service repair manual

1. 500 XC SP
600 XC SP
700 XC SP
800 XC SP
900 FUSION
2005 PERFORMANCE
SERVICE MANUAL
PN9919303
9919303
2005
PERFORMANCE
SERVICE
MANUAL
CVR_9919304 9/2/04 8:37 AM Page 1

2. i
2005 PERFORMANCE
MANUAL
SPECIFICATIONS 1
GENERAL 2
MAINTENANCE 3
FUEL DELIVERY 4
ENGINE 5
CLUTCHING 6
FINAL DRIVE 7
BRAKE SYSTEM 8
STEERING 9
FRONT SUSPENSION 10
REAR SUSPENSION 11
CHASSIS / HOOD 12
ELECTRICAL SYSTEM 13
WIRING DIAGRAMS 14
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 tools. 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 the operator’s perspective when seatedin a normal
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 ofthe 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.

3. 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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. SPECIFICATIONS
1.2
MODEL: 500 XC SP
. . . . . . . . . . . . . .
MODEL NUMBER: S05NE(P)5CS(A,B)
. . . .
ENGINE MODEL: S2715-
-5044-
-PI5C
. . . . .
ENGINE CARBURETION
Engine Type Libertyt Type TM38
Engine Displacement cc 500 Main Jet 410
Bore in / mm 2.78/70.5 Pilot Jet 45
Stroke in / mm 2.52/64 Jet Needle 9DFH6-
-57/2
Cylinders 2 Needle Jet P-
-8
Piston / Cylinder Clearance
in / mm
.0045” -
- .0059”
0.115 -
- 0.149mm
Throttle Gap UnderCutaway
in / mm
0.079”/2.0mm
Piston Ring End Gap in / mm
.014” -
- .020”
0.356 -
- 0.508
Cutaway 1.5
Piston 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 Valve Spring Pink/Yellow Fuel Octane 87 min non-
-oxygentaed
AMBIENT TEMPERATURE
Altitude Below -30°F -30_ to -
-10_F -
-10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
Below -34°C
-30_ to -
-10_F
-34_to -23_C
-
-10_to +10_F
-23_ to -
-12_C
+10_to +30_F
-12_to -
-1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0-
-600 (0-
-2000)
440
#3
430
#3
410
#2
390
#2
380
#2
360
#2
600-
-1200
(2000-
-4000)
420
#3
400
#2
390
#2
370
#2
350
#2
340
#1
1200-
-1800 390 380 360 340 330 310
1200-
-1800
(4000-
-6000)
390
#2
380
#2
360
#2
340
#2
330
#1
310
#1
Meters 1800-
-2400
(6000 8000)
370 350 340 320 300 290
Meters
(Feet) (6000-
-8000)
370
#2
350
#2
340
#2
320
#1
300
#1
290
#1
2400-
-3000
(8000 10000)
340 330 310 300 280 260
(8000-
-10000)
340
#2
330
#2
310
#1
300
#1
280
#1
260
#1
3000-
-3700
(10000 12000)
320 300 290 270 250 240
(10000-
-12000)
320
#2
300
#1
290
#1
270
#1
250
#1
240
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 56 B h d 56/42 36 ER 22 40 74
0-900
(0-3000)
10-
-56 Bushed 56/42-
-36 ER 22:40-
-74
M t
900-1800
10 54 B h d 56/42 36 ER 22 40 74
Meters
(Feet)
900-1800
(3000-6000)
10-
-54 Bushed
Bl k/G 7043058
56/42-
-36 ER 22:40-
-74
(Feet)
1800-2700
10 B h d
Black/Green 7043058
56/42 36 ER 21 40 74
1800-2700
(6000-9000)
10 Bushed 56/42-
-36 ER 21:40-
-74
2700-3700
10MB B h d 56/42 36 ER 21 40 74
2700-3700
(9000-12000)
10MB Bushed 56/42-
-36 ER 21:40-
-74

5. SPECIFICATIONS
1.3
DRIVE CLUTCH CHAINCASE
Type P-
-85 Center Distance 7.92”
Shift Weights 10-
-56 Bushed Gearing : Chain 22:40-
-74
Drive Spring Black/Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads 2202202
Type Team Roller Reverse
Brake Type Type 81
Spring Red/Black
Brake Type Type 81
Helix Angle 56/42-
-36 ER CAPACITIES
BELT Fuel Tank 11.8 gal / 44.7 l
Belt Part Number 3211080 Oil Tank 3.25 qts. / 3.1 l
Belt Width (Projected) 1.438” Coolant 5.6 qts. / 5.3 l
Side Angle (Overall) 28_ Chain Case Oil 9 oz. / 266 ml
Outside Diameter 46.625” SLED DIMENSION
Center Distance 11.50”
Unit Length / Height /
Width in / cm.
113 / 46 / 48
287 / 117 / 122
FRONT SUSPENSION REAR SUSPENSION
Type Edge Type Edge / M-
-10
IFS Shocks
M10/STD 7043082
F/O 7042211 Stock FTS
STD / F/O 7041975
M 10 7042224
Stock IFS Spring Rate M10/STD 68/160
Stock FTS
M-
-10 7042224
Stock IFS Spring Rate M10/STD 68/160
F/O 90/180
IFS Spring Pre-
-Load
M-
-10/STD (Inst. length)
10.56”
F/O .625”
FTS Spring Rate
STD / F/O 160/VAR
M-
-10 160
Front Vertical Travel 10.28”/26cm.
FTS Pre Load
STD / F/O N/A (eyelet to re-
tainer) 3 50”
TRACK
FTS Pre-
-Load tainer) 3.50”
M-
-10 .90”
Width 15”
Stock RTS
STD 7042129
F/O 7042212
Length 121”
Stock RTS F/O 7042212
M-
-10 7042216
Lug Height
STD/F/O .91” / 1.25”
M-
-10 1.0”
Torsion Spring .375(sq.)
Track Tension See page 3 10
M-
-10 RTS Springs 7041935/7041936
Track Tension See page 3.10
Optional Torsion Springs found on page 11.7-
- 11.8
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .70mm/.025”
CDI Marking 4010829 Voltage Regulator N/A
Alternator Output 280w Magneto Pulses 6
Ignition Timing(see conver- 25_ @ 2500 RPM Electric Start STD / M-
-10 Accessory
Ignition Timing(see conver
sion chart on page 13.4)
25_ @ 2500 RPM Electric Start STD / M 10 Accessory
F/O / M-
-10 F/O Standard

6. SPECIFICATIONS
1.4
MODEL: 600 XC SP
. . . . . . . . . . . . . .
MODEL NUMBER: S05N(A,E,P)6E(E,S)(A,B)
. . . .
ENGINE MODEL: S2761-
-6044-
-PI6E
. . . . .
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 38
Engine Displacement cc’s 599 Main Jet 440
Bore in / mm 3.04” / 72.25mm Pilot Jet 45
Stroke in / mm 2.52” / 64mm Jet Needle 9DFH7-
-60 / 3
Cylinders 2 Needle Jet P-
-8
Piston / Cylinder Clearence
in / mm
.0045 -
- .0059”
.115 -
- .149mm
Throttle Gap UnderCutaway
in / mm
0.079”
2.0 mm
Piston Ring End Gap
in / mm
.014”-
- .020”
.356 -
- .508mm
Cutaway 2.5
Piston Marking 3021308 Valve Seat 1.5
Piston 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 Air Screw 1.0 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#4
440
#3
420
#3
400
#3
390
#2
600--1200
(2000--4000)
450
#4
430
#4
410
#4
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
M t
1200--1800
(4000--6000)
420
#4
400
#4
390
#3
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(6000 8000)
400 380 360 340 330 310
(Feet) (6000--8000)
400
#4
380
#3
360
#2
340
#2
330
#2
310
#2
2400--3000
(8000 10000)
370 350 330 320 300 280
(8000--10000)
370
#3
350
#2
330
#2
320
#2
300
#2
280
#2
3000--3700
(10000 12000)
340 330 310 290 270 260
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#1
260
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 58 58 42 36 ER 23 39: 74P
0-900
(0-3000)
10-58 58--42--.36 ER 23--39: 74P
M t
900-1800
10 56 58 42 36 ER 23 39 : 74P
Meters
(Feet)
900-1800
(3000-6000)
10-56
Dark Blue/White Red / Blue
58--42--.36 ER 23--39 : 74P
(Feet)
1800-2700
10 54
Dark Blue/White Red / Blue
58 42 36 ER 22 39 : 74P
1800-2700
(6000-9000)
10--54 58--42--.36 ER 22--39 : 74P
2700-3700
10 58 42 36 ER 22 39 : 74P
2700-3700
(9000-12000)
10 58--42--.36 ER 22--39 : 74P

7. SPECIFICATIONS
1.5
DRIVE CLUTCH CHAINCASE
Type P-
-85 Center Distance 7.92” / 20.12cm
Shift Weights 10-
-58 Gearing : Chain 23-
-39 : 74 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
Brake Type Liquid Cooled
Driven Spring Red / Blue
Brake Type Liquid Cooled
Driven Helix Angle 58-
-42-
-.36 ER CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm Coolant 5.6 Qts / 5.3 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Width in / cm
113” / 48” / 48”
287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks STD (F/O)
7043082
(7042211)
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate 68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M-
-10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre-
-Load
(F/O)
3.25” / 8.26cm
(.625” / 16 mm)
M-
-10 FTS Spring Rate 160#/in
Front Vertical Travel 10.28” / 26cm FTS Pre-
-Load .25” / .635 cm
TRACK M-
-10 FTS Pre-
-Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
Lug Height
(M-
-10/F/O)
.91” / 2.3 cm
(1” / 2.54 cm /
1.25”/3.175cm)
M-
-10 RTS Fox IFP Res PN 7042216
T k T i S P 3 10
M-
-10 RTS Spring Rate
(M-
-10 ACE Spring Rate)
210/278 #/in.
(220/1140)
Track Tension See Page 3.10 Torsion Springs .375(Sq.) 77_
Optional M-
-10 Springs see page 11.7-
- 11.8
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010830 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing (see conver-
24_@3500 RPM±1 5_ Electric Start Accessory
Ignition Timing (see conver
sion chart on page 13.4 )
24_@3500 RPM±1.5_ Electric Start Accessory

8. SPECIFICATIONS
1.6
MODEL: 700 XC SP
. . . . . . . . . . . . . .
MODEL NUMBER: S05N(E,P)7CS(A,B)
. . . .
ENGINE MODEL: S2469-
-7070-
-PR7C
. . . . .
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc’s 701 Main Jet 440
Bore in / mm 3.19” / 81mm Pilot Jet 45
Stroke in / mm 2.68” / 68mm Jet Needle 9DGN-
-57 / 3
Cylinders 2 Needle Jet P-
-8
Piston / Cylinder Clearence
in / mm
.0044-
- .0058”
.111-
- .147mm
Throttle Gap UnderCutaway
in / mm
0.079”
2.0 mm
Piston Ring End Gap
in / mm
.012-
- .018”
.304 -
- .457mm
Cutaway 1.5
Piston Marking 3021307 Valve Seat 1.8
Piston Ring Marking N/A Starter Jet 145
Operating RPM ±200 8000 Fuel Screw 2.5 Turns
Idle RPM ±200 1400 Pilot Air Jet N/A
Engagement RPM ±300 3500 Air Screw 1.25 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#3
440
#3
420
#3
400
#3
390
#2
600--1200
(2000--4000)
450
#3
430
#3
410
#3
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
M t
1200--1800
(4000--6000)
420
#3
400
#3
390
#3
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(6000 8000)
400 380 360 340 330 310
(Feet) (6000--8000)
400
#3
380
#3
360
#2
340
#2
330
#2
310
#2
2400--3000
(8000 10000)
370 350 330 320 300 280
(8000--10000)
370
#3
350
#2
330
#2
320
#2
300
#2
280
#2
3000--3700
(10000 12000)
340 330 310 290 270 260
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#2
260
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 62 62 42 46 ER 25 41: 76P
0-900
(0-3000)
10-62 62--42--.46 ER 25--41: 76P
M t
900-1800
10 60 62 42 46 ER 25 41: 76P
Meters
(Feet)
900-1800
(3000-6000)
10-60
Black/Green 7043063
62--42--.46 ER 25--41: 76P
(Feet)
1800-2700
10 58
Black/Green 7043063
62 40 46 ER 23 39 : 74P
1800-2700
(6000-9000)
10--58 62--40--.46 ER 23--39 : 74P
2700-3700
10 56 62 40 46 ER 23 39 : 74P
2700-3700
(9000-12000)
10--56 62--40--.46 ER 23--39 : 74P

9. SPECIFICATIONS
1.7
DRIVE CLUTCH CHAINCASE
Type P-
-85 Center DIstance 7.92” / 20.12cm
Shift Weights 10-
-62 Gearing : Chain 25-
-41 : 76 P
Drive Spring Black / Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
Brake Type Liquid Cooled
Driven Spring 7043063
Brake Type Liquid Cooled
Helix Angle 62-
-42-
-.46 ER CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm Coolant 5.2 Qts / 4.9 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Width in / cm
113” / 48” / 48”
287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks STD (F/O)
7043082
(7042211)
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate 68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M-
-10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre-
-Load
(F/O)
3.25” / 8.26cm
(.625” / 16 mm)
M-
-10 FTS Spring Rate 160#/in
Front Vertical Travel 10.28” / 26cm FTS Pre-
-Load .25” / .635 cm
TRACK M-
-10 FTS Pre-
-Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
Lug Height
(M-
-10/F/O)
.91” / 2.3 cm
(1” / 2.54 cm /
1.25”/3.175cm)
M-
-10 RTS Fox IFP Res PN 7042216
T k T i S P 3 10
M-
-10 RTS Spring Rate
(M-
-10 ACE Spring Rate)
210/278 #/in.
(220/1140)
Track Tension See Page 3.10 Torsion Springs .375(Sq.) 77_
Optional M-
-10 Springs see page 11.7-
- 11.8
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010839 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing (see conver-
20_@2000 RPM±1 5_ Electric Start Accessory
Ignition Timing (see conver
sion chart on page 13.4 )
20_@2000 RPM±1.5_ Electric Start Accessory
STD M-
-10

10. SPECIFICATIONS
1.8
MODEL: 800 XC SP
. . . . . . . . . . . . . .
MODEL NUMBER: S05N(E,P)8CS(A,B)
. . . .
ENGINE MODEL: S2774-
-8070-
-PI8C
. . . . .
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc’s 794 Main Jet 460
Bore in / mm 3.35” / 85mm Pilot Jet 40
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN5-
-57 / 3
Cylinders 2 Needle Jet P-
-8
Piston / Cylinder Clearence
in / mm
.006 -
- .0074”
.152-
- .188mm
Throttle Gap UnderCutaway
in / mm
0.079”
2.0 mm
Piston Ring End Gap
in / mm
.016-
- .022”
.406 -
- .559mm
Cutaway 1.5
Piston Marking 3021315 Valve Seat 1.8
Piston Ring Marking N/A Starter Jet 135
Operating RPM ±200 7900 Fuel Screw 2.5 Turns
Idle RPM ±200 1500 Pilot Air Jet N/A
Engagement RPM ±300 3500 Air Screw 1.5 Turns
Exhaust Valve Spring Pink/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_ to --10_F --10_to +10_F +10_to +30_F +30_to +50_F Above +50_F
Altitude Below -30 F
Below -34°C
-30_ to --10_F
-34_to -23_C
--10_to +10_F
-23_ to --12_C
+10_to +30_F
-12_to --1_C
+30_to +50_F
-1_to +10_C
Above +50_F
Above +10_C
0--600
(0--2000)
500
#4
480
#4
460
#3
440
#3
420
#2
400
#2
600--1200
(2000--4000)
470
#4
450
#3
430
#3
410
#2
400
#2
380
#2
1200--1800 440 420 400 390 370 350
M t
1200--1800
(4000--6000)
440
#3
420
#3
400
#2
390
#2
370
#2
350
#2
Meters
(Feet)
1800--2400
(6000 8000)
410 400 380 360 340 320
(Feet) (6000--8000)
410
#3
400
#2
380
#2
360
#2
340
#2
320
#2
2400--3000
(8000 10000)
390 370 350 330 310 290
(8000--10000)
390
#2
370
#2
350
#2
330
#2
310
#2
290
#2
3000--3700
(10000 12000)
360 340 320 300 290 270
(10000--12000)
360
#2
340
#2
320
#2
300
#2
290
#2
270
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 64 62 46 46 ER 25 41: 76P
0-900
(0-3000)
10-64 62--46--.46 ER 25--41: 76P
M t
900-1800
10 62 62 42 46 ER 25 41: 76P
Meters
(Feet)
900-1800
(3000-6000)
10-62
Dark Blue /
7043063
62--42--.46 ER 25--41: 76P
(Feet)
1800-2700
10 60
Dark Blue /
White
7043063
62 40 46 ER 23 39 : 74P
1800-2700
(6000-9000)
10--60
White
62--40--.46 ER 23--39 : 74P
2700-3700
10 58 62 40 46 ER 23 39 : 74P
2700-3700
(9000-12000)
10--58 62--40--.46 ER 23--39 : 74P

11. SPECIFICATIONS
1.9
DRIVE CLUTCH CHAINCASE
Type P-
-85 Center Distance 7.92” / 20.12cm
Shift Weights 10-
-64 Gearing : Chain 25-
-40 : 76 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
Brake Type Liquid Cooled
Driven Spring 7043063
Brake Type Liquid Cooled
Helix Angle 62-
-46-
-.46 CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm Coolant 5.6 Qts / 5.3 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Width in / cm
113” / 48” / 48”
287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks STD (F/O)
7043082
(7042211)
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate 68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M-
-10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre-
-Load
(F/O)
3.25” / 8.26cm
(.625” / 16 mm)
M-
-10 FTS Spring Rate 160#/in
Front Vertical Travel 10.28” / 26cm FTS Pre-
-Load .25” / .635 cm
TRACK M-
-10 FTS Pre-
-Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
Lug Height
(M-
-10/F/O)
.91” / 2.3 cm
(1” / 2.54 cm /
1.25”/3.175cm)
M-
-10 RTS Fox IFP Res PN 7042216
T k T i S P 3 10
M-
-10 RTS Spring Rate
(M-
-10 ACE Spring Rate)
210/278 #/in.
(220/1140)
Track Tension See Page 3.10 Torsion Springs .375(Sq.) 77_
Optional M-
-10 Springs see page 11.7-
- 11.8
ELECTRICAL
Flywheel I.D. 4010677 Spark Plug / Gap RN57YCC / .028” / .70mm
CDI Marking 4010842 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing (see conver- 29_@3250 RPM±1.5_ Electric Start Accessory
Ignition Timing (see conver
sion chart on page 13.4 )
29 @3250 RPM±1.5
w/TPS disconnected
Electric Start Accessory

12. SPECIFICATIONS
1.10
MODEL: 900 FUSION
. . . . . . . . . . . . . .
MODEL NUMBER: S05MP8D(E,S)(A,B,C)
. . . .
ENGINE MODEL: S2883-
-8686-
-PI8D
. . . . .
ENGINE FUEL SYSTEM
Engine Type Libertyt Type Clean Fire Injection
Engine Displacement cc 866 Regulator Pressure 4 Bar (58psi)
Bore in / mm 3.46”/ 83mm THROTTLE BODY
Stroke in / mm 3.15” / 80mm Throttle Body Bore Size in/cm 2” / 51mm
Cylinders 2 TPS voltage @ idle .92 -
- .94
Piston / Cylinder Clearance
in / mm
.0045” -
- .0098”
.114 -
- .249
Throttle Body Manufacture Mikuni
Piston Ring End Gap in / mm
.016” -
- .022”
.406-
-.56
DRIVE CLUTCH
Piston Marking 3021327 Type P-
-85
Piston Ring Marking N/A Center Distance in/cm 11.5” / 29.2
Operating RPM ±200 7500 Spring Dark Blue / White
Idle RPM ±200 1700 Shift Weight 10-
-74
Engagement RPM ±300 3700 DRIVEN CLUTCH
Exhaust Valve Spring Purple Type TEAM
CHAINCASE Spring 7043063
Center Distance in/cm 11.35” / 28.83cm Helix 62/46-
-36 ER
Gearing 25 : 37 -
- 92P BELT
Reverse Electronic Width in/cm 1.438” / 3.652cm
Brake Pads 2202727 Length in/cm 46.625” / 118.4275cm
Brake Type Type 94 (DOT 4) Part Number 3211080
CAPACITIES DIMENSIONS
Fuel Tank gal./l 10.8 / 40.9 Length in/cm 112.5 / 286
Oil Tank qts./l 3 / 2.8 Height in/cm 47 / 119
Coolant qts. / l 6.7 / 6.3
Width in/cm 47 25 / 120
Chain Case Oil oz. / ml 11 / 325.3
Width in/cm 47.25 / 120
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven Chaincase
Altitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
10 74 25 37 92
0-900
(0-3000)
10-
-74 25:37-
-92
900-1500
10 70 25 37 92
900-1500
(3000-5000)
10-
-70 25:37-
-92
1500-2100
10 68 22 39 92
Meters
1500-2100
(5000-7000)
10-
-68
Dark Blue /
7043063 62/46 36 ER
22:39-
-92
Meters
(Feet) 2210-2700
10 66
Dark Blue /
White
7043063 62/46-
-36 ER
22 39 92
(Feet) 2210-2700
(7000-9000)
10-
-66
White
22:39-
-92
2700-
-3350
(9000-
-11000)
10-
-64 22:39-
-92
3350-
-4000
(11000-
-13000)
10-
-62 22:39-
-92

13. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.

14. SPECIFICATIONS
1.11
FRONT SUSPENSION REAR SUSPENSION
Type IQ Type IQ
Stock IFS Shocks 7042258 Stock FTS 7042327
F/O IFS Shocks 7043095 F/O FTS 7043096
Stock IFS Spring Rate 100# Stock FTS Spring Rate 170#
F/O Spring Rate 120# F/O FTS Spring Rate 190#
Stock Spring Pre-
-Load 10.25”/26cm installed length Stock Spring Pre-
-Load 7.25 installed length
F/O Spring Rate 11.17”/28cm installed length F/O FTS Spring Pre-
-Load 7.25 installed length
Front Vertical Travel 10in / 25.4cm Stock RTS 7042218
TRACK F/O RTS 7043097
Width in/cm 15/38.1 TORSION SPRINGS
Length in/cm 121/307.34 Stock Torsion Spring .359/80_ 12.5#
Lug Height in/cm 1.25/3.175 Light Torsion Spring .359/80_ 11.25#
Track Tension See page 3.10 Heavy Torsion Spring .405/80_ 16.25#
ELECTRICAL
Flywheel I.D. 4011119 Spark Plug / Gap
Champion RN57YCC /
.025mm(.003”)
Base ECU 4011081 Voltage Regulator 4010866
Alternator Output 400watts Stator 4010727
Ignition Timing(see conver- 14_ @ 3000RPM Electric Start TBD
Ignition Timing(see conver
sion chart on page 13.4)
14_ @ 3000RPM Electric Start TBD

15. 2005 Model Number Designation 2.1
. . . . . . . . . . . . . . . . . . . . . . . . .
Tunnel Decal 2.1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Identification Number 2.2
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2005 Publication Part Numbers 2.3
. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service Precautions 2.4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque Specifications 2.5
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Decimal Equivalents 2.6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tap Drill Sizes 2.7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conversion Chart 2.8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Wash and Spark Plug Color 2.9
. . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Inspections 2.10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston Measurements 2.11
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Honing 2.12
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Port Chamfering 2.13
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting Rod Bearing Inspection 2.14
. . . . . . . . . . . . . . . . . . . . . . .
Crankshaft Indexing 2.15 -
- 2.17
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Operation and Troubleshooting 2.18
. . . . . . . . . . . . . . . . . . .
Oil Pump Bleeding 2.19
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pump Adjustment 2.20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling System Overview 2.21
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
900 Fusion Cooling System 2.22
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16. GENERAL INFORMATION
2.1
2005 MODEL NUMBER DESIGNATION
EXAMPLE: S05NB4BS
S 05 N B 4 B S #
Identifier
(1st Digit)
ModelYear
(2nd/3rd Dig-
it)
Model Line
(4th Digit)
Model Type
(5th Digit)
Engine Size
(cc)
(6th Digit)
Engine modifier
(6th/7th Digit)
VIN
Identifier
(8th Digit)
Option
Identifier
(9th
Digit)
S=Snow 05=2005 M=Fusion A=50th Anniv Spe-
cial
0=0-
-99cc 1A=121 F/C OHV 4 cycle Fuji E=Europe unit
N=Edge B=Basic or Stan-
dard
1=100-
-199 3A=340 F/C Piston Port S=Standard
Production
Unit
P=IQ RMK D=Classic 2=200-
-299cc 4B=488 L/C Piston Port
S=Gen II E=M-
-10 Perfor-
mance
3=300-
-399cc 4C=440 EV L/C Case Reed (Dom)
W=Mini Indy J=136 RMK 4=400-
-499cc 5B=544 F/C Cylinder Reed
K=144 RMK 5=500-
-599cc 5C=500 EFV L/C Case Reed 2 Cyl
(Dom)
L=151 RMK 6=600-
-600cc 6E=600 EV L/C Case Reed 2 Cyl
(Dom)
M=159 RMK 7=700-
-799cc 7C=700 EV L/C Case Reed 2 Cyl
(Dom)
N=166 RMK 8=800-
-899cc 7D=780 4-
-stroke EFI 2 Cyl (Dom)
P=Performance 9=900+cc 8C=800 EV L/C Case Reed 2 Cyl
(Dom)
S=Switchback 8D=866 EV SDI Case Reed
T=Touring
U=Utility
X=Racer/Pro X
MODEL NO.
V.I.N. NO.
MFD. DATE:
THIS VEHICLE CONFORMS TO ALL APPLICABLE
U.S. FEDERAL AND STATE REQUIREMENTS AND
CANADA MOTOR VEHICLE SAFETY STANDARDS
IN EFFECT ON THE DATE OF MANUFACTURE.
MADE IN U.S.A.
7072133
Mfd. by Polaris Industries Inc.. in Roseau, MN under one or
more of the following patents:
U.S. Patents
3,605,511 3,613,810 5,050,559
3,580,647 3,867,991 5,048,503
3,483,766 4,793,950 5,056,482
3,533,662 5,038,881 5,099,813
3,545,821 5,172,675 5,074,271
3,605,510 5,090,386 5,191,531
3,525,412 5,050,564 3,613,811
PATENT NOTICE
Patented Canada
882,491/71
883,694/71
864,394/71
Canadian Rd.
34,573/71
34,572/71
1,227,823/87
TUNNEL DECAL
These numbers should be referred to in any correspondence regarding warranty, service or replacement parts.
The machine model and serial number identification decal is located on the right front side of the tunnel. The serial number is
permanently stamped into the tunnel. The model number is embossed on the decal.
Whenever corresponding about an engine it is important that the engine model and serial numbers be called out. Laser engraved
model and serial numbers are located on the crankcase (intake side).