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
and exhaust, which contain chemicals
known to the State of California to
cause cancer and birth defects or other
reproductive harm, onto the snow on
which they operate. Keep this engine
properly tuned and avoid unnecessary
idling and spillage during fueling.
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our
world-wide family of Polaris owners. We proudly produce an exciting
line of utility and recreational products.
S Snowmobiles
S All-terrain vehicles (ATVs)
S RANGER utility vehicles
S Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable 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 Service Dealer
(MSD) T echnician.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. B e sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our complete line of apparel, parts and
accessories, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
1
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris
Industries Inc.
RIDER SELECT is a trademark of Polaris Industries Inc.
Copyright 2005 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting 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
TABLE OF CONTENTS
Introduction4...............................
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner’s manual.
Safety7.....................................
This section describes safe vehicle operation and identifies warning
decals and their locations.
Features25..................................
This section identifies the locations of your snowmobile’s controls and
features.
The Perfect Fit39............................
This section explains how to tailor the suspension and other features
for an optimum riding experience.
Pre-Ride Inspections58......................
This section explains procedures that must be performed before riding.
Operation64.................................
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance76..............................
This section defines your role, and your dealer’s role, in your
snowmobile’s regular maintenance.
Polaris Products1 17.........................
T roubleshooting1 18.........................
Warranty124................................
Maintenance Log132.........................
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.
Index134....................................
3
INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain 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 at specific mileage intervals.
You and your dealer must complete the registration form included with
your snowmobile and forward it to us. This completed form is
necessary to ensure warranty coverage.
Protect and preserve your right to ride by joining your local trail riding
clubs.
4
INTRODUCTION
Preservation of the Environment
Polaris is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection 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 most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
Polaris snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may
not be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.
Air Pollution
Polaris engineers continuously investigate ways to reduce emission
levels of two-stroke engines. We expect our efforts to lead to the
reduction of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
5
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 lost, the ignition switch
must be replaced.
1
Vehicle Model Number:
Tunnel VIN (1)(lower right side of the tunnel):
Engine Serial Number (on recoil housing):
Key Number:
6
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. Your safety is involved when these words
and 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 warning indicates a potential hazard that may
result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may
result in minor injury or damage to the vehicle.
CAUTION
A caution indicates a situation that may result in damage to the
vehicle.
NOTE:
A note will alert you to important information or instructions.
7
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 attention. DO NOT drink
alcohol or use drugs or medications before or while driving or
riding as a passenger. They will reduce your alertness and slow
your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra
caution to ensure operator safety. Make sure your snowmobile is
in excellent operating condition at all times. Always check major
and vital safety components before every ride.
All Polaris snowmobiles are designed and tested to provide safe
operation when used as directed. Failure of critical machine
components may result from operation with any modifications,
especially those that increase speed or power. DO NOT
MODIFY YOUR MACHINE. The snowmobile may become
aerodynamically unstable at speeds higher than those for which it
is designed. Loss of control may occur at higher speeds.
Modifications may also create a safety hazard and lead to bodily
injury.
The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the snowmobile.
8
SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be
partially exposed for proper operation.
WARNING
Serious injuries may result if hands,
feet, or clothing become entangled in
the track. Be alert when riding, and
remain properly seated to stay clear
of the track.
Never hold the snowmobile up or
stand behind it 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 adjustment, secure shields and
guards, secure the hood, and then restart the engine to check its
operation.
WARNING
Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting
adjustments.
9
SAFETY
Operator Safety
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience; but under most conditions,
the proper position is to be seated with both feet on the running boards
and both hands on the handlebar grips for proper throttle, brake and
steering control.
WARNING
Improper riding position may reduce control and could result in
serious injury or death. Always be properly seated and in position
to control your vehicle.
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you’re going and how long you expect to be gone.
If it isn’t possible to ride with others, and you must travel into remote
areas, always carry survival equipment that’s appropriate to the
conditions you may encounter. Such equipment may include, but is
not limited to: extra clothing, a sleeping bag, a flashlight, food and
water, a signaling mirror, a means of building a fire, and a two-way
radio or cellular t elephone.
For added protection, carry the following items on your snowmobile at
all times:
SSpare Drive BeltSExtra Set of Spark Plugs
STow RopeSExtra Oil
SFuel DeicerSWinter Survival Kit
STrail MapSOwner’s Manual
SFirst Aid KitSTool Kit
10
SAFETY
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.
WARNING
Avoid wearing loose
clothing or long
scarves, which can
become entangled in
moving parts and
cause serious injury .
Always wear an
approved helmet and
eye protection.
Disabled Operators
Safe operation of this rider-active vehicle requires good judgement and
physical skills. Operators with cognitive or physical disabilities have
an increased risk of loss of control, which could result in serious injury
or death.
11
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.
Always observe all state and local laws governing snowmobile
operation and speed limits. Always be alert and pay attention to the
trail ahead. Multiplying speed (MPH) by 1.5 will equal the
approximate number of feet per second your machine travels. If your
speed is 40 MPH, your machine is traveling about 60 feet per second.
If you look back for only two seconds, your machine will travel about
120 feet. If your speed is 60 MPH, your machine will travel about 180
feet in two seconds.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t over-drive your headlight beam.
Always be able to bring your machine to a stop in the distance
illuminated by the headlight.
12
SAFETY
Operator Safety
Driver Awareness
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 wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your machine will drown out
the sound of approaching vehicles. Look
ahead, behind, and to both sides before
turning or crossing railroad tracks or
highways. Steep embankments may also
hide your view. Always leave yourself a
way out.
Variances in snow depth and/or water
currents may result in uneven ice
thickness. You may drown if you break
through the ice. Avoid travelling on frozen bodies of water.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.
13
SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
S Take an avalanche class
S Travel with experienced people
S Travel on designated trails
S Make sure each person is equipped with
a shovel, probe and avalanche beacon.
You don’t have to be snowmobiling on a slope for an avalanche to
occur. Be aware t hat all of the snow is connected. You may be riding
on a flat slope or snow covered road, but if the snowpack above is
unstable enough you can trigger an avalanche on a steeper slope above
you. Always be aware of snow conditions above you as you travel in
mountainous terrain.
Before riding in mountainous terrain, call or log on to your local
avalanche advisory to get current weather and snow stability
information.
For more information about avalanche training 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
SAFETY
Operator Safety
Ice and Snow Build-up
WARNING
Ice and snow build-up 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 is encountered, remove ice and snow build-up that may be
obstructing the steering linkage.
NOTE:If your snowmobile is equipped with RIDER SELECT,
perform this check in both the full up and full down steering
positions.
Driving on Slippery Surfaces
WARNING
Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution.
Driving on ice or hard-packed snow reduces steering and braking
control, which may result in loss of control and serious injury or
death. Slow down and use extra caution when operating on
slippery surfaces.
Driving Downhill
When riding downhill, shift your weight to the rear of the machine and
reduce your speed to a minimum. Apply just enough throttle to keep
the clutch engaged, allowing the engine’s compression to help slow the
machine and keep it from rolling freely downhill.
WARNING
When driving on long downhill stretches, pump the brakes.
Riding the brakes may cause the brake system to overheat,
which may result in brake failure.
Excessive or repetitive use of the brakes for high speed stops will
also cause an overheated brake system. This condition may lead
to a sudden loss of brakes and/or fire and may result in serious
injury or death.
15
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 terrain. If climbing a hill is
unavoidable, keep your weight low and forward. If you must cross the
face of a slope, keep your weight on the uphill side of the machine to
maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops or other people or vehicles that may be on the
other side of the hill.
If you’re unable to continue up a hill, turn the machine downhill before
it loses momentum. If this isn’t possible, spin the track just enough to
dig in to prevent it from rolling back down the hill. Stop the engine
and set the parking brake (if equipped). Keeping away from the
downhill side of the machine, pull the rear of the snowmobile around
and point the front end and skis downhill. Remount the machine,
restart the engine, release the parking brake, and descend the hill
carefully.
16
SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer. Operation of the engine with the belt removed may
result in injury or damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer 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 before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the machine i nto motion, but always operate
within safety limits.
Maneuverability
While much control and maneuverability is achieved through the
steering system and skis, maximum control is achieved by the shifting
of your body weight. Maneuverability will change for lighter operators
or machines designed to carry a load.
17
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 models, cooling for the engine,
adequate snow cover is a requirement for operation of your machine.
Driving in too little snow will result in excessive wear and damage to
the slide rail, track and/or engine.
If the machine becomes stuck in snow, clear the running board area of
snow, then step down the snow in front of the machine so that when
the throttle is opened, the snowmobile will be able to climb up and
over the snow.
CAUTION
When operating on icy surfaces or hard-packed snow, avoid
overheating the slide rail and track. Lack of lubrication and
cooling will cause overheating of the slide rail and track, resulting
in premature wear and failure. If frequently operating in low
cooling conditions, see your dealer for an optional wheel kit that
will reduce the wear from overheating.
18
SAFETY
Operator Safety
Driving Responsibly
Every snowmobile handles differently, and even the most docile
conditions may become dangerous if operators drive improperly. If
you’re new t o snowmobiling, acquaint yourself with the machine and
with what it will and won’t do under various conditions. Even
seasoned drivers should spend some time getting the feel for a machine
before attempting ambitious maneuvers.
S A snowmobile depends on the rider’s body position for proper bal-
ance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
S Before allowing someone else use your snowmobile, know the ex-
tent of their operating skills. Check to see if they’ve taken a snowmobile safety course and have an operator’s certificate. For their
protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.
S Don’t “jump” your snowmobile. Jumping may injure your back be-
cause of spinal compression. The seat and suspension of your snowmobile have been designed to provide protection under normal
riding conditions. Your snowmobile is not intended for this kind of
use.
S Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
S When traveling in a group of snowmobiles, don’t tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow
and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions.
Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.
S Remove the key from the ignition when you leave the snowmobile
unattended.
19
SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when
temperatures become dangerous for riding.
Warning decals have been placed on the snowmobile for your
protection. Read and follow the instructions 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
to purchase a replacement. Replacement safety decals are provided by
Polaris at no charge. The part number is printed on the decal.
Clutch Cover Warning
This warning decal is found under the hood on the clutch cover:
Pressure Cap Warning
This warning decal is found under the hood on the pressure cap of
applicable liquid cooled models:
Do not open hot. Test or replace when changing
coolant. Press down and turn to release cap. 13 PSI
21
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 is on the console below the
steering post:
+
22
+
SAFETY
Safety Decals and Locations
Reverse Warning
The reverse warning decal is located
on the console below the
windshield:
Reverse operation, even at low
speeds, may cause loss of control
resulting in serious injury or
death. To avoid loss of control,
always:
S Look behind before and 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
controlto reverse. Flashinglight on dash indicates reverse operation.
S Push button again to return to forward.
Operation Warning
The operation warning decal is
located on the console above the
storage compartments. See page 24
for the text.
+
+
23
SAFETY
Safety Decals and Locations
Operation Warning
Operation Warning Decal:
S To avoid serious injury or death, read and understand all warnings
and the Owner’s Manual before operation. If the manual is missing,
contact a Polaris dealer for a replacement.
S This vehicle is capable of high speeds. Buried objects or uneven ter-
rain can cause loss of control. Reduce speed and use extreme cau-
tion when operating in unfamiliar terrain.
S Excessive speed, especially at night or with limited visibility, can re-
sult in insufficient time for you to react to terrain changes, to avoid
unexpected obstacles, or to stop safely.
S Never consume alcohol or drugs before or while operating this ve-
hicle.
S In an emergency, push down the Auxiliary Shut-Off Switch, located
on the top of the throttle control assembly, to stop the engine. Then
pull the brake lever to stop.
S Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
S This vehicle is designed for adult use only. Check local laws for age
requirements.
S When operating with a passenger (on approved models only) reduce
speed and allow extra space for steering and stopping. A passenger
reduces your ability to control the vehicle.
S When operating on hard-packed snow, ice, or when crossing roads,
steering and braking ability are greatly reduced. Reduce speed and
allow extra space to turn or 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 when used for long periods. Do not leave
brake engaged for more than five minutes.
S Before starting engine, check throttle, brake, and steering for proper
operation. Make sure hood is latched. Be seated and in position to
control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when refueling.
24
FEATURES
5
4
3
2
1
14
1. Hood
2. Headlight
3. Windshield
4. Handlebar
5. Seat
6. Snow Flap
7. Suspension
8. Track
9. Storage Compartment
10. Rear Bumper
1 1. T aillights
12. Nosepan
13. Front Bumper
14. Skis
13
12
6
7
8
9
11
9
10
25
FEATURES
4
5
3
2
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. Thumbwarmer Switch
14. Electronic Reverse Button
15. MFD Control
6
9
7
8
1
11
10
12
15
13
14
26
FEATURES
RIDER SELECT Adjustable Steering System
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 injury or
death. Always stop the snowmobile before attempting to adjust
the steering system.
1. Stop the snowmobile.
2. Press the release button and move
the handlebar forward or rearward to
the desired position.
SettingPositionRiding Style
Comfort1, 2Pull the system rearward to one of the first
two positions for all-day trail riding comfort.
Control3, 4, 5Move the system to one of the middle three
positions for improved handling and cornering on the trails.
Attack6, 7Push the system forward to one of the last
two positions for easy sitting-to-standing
transitions and maximum agility in rugged
terrain.
WARNING
Do not lubricate the RIDER SELECT mechanism. Doing so could
cause loss of control and result in serious injury or death. The
RIDER SELECT mechanism is lubricated for life at the factory.
WARNING
Some aftermarket accessories (including windshields and cargo
bags) may interfere with the handlebar. Such accessories could
limit your ability to steer the vehicle and/or may contact the brake
lever. This could lead to loss of control resulting in serious injury
or death. Always be sure that accessories do not contact the
handlebar or brake lever at any steering position and at any
RIDER SELECT position.
27
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