2005 Polaris 900 Fusion SNOWMOBILE Service Repair Manual

CVR_9919304

9/2/04

8:37 AM

Page 1

2005 PERFORMANCE SERVICE MANUAL

2005 PERFORMANCE

SERVICE MANUAL 500 XC SP 600 XC SP 700 XC SP 800 XC SP 900 FUSION

9919303

PN9919303

2005 PERFORMANCE MANUAL 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 familiar 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 importance.

All references to left and right side of the vehicle are from the operator’s perspective when seated in 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 of the manual for location of specific page numbers and service information. Keep this manual available for reference in the shop area.

At the time of publication all information contained in this manual was technically correct. However, all materials and specifications are subject to change without notice.

Comments or suggestions about this manual may be directed to: Polaris Sales Inc. Snow Engineering Publications Department 2100 Hwy 55 Medina, Minnesota 55340.

2005 PERFORMANCE MANUAL (PN9919303) Copyright 2004 Polaris Sales Inc. Printed in U.S.A.

SPECIFICATIONS

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

i

500 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

700 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 XC SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 FUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 -- 1.3 1.4 -- 1.5 1.6 -- 1.7 1.8 -- 1.9 1.10 -- 1.11

SPECIFICATIONS 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 -30°F 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 (4000--6000)

390 #2

380 #2

360 #2

340 #2

330 #1

310 #1

370 #2

350 #2

340 #2

320 #1

300 #1

290 #1

340 #2

330 #2

310 #1

300 #1

280 #1

260 #1

320 #2

300 #1

290 #1

270 #1

250 #1

240 #1

1800--2400 (6000--8000) (6000 8000)

Meters (Feet)

2400--3000 (8000--10000) (8000 10000) 3000--3700 (10000--12000) (10000 12000)

DRIVE CLUTCH

Altitude

Meters M t (Feet)

1.2

Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Chaincase Gearing

56/42 -36 56/4236 ER

22 40 -74 22:4074

56/42 -36 56/4236 ER

22 40 -74 22:4074

0-900 (0-3000)

10 -56 1056 Bushed B h d

900-1800 (3000-6000)

10 -54 1054 Bushed B h d

1800-2700 (6000-9000)

10 Bushed B h d

56/42 -36 56/4236 ER

21 40 -74 21:4074

2700-3700 (9000-12000)

10MB Bushed B h d

56/42 -36 56/4236 ER

21 40 -74 21:4074

Bl k/G Black/Green

7043058

SPECIFICATIONS 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

Brake Pads

2202202

Brake Type

Type 81

DRIVEN CLUTCH Type

Team Roller Reverse

Spring

Red/Black

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”

Center Distance

11.50”

SLED DIMENSION Unit Length / Height / Width in / cm.

FRONT SUSPENSION

113 / 46 / 48 287 / 117 / 122

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 M-

FTS Spring Rate

STD / F/O 160/VAR M-- 10 160

FTS PrePre - Load

STD / F/O N/A (eyelet to retainer) 3.50” 3 50” M-- 10 .90”

Stock RTS

STD 7042129 F/O 7042212 M-- 10 7042216

Torsion Spring

.375(sq.)

M-- 10 RTS Springs

7041935/7041936

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”

Front Vertical Travel

10.28”/26cm.

TRACK

Width

15”

Length

121”

Lug Height

STD/F/O .91” / 1.25” M-- 10 1.0”

Track Tension

See page 3.10 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 converconver sion chart on page 13.4)

25_ @ 2500 RPM

Electric Start

STD / M M-- 10 Accessory F/O / M-- 10 F/O Standard

1.3

SPECIFICATIONS MODEL: . . . . . . . . . . . . . . 600 XC SP MODEL NUMBER: . . . . S05N(A,E,P)6E(E,S)(A,B) ENGINE MODEL: . . . . . S2761--6044--PI6E ENGINE

CARBURETION

Engine Type

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 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

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 (4000--6000)

420 #4

400 #4

390 #3

370 #2

350 #2

330 #2

400 #4

380 #3

360 #2

340 #2

330 #2

310 #2

370 #3

350 #2

330 #2

320 #2

300 #2

280 #2

340 #2

330 #2

310 #2

290 #2

270 #1

260 #1

0--600 (0--2000)

Meters M t (Feet)

1800--2400 (6000--8000) (6000 8000) 2400--3000 (8000--10000) (8000 10000) 3000--3700 (10000--12000) (10000 12000)

DRIVE CLUTCH

Altitude

Meters M t (Feet)

1.4

Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Chaincase Gearing

58 42 36 ER 58--42--.36

23 39: 74P 23--39:

58 42 36 ER 58--42--.36

23 39 : 74P 23--39

0-900 (0-3000)

10 58 10-58

900-1800 (3000-6000)

10 56 10-56

1800-2700 (6000-9000)

10 54 10--54

58 42 36 ER 58--42--.36

22 39 : 74P 22--39

2700-3700 (9000-12000)

10

58 42 36 ER 58--42--.36

22 39 : 74P 22--39

Dark Blue/White

Red / Blue

SPECIFICATIONS 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

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH Type

Team Roller Reverse

Driven Spring

Red / Blue

Driven Helix Angle

58-- 42-- .36 ER BELT

CAPACITIES 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

Center Distance

11.5” / 29.2cm

SLED DIMENTIONS Unit Length / Height / Width in / cm

FRONT SUSPENSION

113” / 48” / 48” 287 / 122 / 122 cm

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

M-- 10 FTS Pre-- Load

.90” / 23mm

TRACK 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

M-- 10 RTS Spring Rate (M-- 10 ACE Spring Rate)

210/278 #/in.

(220/1140)

Torsion Springs

.375(Sq.) 77_

T kT Track Tension i

S Page See P 33.10 10

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 conver-

24_@3500 RPM±1.5_ RPM±1 5_

Electric Start

Accessory

sion chart on page 13.4 )

1.5

SPECIFICATIONS 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 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

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 (4000--6000)

420 #3

400 #3

390 #3

370 #2

350 #2

330 #2

400 #3

380 #3

360 #2

340 #2

330 #2

310 #2

370 #3

350 #2

330 #2

320 #2

300 #2

280 #2

340 #2

330 #2

310 #2

290 #2

270 #2

260 #2

0--600 (0--2000)

Meters M t (Feet)

1800--2400 (6000--8000) (6000 8000) 2400--3000 (8000--10000) (8000 10000) 3000--3700 (10000--12000) (10000 12000)

DRIVE CLUTCH

Altitude

Meters M t (Feet)

1.6

Shift Weight

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Chaincase Gearing

62 42 46 ER 62--42--.46

25 41: 76P 25--41:

62 42 46 ER 62--42--.46

25 41: 76P 25--41:

0-900 (0-3000)

10 62 10-62

900-1800 (3000-6000)

10 60 10-60

1800-2700 (6000-9000)

10 58 10--58

62 40 46 ER 62--40--.46

23 39 : 74P 23--39

2700-3700 (9000-12000)

10 56 10--56

62 40 46 ER 62--40--.46

23 39 : 74P 23--39

Black/Green

7043063

SPECIFICATIONS 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

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH Type

Team Roller Reverse

Driven Spring

7043063

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

Center Distance

11.5” / 29.2cm

SLED DIMENTIONS Unit Length / Height / Width in / cm

FRONT SUSPENSION

113” / 48” / 48” 287 / 122 / 122 cm

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

M-- 10 FTS Pre-- Load

.90” / 23mm

TRACK 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

M-- 10 RTS Spring Rate (M-- 10 ACE Spring Rate)

210/278 #/in.

(220/1140)

Torsion Springs

.375(Sq.) 77_

T kT Track Tension i

S Page See P 33.10 10

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 conver-

20_@2000 RPM±1.5_ RPM±1 5_

Electric Start

Accessory STD M-- 10

sion chart on page 13.4 )

1.7

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SPECIFICATIONS 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 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

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 (4000--6000)

440 #3

420 #3

400 #2

390 #2

370 #2

350 #2

410 #3

400 #2

380 #2

360 #2

340 #2

320 #2

390 #2

370 #2

350 #2

330 #2

310 #2

290 #2

360 #2

340 #2

320 #2

300 #2

290 #2

270 #2

0--600 (0--2000)

Meters M t (Feet)

1800--2400 (6000--8000) (6000 8000) 2400--3000 (8000--10000) (8000 10000) 3000--3700 (10000--12000) (10000 12000)

DRIVE CLUTCH

Altitude

Meters M t (Feet)

1.8

Shift Weight

0-900 (0-3000)

10 64 10-64

900-1800 (3000-6000)

10 62 10-62

1800-2700 (6000-9000)

10 60 10--60

2700-3700 (9000-12000)

10 58 10--58

Clutch Spring

Dark Blue / White

DRIVEN CLUTCH Clutch Spring

Driven Helix

Chaincase Gearing

62 46 46 ER 62--46--.46

25 41: 76P 25--41:

62 42 46 ER 62--42--.46

25 41: 76P 25--41:

62 40 46 ER 62--40--.46

23 39 : 74P 23--39

62 40 46 ER 62--40--.46

23 39 : 74P 23--39

7043063

SPECIFICATIONS 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

Brake Pads

Type 81

Brake Type

Liquid Cooled

DRIVEN CLUTCH Type

Team Roller Reverse

Driven Spring

7043063

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

Center Distance

11.5” / 29.2cm

SLED DIMENTIONS Unit Length / Height / Width in / cm

FRONT SUSPENSION

113” / 48” / 48” 287 / 122 / 122 cm

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

M-- 10 FTS Pre-- Load

.90” / 23mm

TRACK 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

M-- 10 RTS Spring Rate (M-- 10 ACE Spring Rate)

210/278 #/in.

(220/1140)

Torsion Springs

.375(Sq.) 77_

T kT Track Tension i

S Page See P 33.10 10

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 conver-

29 @3250 RPM±1.5_ 29_@3250 RPM±1.5 w/TPS disconnected

Electric Start

Accessory

sion chart on page 13.4 )

1.9

SPECIFICATIONS 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

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

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

Exhaust Valve Spring

Purple

THROTTLE BODY

DRIVE CLUTCH

DRIVEN CLUTCH

CHAINCASE

Type

TEAM

Spring

7043063

Helix

62/46-- 36 ER

Center Distance in/cm

11.35” / 28.83cm

Gearing

25 : 37 - 92P

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

BELT

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

Chain Case Oil oz. / ml

11 / 325.3

Width in/cm

47 25 / 120 47.25

DRIVE CLUTCH

Altitude

Meters (Feet)

Clutch Spring

DRIVEN CLUTCH Clutch Spring

Driven Helix

Chaincase Gearing

0-900 (0-3000)

10 -74 1074

25 37 -92 25:3792

900-1500 (3000-5000)

10 -70 1070

25 37 -92 25:3792

1500-2100 (5000-7000)

10 -68 1068

2210-2700 (7000-9000) 2700--3350 (9000--11000) 3350--4000 (11000--13000)

1.10

Shift Weight

10 -66 1066

Dark Blue / White

22 39 -92 22:3992 7043063

62/46 -36 62/4636 ER 22 39 -92 22:3992

10--64

22:39--92

10--62

22:39--92

SPECIFICATIONS 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

F/O RTS

7043097

TRACK 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 converconver sion chart on page 13.4)

14_ @ 3000RPM

Electric Start

TBD

1.11