2006 Polaris 700 Fusion Owners Manual

2006 Polaris 700 Fusion Manual

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2006 Polaris 700 Fusion manual content summary:

  • 2006 Polaris 700 Fusion | Owners Manual - Page 1
  • 2006 Polaris 700 Fusion | Owners Manual - Page 2
  • 2006 Polaris 700 Fusion | Owners Manual - Page 3
    WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. PROPOSITION 65 WARNING Snowmobile engines discharge fuel
  • 2006 Polaris 700 Fusion | Owners Manual - Page 4
    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master
  • 2006 Polaris 700 Fusion | Owners Manual - Page 5
    or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2006 700/900 Fusion Owner's Manual P/N 9919666 2
  • 2006 Polaris 700 Fusion | Owners Manual - Page 6
    your snowmobile's regular maintenance. Operation ...64 Maintenance ...76 Polaris Products ...Troubleshooting ...Warranty ...Maintenance Log ...117 118 124 132 Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an
  • 2006 Polaris 700 Fusion | Owners Manual - Page 7
    with the snowmobile when sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer
  • 2006 Polaris 700 Fusion | Owners Manual - Page 8
    of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 9
    INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are
  • 2006 Polaris 700 Fusion | Owners Manual - Page 10
    symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert to the vehicle. NOTE: A note will alert you to important information or instructions. 7
  • 2006 Polaris 700 Fusion | Owners Manual - Page 11
    SAFETY Operator Safety Follow the recommended maintenance program outlined beginning on page 78 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full
  • 2006 Polaris 700 Fusion | Owners Manual - Page 12
    while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 13
    your snowmobile at all times: SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner's Manual SFirst Aid Kit STool Kit 10
  • 2006 Polaris 700 Fusion | Owners Manual - Page 14
    Operator Safety Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 20. SAFETY WARNING Avoid wearing loose clothing or long scarves, which can become entangled in moving parts
  • 2006 Polaris 700 Fusion | Owners Manual - Page 15
    SAFETY Operator Safety Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather.
  • 2006 Polaris 700 Fusion | Owners Manual - Page 16
    Operator Safety Driver Awareness SAFETY Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy
  • 2006 Polaris 700 Fusion | Owners Manual - Page 17
    and avalanche conditions, contact local law enforcement in your area, or visit either the American Avalanche Association online at www.americanavalancheassociation.org or the U.S. Forest Service National Avalanche Center at www.avalanche.org. 14
  • 2006 Polaris 700 Fusion | Owners Manual - Page 18
    may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty
  • 2006 Polaris 700 Fusion | Owners Manual - Page 19
    SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly
  • 2006 Polaris 700 Fusion | Owners Manual - Page 20
    or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced
  • 2006 Polaris 700 Fusion | Owners Manual - Page 21
    SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled
  • 2006 Polaris 700 Fusion | Owners Manual - Page 22
    Operator Safety SAFETY Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions.
  • 2006 Polaris 700 Fusion | Owners Manual - Page 23
    SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed in MPH 40 35 30 25 20 15 Actual Thermometer Reading (°F) 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40
  • 2006 Polaris 700 Fusion | Owners Manual - Page 24
    of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. If any decal becomes illegible or comes off, contact your Polaris dealer
  • 2006 Polaris 700 Fusion | Owners Manual - Page 25
    SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. + "No Passenger" Warning The "NO PASSENGER" warning decal
  • 2006 Polaris 700 Fusion | Owners Manual - Page 26
    while backing up. S Avoid sharp turns. S Shift to or from reverse only when stopped. S Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse: + S Machine stopped and engine at idle, push yellow button on LH S Push button again to return to forward. control to
  • 2006 Polaris 700 Fusion | Owners Manual - Page 27
    stop. S To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. S Repeated stops from high speed may cause fading or sudden loss of braking ability. S Parking brake may relax
  • 2006 Polaris 700 Fusion | Owners Manual - Page 28
    FEATURES 3 2 1 6 4 5 8 7 12 14 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hood Headlight Windshield Handlebar Seat Snow Flap Suspension Track Storage Compartment Rear Bumper Taillights Nosepan Front Bumper Skis 9 11 10 9 25
  • 2006 Polaris 700 Fusion | Owners Manual - Page 29
    FEATURES 4 5 3 2 6 9 7 8 1. Fuel Filler Cap 2. Ignition Switch 3. Brake Lever 4. MFD Gauge 5. Headlight Adjuster 6. Engine Stop Switch 7. Throttle Control 8. Hood Hold Down Straps 9. Recoil Starter Handle 10. Headlight Dimmer Switch 11. Park Brake 12. Handlebar Grip Warmer Switch 13.
  • 2006 Polaris 700 Fusion | Owners Manual - Page 30
    RIDER SELECT Adjustable Steering System FEATURES The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious
  • 2006 Polaris 700 Fusion | Owners Manual - Page 31
    FEATURES Seat Storage Compartment Open or close the storage compartments with the key. Adjustable Headlights Adjust the headlight beam by moving the adjuster to the left (to lower the beam) or to the right (to raise the beam). Access Panel The access panel (1) is provided for cleaning debris from
  • 2006 Polaris 700 Fusion | Owners Manual - Page 32
    and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. DET Troubleshooting Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see
  • 2006 Polaris 700 Fusion | Owners Manual - Page 33
    Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 3 4 5 6 7 8 Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH - Miles per hour KPH - Kilometers per hour RPM
  • 2006 Polaris 700 Fusion | Owners Manual - Page 34
    Instrumentation MFD Settings FEATURES With the engine running, use the MFD Control Switch (1) to set the 1 MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of 2 measurement. While
  • 2006 Polaris 700 Fusion | Owners Manual - Page 35
    FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. NOTE: The analog will always display either MPH or engine RPM (whichever setting
  • 2006 Polaris 700 Fusion | Owners Manual - Page 36
    Instrumentation FEATURES MFD Digital Display Programs Performance Program Clock Setting 1. While in the CLOCK display, press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour, or press and hold the SET button to advance the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 37
    FEATURES Instrumentation MFD Digital Display Programs Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and
  • 2006 Polaris 700 Fusion | Owners Manual - Page 38
    to view maximum vehicle speed, maximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine Program will display the history of the Maximum Speed, Maximum RPM and Service Interval settings. Maximum Speed/RPM Reset While in either the MAX MPH
  • 2006 Polaris 700 Fusion | Owners Manual - Page 39
    "ENG" will flash in the icon area for five seconds each time the vehicle is started until the service reminder is reset. To reset the reminder at the existing interval: 1. Enter the service interval screen. 2. Press and hold the SET button for ten seconds, continuing to hold even after the display
  • 2006 Polaris 700 Fusion | Owners Manual - Page 40
    Instrumentation FEATURES MFD Battery Replacement If the clock function of the MFD isn't A working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery B compartment (A). It has a red
  • 2006 Polaris 700 Fusion | Owners Manual - Page 41
    FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or
  • 2006 Polaris 700 Fusion | Owners Manual - Page 42
    IQ Front Suspension Adjustments Independent Front Suspension (IFS) THE PERFECT FIT Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions.
  • 2006 Polaris 700 Fusion | Owners Manual - Page 43
    THE PERFECT FIT WARNING IQ Front Suspension Adjustments Always verify ski alignment before making adjustments to the IFS. See page 110 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set
  • 2006 Polaris 700 Fusion | Owners Manual - Page 44
    Front Suspension Adjustments IQ Front Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. A
  • 2006 Polaris 700 Fusion | Owners Manual - Page 45
    and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. Front Springs The front springs can be changed if spring preload
  • 2006 Polaris 700 Fusion | Owners Manual - Page 46
    IQ Rear Suspension Adjustments THE PERFECT FIT Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension
  • 2006 Polaris 700 Fusion | Owners Manual - Page 47
    THE PERFECT FIT IQ Rear Suspension Adjustments To set up the IQ rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may
  • 2006 Polaris 700 Fusion | Owners Manual - Page 48
    IQ Rear Suspension Adjustments Torsion Spring Tension THE PERFECT FIT To adjust rear torsion spring tension, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. See your dealer for more information. 1. Soft
  • 2006 Polaris 700 Fusion | Owners Manual - Page 49
    THE PERFECT FIT Suspension Coupling IQ Rear Suspension Adjustments On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension
  • 2006 Polaris 700 Fusion | Owners Manual - Page 50
    IQ Rear Suspension Adjustments THE PERFECT FIT Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front
  • 2006 Polaris 700 Fusion | Owners Manual - Page 51
    weight transfer or ski lift during acceleration, rotate the RRSS to a lower position. NOTE: Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride. 48
  • 2006 Polaris 700 Fusion | Owners Manual - Page 52
    FAST M-10 Rear Suspension Adjustments THE PERFECT FIT The M-10 suspension has been designed to be very sensitive to rider weight. Changes in rider weight of 25 lbs. (11 kg) or more might require appropriate changes in settings. The following information has been compiled to assist you in tuning
  • 2006 Polaris 700 Fusion | Owners Manual - Page 53
    THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear suspension adjustment. It will have the MOST effect on the rear suspension performance. To adjust the FRA: 1. Refer to the initial set-up reference chart (
  • 2006 Polaris 700 Fusion | Owners Manual - Page 54
    FAST M-10 Rear Suspension Adjustments Static Sag and Ride Height Settings THE PERFECT FIT Rear Spring Preload If FRA position alone does not allow the setup of the proper amount of sag, the center retainer of the rear track shock can be replaced with optional retainers to adjust the preload and
  • 2006 Polaris 700 Fusion | Owners Manual - Page 55
    THE PERFECT FIT FAST M-10 Rear Suspension Adjustments Ski Pressure Ski pressure is set at the factory to deliver the optimum balance between ride and handling. If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter strap and front arm
  • 2006 Polaris 700 Fusion | Owners Manual - Page 56
    FAST M-10 Rear Suspension Adjustments Ski Pressure 4. There are also two front arm mounting holes in the slide rail that can adjust ski pressure. The lower hole (1) increases ski pressure while the upper hole (2) decreases ski pressure. NOTE: 2 1 THE PERFECT FIT By design, the BIASED COUPLE design
  • 2006 Polaris 700 Fusion | Owners Manual - Page 57
    THE PERFECT FIT Handlebar Position Handlebar Angle Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 27. Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster block
  • 2006 Polaris 700 Fusion | Owners Manual - Page 58
    , clutches, fuel systems, and exhaust systems. NOTE: Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 55
  • 2006 Polaris 700 Fusion | Owners Manual - Page 59
    THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from
  • 2006 Polaris 700 Fusion | Owners Manual - Page 60
    Traction Products n Carbide Skags THE PERFECT FIT A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle
  • 2006 Polaris 700 Fusion | Owners Manual - Page 61
    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item Drive Belt
  • 2006 Polaris 700 Fusion | Owners Manual - Page 62
    and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. n Throttle Safety Switch Test the throttle safety switch system
  • 2006 Polaris 700 Fusion | Owners Manual - Page 63
    needed. See page 96. Check for the presence of air in the fluid system. See page 97 for more information, or see your dealer for service. WARNING Continued use of "spongy" brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes
  • 2006 Polaris 700 Fusion | Owners Manual - Page 64
    is in use. If the park brake light does not come on when the park brake or service brake is in use, have it serviced by your dealer. Lock Release To release the lock, squeeze the brake lever tightly. The lock will return to the unlock position. WARNING If the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 65
    PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, remove any ice and snow build-up that may
  • 2006 Polaris 700 Fusion | Owners Manual - Page 66
    Start the Engine and Check PRE-RIDE INSPECTIONS n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. n Ignition Switch: Make sure the engine stops when the ignition switch is turned to OFF. n Tether
  • 2006 Polaris 700 Fusion | Owners Manual - Page 67
    OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 59. Do not
  • 2006 Polaris 700 Fusion | Owners Manual - Page 68
    track surfaces. Avoid operating on ice, hard-packed surfaces or roads. Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. Premix the first tank of gasoline with one pint of Polaris injection oil
  • 2006 Polaris 700 Fusion | Owners Manual - Page 69
    OPERATION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. Maintain the oil level at the bottom of the filler neck. See page 67. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of
  • 2006 Polaris 700 Fusion | Owners Manual - Page 70
    Oil n Low Oil Level OPERATION The low oil indicator light will alert the operator if the oil level is low. Add oil before further operation of the snowmobile. See page 66 for oil recommendations. CAUTION Operating the snowmobile without adequate engine lubrication can result in serious engine
  • 2006 Polaris 700 Fusion | Owners Manual - Page 71
    OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. S Do not overfill the tank. Do not fill the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 72
    Fuel OPERATION For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in
  • 2006 Polaris 700 Fusion | Owners Manual - Page 73
    behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss
  • 2006 Polaris 700 Fusion | Owners Manual - Page 74
    n Engine Stop Switch Push down on the engine stop switch (A) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. OPERATION n Throttle Safety Switch A The throttle safety switch is designed to stop the engine whenever all pressure is
  • 2006 Polaris 700 Fusion | Owners Manual - Page 75
    may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service. If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 76
    Emergency Stopping OPERATION The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 71 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (
  • 2006 Polaris 700 Fusion | Owners Manual - Page 77
    OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is
  • 2006 Polaris 700 Fusion | Owners Manual - Page 78
    Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4″ (10 cm) off the ground. Remove the key and cover
  • 2006 Polaris 700 Fusion | Owners Manual - Page 79
    and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups
  • 2006 Polaris 700 Fusion | Owners Manual - Page 80
    specified maintenance is performed, including the emission-related maintenance outlined in these sections of the manual. You must inspect the air intake system on your snowmobile prior to each use ( that you contact an authorized Polaris dealer to perform any service that may be necessary. 77
  • 2006 Polaris 700 Fusion | Owners Manual - Page 81
    MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 132. The recommended
  • 2006 Polaris 700 Fusion | Owners Manual - Page 82
    Periodic Maintenance Interval Table MAINTENANCE The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use
  • 2006 Polaris 700 Fusion | Owners Manual - Page 83
    MAINTENANCE Item Periodic Maintenance Interval Table See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake fluid Idle RPM Throttle Lever Oil Pump
  • 2006 Polaris 700 Fusion | Owners Manual - Page 84
    Periodic Maintenance Interval Table Item See Page 150 mi. (240 km) 500 mi. (800 km) MAINTENANCE Frequency 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud
  • 2006 Polaris 700 Fusion | Owners Manual - Page 85
    MAINTENANCE Lubrication Front Suspension The Fusion front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before
  • 2006 Polaris 700 Fusion | Owners Manual - Page 86
    Lubrication MAINTENANCE + Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Throttle Cable Lubricate the throttle cable
  • 2006 Polaris 700 Fusion | Owners Manual - Page 87
    MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2). Change the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 88
    Lubrication MAINTENANCE Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely 3. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 89
    than intended for that plug. Always use the spark plugs recommended for your snowmobile. S Use recommended spark plugs with the proper gap. See your Owner's Manual Supplement for the recommended spark plug and gap. S Use only resistor-type spark plugs. S Torque spark plugs to 18-22 ft. lbs. (24-30
  • 2006 Polaris 700 Fusion | Owners Manual - Page 90
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body
  • 2006 Polaris 700 Fusion | Owners Manual - Page 91
    be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Lines Inspect the fuel lines regularly for signs of deterioration
  • 2006 Polaris 700 Fusion | Owners Manual - Page 92
    Oil Filter Inspect oil line condition at 1000 miles (1600 km). The oil filter should be changed annually or every 1000 miles (1600 km). The oil filter is located on the left side of the bulkhead behind the drive clutch. Have your dealer perform the filter change and bleeding operation. NOTE: The
  • 2006 Polaris 700 Fusion | Owners Manual - Page 93
    cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure
  • 2006 Polaris 700 Fusion | Owners Manual - Page 94
    to protect the engine, the system should be completely drained every two years and a fresh mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your
  • 2006 Polaris 700 Fusion | Owners Manual - Page 95
    MAINTENANCE Cooling System Bleeding the Cooling System 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. WARNING Steam and hot liquids will cause serious burns to your skin.
  • 2006 Polaris 700 Fusion | Owners Manual - Page 96
    Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 97
    MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. A Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2″ (1.3 cm).
  • 2006 Polaris 700 Fusion | Owners Manual - Page 98
    Brakes 1. 2. 3. 4. MAINTENANCE 1 Brake Components Brake Caliper Brake Disc Backing Plate Brake Pad Material (Replace when thickness is less than 1/16″/1.5mm). 4 2 3 Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops (see page 94), bring the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 99
    MAINTENANCE Brakes Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop,
  • 2006 Polaris 700 Fusion | Owners Manual - Page 100
    Brakes MAINTENANCE Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and
  • 2006 Polaris 700 Fusion | Owners Manual - Page 101
    MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. Removing Halogen Bulbs 1. Remove the plenum covering from the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 102
    Lights MAINTENANCE Taillight/Brakelight Replacement 1. Open the rear storage compartment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight. 5. Replace the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 103
    is important for maintaining optimum performance. See your Owner's Manual Supplement for the recommended offset between the drive and driven change the shift pattern, resulting in poor performance. See your dealer for service and adjustments. NOTE: A worn belt will continue to function, but will
  • 2006 Polaris 700 Fusion | Owners Manual - Page 104
    Clutch System n Drive Belt Condition MAINTENANCE Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist.
  • 2006 Polaris 700 Fusion | Owners Manual - Page 105
    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If
  • 2006 Polaris 700 Fusion | Owners Manual - Page 106
    Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4" (3.2 cm). MAINTENANCE A B Drive Belt
  • 2006 Polaris 700 Fusion | Owners Manual - Page 107
    keep the tool kit with the snowmobile. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine in peak operating condition. Maintenance Items The tools and maintenance items mentioned
  • 2006 Polaris 700 Fusion | Owners Manual - Page 108
    rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand A WARNING Operating with insufficient lubrication between the slider and track guide clips can cause track failure, loss of vehicle control and loss
  • 2006 Polaris 700 Fusion | Owners Manual - Page 109
    check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly
  • 2006 Polaris 700 Fusion | Owners Manual - Page 110
    adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off. 2. Lift the rear of the machine and safely support it off the ground. 3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of
  • 2006 Polaris 700 Fusion | Owners Manual - Page 111
    MAINTENANCE Track Tension Track Maintenance 4. Check for specified slack (1) between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 107. If the track needs adjustment: 5. Loosen the rear idler shaft bolt (2). 6. Loosen the locknuts (3). 4 3
  • 2006 Polaris 700 Fusion | Owners Manual - Page 112
    Steering System MAINTENANCE Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. + + + + 109
  • 2006 Polaris 700 Fusion | Owners Manual - Page 113
    MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead
  • 2006 Polaris 700 Fusion | Owners Manual - Page 114
    worn to half their original diameter. NOTE: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the machine so the skis are approximately 6″ (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag (1) downward
  • 2006 Polaris 700 Fusion | Owners Manual - Page 115
    MAINTENANCE Suspension Maintenance n Slider Wear Measure slider thickness at several points along the rail. Have your dealer replace the slider when it's worn to the top of the wear groove (A). Do not operate the snowmobile if slider thickness measures less than 7/16″ (1.1 cm) at any point. 7/16″
  • 2006 Polaris 700 Fusion | Owners Manual - Page 116
    reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check suspension mounting bolts for tightness. n Check rear
  • 2006 Polaris 700 Fusion | Owners Manual - Page 117
    MAINTENANCE Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 117 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with
  • 2006 Polaris 700 Fusion | Owners Manual - Page 118
    except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the engine and be fogged with fogging oil. Follow the engine fogging instructions provided on the container. Always add Premium Carbon Clean or a fuel conditioner
  • 2006 Polaris 700 Fusion | Owners Manual - Page 119
    moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be
  • 2006 Polaris 700 Fusion | Owners Manual - Page 120
    POLARIS PRODUCTS Part No. 2870791 2871098 2871097 2871240 2871721 2871722 2872347 2874438 2874439 2874443 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2872189 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium 2-
  • 2006 Polaris 700 Fusion | Owners Manual - Page 121
    TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution S SEE YOUR DEALER. S SEE YOUR DEALER. Erratic engine Drive clutch binding operating RPM during Driven
  • 2006 Polaris 700 Fusion | Owners Manual - Page 122
    Engine Troubleshooting Problem Noise in drive system TROUBLESHOOTING Probable Cause Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn,
  • 2006 Polaris 700 Fusion | Owners Manual - Page 123
    TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable or pump. Add isopropyl alcohol to the fuel system. S Mixture is too lean. This indicates a major engine problem that must be repaired before the engine is run. SEE YOUR DEALER. S Replace the plug. S SEE YOUR
  • 2006 Polaris 700 Fusion | Owners Manual - Page 124
    IQ Suspension Troubleshooting Problem Rear suspension bottoms too easily TROUBLESHOOTING Solution (perform only one change at a time) S Adjust torsion spring preload to achieve proper static sag (see page 44). S Change torsion spring to stiffer optional
  • 2006 Polaris 700 Fusion | Owners Manual - Page 125
    TROUBLESHOOTING Problem Rear suspension bottoms too easily M-10 Suspension Troubleshooting Solution (perform only one change at a time) S Increase FRA position (see page 50). S Install appropriate optional center retainer on rear track shock (see page 51). S
  • 2006 Polaris 700 Fusion | Owners Manual - Page 126
    Causes Driving at low RPM Insufficient warm-up TROUBLESHOOTING Belt Wear/Burn Diagnosis Solutions S Drive at higher RPMs. Gear the machine down. Check belt deflection. S Warm the engine at least five minutes. Take the
  • 2006 Polaris 700 Fusion | Owners Manual - Page 127
    information contained in this manual. Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1. Serial number 5. Details of trouble experienced 2. Model number
  • 2006 Polaris 700 Fusion | Owners Manual - Page 128
    preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to
  • 2006 Polaris 700 Fusion | Owners Manual - Page 129
    dealer is YOUR responsibility). Polaris recommends that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Your dealer will contact the appropriate personnel at Polaris if
  • 2006 Polaris 700 Fusion | Owners Manual - Page 130
    dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty
  • 2006 Polaris 700 Fusion | Owners Manual - Page 131
    oil. S Piston seizures, unless caused by a defective engine component. S Failures caused due to improper adjustments. S Failure due to unauthorized service. S Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner
  • 2006 Polaris 700 Fusion | Owners Manual - Page 132
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle
  • 2006 Polaris 700 Fusion | Owners Manual - Page 133
    WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified snowmobile engine meets
  • 2006 Polaris 700 Fusion | Owners Manual - Page 134
    for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary. It is a potential violation of the Clean Air
  • 2006 Polaris 700 Fusion | Owners Manual - Page 135
    MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)
  • 2006 Polaris 700 Fusion | Owners Manual - Page 136
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 133
  • 2006 Polaris 700 Fusion | Owners Manual - Page 137
    ...Driving on Slippery Surfaces ...Driving Responsibly ...93 13 83 15 16 15 19 B Bearings ...115 Before Starting the Engine ...59-62 Belt Troubleshooting ...123 Bleeding the Cooling System ...92 Bleeding the Hydraulic Brake System 97 Brake Components ...95 Brake Fluid ...96 Brake Lever Travel ...60
  • 2006 Polaris 700 Fusion | Owners Manual - Page 138
    ...21-24 Sag ...44 Sag/Ride Height, M10 ...49-51 Scissor Stop ...46-47 Seat Storage Compartment ...28 Second Year Engine Service Contract 128 Service And Warranty Information . 124 Shock Absorber Components ...40 Shock Spring Preload, Front ...41 Shock Valving ...42 Shock, PPS ...45 Shocks, Rear
  • 2006 Polaris 700 Fusion | Owners Manual - Page 139
    Preparation ...10 Suspension ...116 Suspension Coupling ...46 Suspension Maintenance ...112-113 Suspension Performance Tips ...43 Suspension Troubleshooting, IQ ...121 Suspension Troubleshooting, M10 . 122 Suspension, Front ...39-42 Suspension, Rear, IQ ...43-48 Suspension, Rear, M10 ...49-53
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