cleaning
    41
- The Perfect Fit
  42
  - Ifs Adjustment Options
    42
  - Shock Absorber Components
    43
  - Front Suspension Adjustments
    44
  - Shock Valving
    45
    
    Front Springs
    45
    
    Suspension Performance Tips
    46
    
    Torsion Spring Tension
    48
    
    Suspension Coupling
    49
    
    Weight Transfer During Acceleration
    51
    
    Fra Position
    53
  - Rear Spring Preload
    54
    
    Handlebar Position
    57
    
    Handlebar Angle
    57
    
    Traction Products
    60
    
    Wear Strips
    60
Pre-Ride Inspections Pre-Ride Checklist

61
- Pre-Ride Inspections
  61
  - Before Starting the Engine
    62
  - Brake Lever Travel
    63
  - Park Brake Lever Lock
    64
- Recoil Rope
  65
  - Start the Engine and Check
    66
- Steering System
  65
  - Hood Latches
    65
- Operation
  67
  - Starting the Engine
    67
  - Slide Rail and Track Cooling
    68
  - Oil Injection System
    69
  - Variable Exhaust System
    69
  - Oil Recommendations
    69
  - Low Oil Level
    70
    
    Fuel Level
    72
    
    Fuel System Deicers
    72
    
    Track Warm-Up
    73
    
    Engine Stop Switch
    74
    
    Throttle Lever
    75
- Ignition Switch
  76
  - Emergency Starting
    76
  - Emergency Stopping
    76
  - Daily Storage
    78
- Maintenance
  79
  - Emission Control Information
    80
- Taillight/Brakelight/Headlight
  83
- Rear Wheel Idler Bolts
  84
- Ski Saddle and Spindle Bolts
  84
- Suspension Mounting Bolts
  84
- Tether Switch/Strap
  84
  - Front Suspension
    85
  - Rear Suspension
    85
  - Throttle Cable
    86
  - Driveshaft Bearing
    86
  - Chaincase Oil
    87
  - Oil Check
    87
  - Spark Plugs
    89
  - Intake Filter
    91
    
    Fuel Injectors
    91
    
    Fuel Pump
    91
    
    Fuel Lines
    91
  - Oil Filter
    92
    
    Exhaust System
    93
    
    Cooling System
    93
    
    Coolant Level
    94
    
    Flushing the Cooling System
    94
    
    Bleeding the Cooling System
    95
    
    Drive Chain Tension
    96
    
    Hydraulic Brake Inspection
    97
    
    Brake Components
    98
    
    Brake Fluid
    99
    
    Bleeding the Hydraulic Brake System
    100
    
    Removing Halogen Bulbs
    101
    
    Installing Halogen Bulbs
    101
    
    Taillight/Brakelight Replacement
    102
    
    Clutch System
    103
    
    Drive Belt Condition
    104
    
    Drive Belt Removal
    104
    
    Drive Belt Installation
    105
    
    Drive Belt Adjustment
    106
    
    Torque Stop
    106
    
    Tool Kit
    107
    
    Fall Tune-Up
    107
    
    Track Inspection
    108
- Track Alignment/Condition
  109
  - Track Tension
    110
  - Steering Inspection and Adjustment
    112
  - Ski Alignment
    113
  - Ski Skags
    114
  - Skag Replacement
    114
  - Suspension Maintenance
    115
  - Slider Wear
    115
  - Pre-Ride Suspension Inspection
    116
    
    Cleaning and Preservation
    117
    
    Controls and Linkage
    117
    
    Clutch and Drive System
    118
    
    Engine Protection
    118
    
    Electrical Connections
    119
    
    Transporting the Snowmobile
    119
- Polaris Products
  120
- Troubleshooting
  121
  - Belt Troubleshooting
    126
- Warranty
  127
  - Limited Warranty
    128
  - Engine Oil
    129
- An Accurate Log of Maintenance and Services Performed on the
  135
- Maintenance Log
  135
- Present this Section of Your Manual to Your Dealer each Time Your
  135
- Snowmobile Is Serviced. this will Provide You and Future Owners with
  135
- Index
  137

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