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Fusion owners
started by 800storm
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October 20th 2008 at 8:26 PM
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800storm
900 fusion
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555 Posts 
Group: Members
Member Since: February 19th 2007
Location: webster, ny, USA
Current Sled: 2005 900 fusion
2008-2009 Miles: 600
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There is alot of topics that has to do with fusions and alot of good idea's.I thought that I would start this topic so if any of us have any questions we can just look back though this thread, instead of asking the same questions over again.
enjoy fusion owners!
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Site Supporter
Group: Site Supporters
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October 20th 2008 at 10:40 PM
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FireCat59
Senior Member
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3113 Posts 
Group: Members
Member Since: February 3rd 2007
Location: Camden, NY, USA
Current Sled: 05 F7 SP
2008-2009 Miles: 800
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Very good idea. It seems like every week somebody is asking about them or needs help on them.
"Who cares about triples, I could hit myself in the face with a frying pan and feel just as good as riding 10 miles on xtra 10." hahaha
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October 21st 2008 at 7:56 AM
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01ves800
Junior Member
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288 Posts 
Group: Members
Member Since: October 23rd 2007
Location: Erie, pa, USA
Current Sled: 01 xcsp800 ves
2008-2009 Miles: 78
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Ok i guess i will start with the ?. To all the 900 fusion owners out there what sled did you own prior to that? The reason i ask is beacuse i have the edge 800 and am pretty darn happy with it, but i also really like the thought of fuel injection, 900cc and rider forward. Is it worht makeing the switch to the fusion or go straight to the d8. What were the major diffrences from 05 to 06. I know there was alot changed but is it worth passing a good deal on an 05 to go for the 06. Thanx guys.
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October 21st 2008 at 8:09 PM
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polaris1man
Average Member
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738 Posts
Group: Members
Member Since: December 22nd 2007
Location: Nashwauk, Minnesota, USA
Current Sled: Polaris SKS700
2008-2009 Miles: not many
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A buddy of mine has 2-900 fusions and is in love with them!! Can't remember when I did the clutches on them for him, but he did drop the '06 clutching into them, and it is a world of difference, no prob's hitting the c-note on a 1/4 mile ice (shaved) for radar runs with a couple hundred studs in the track. Make sure you if you are getting an '05, that you get all the updates signed off on by Polaris, torque arm, vent kit, and certain serial numbers had some piston problems, other than the damn vibration, the 900 mill is one scary machine
Three-1999 Polaris SKS700's
2000 Polaris SKS700
2000 Polaris Ranger 6x6
2007 Polaris Sportsman 800 EFI X2
2000 Yamaha YZ 250
1996 Yamaha WR250
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October 21st 2008 at 9:21 PM
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polarissledneck28
I hate good weather
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3004 Posts
Group: Members
Member Since: July 17th 2005
Location: Manlius, NY, USA
Current Sled: 2004 polaris edge 700
2008-2009 Miles: 450
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that is a good idea. I don't have mine anymore, but any input I can give... I will.
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October 22nd 2008 at 8:36 AM
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FUSION900PA
Average Member
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942 Posts
Group: Members
Member Since: October 20th 2005
Location: Edinburg, PA, USA
Current Sled: SNOW CHECK 09 D8 SP
2008-2009 Miles: 1100
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I will miss the torque of this sled... i loved my fusion too
"If you ain't first, you're last" Ricky Bobby
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October 22nd 2008 at 4:04 PM
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shnill
zomg its fast...
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166 Posts
Group: Members
Member Since: September 28th 2008
Location: greely, on, Canada
Current Sled: 2009 polaris IQ 800
2008-2009 Miles: About 800
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whats the top rpm you've gotten - out of the 900
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October 22nd 2008 at 4:20 PM
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800storm
900 fusion
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555 Posts
Group: Members
Member Since: February 19th 2007
Location: webster, ny, USA
Current Sled: 2005 900 fusion
2008-2009 Miles: 600
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I heard that they run the best at 8500. Still working on it.
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October 22nd 2008 at 6:52 PM
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Mr.Dummie
Junior Member
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328 Posts
Group: Members
Member Since: December 1st 2007
Location: Pinehouse Lake, Saskatchewan, Canada
Current Sled: 2007 600 HO Switchback
2008-2009 Miles: 548.4
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I know someone that recently bought a 900 here in town...As soon as he experiences any problems I'm making an offer. I love my Switchback but I also want a short track!
3" Bar Riser
Sno Stuff Traction Strips
PowerMadd * Series Handgaurds w/Extensions
SLP 2 1/2" Flo Rites x4
SLP Air Horn Kit
SLP Single Pipe
Sno Stuff Rumble Pack
EPI Clutch Kit
VForce 3 Reeds
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October 22nd 2008 at 7:29 PM
[ Modified October 22nd 2008 at 7:31 PM
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01ves800
Junior Member
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288 Posts
Group: Members
Member Since: October 23rd 2007
Location: Erie, pa, USA
Current Sled: 01 xcsp800 ves
2008-2009 Miles: 78
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There is a dealer about 3 miles where we go riding wheelers has 13 of them still siting in crates brand new. He parted 2 out last year and sold 2 others. I am thinking of going and making them an offer on 1 but still love my 800. With porting this thing is a torque monster. just didnt know if i want to sacrifice my well broke in sled for a head ache but sound like most ppl like them and are relaible units when showed the right wrench. There seems to be slew of them around here so it shouldnt be a problem picking one up used either.
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October 22nd 2008 at 8:24 PM
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800storm
900 fusion
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555 Posts
Group: Members
Member Since: February 19th 2007
Location: webster, ny, USA
Current Sled: 2005 900 fusion
2008-2009 Miles: 600
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Quote originally posted by 01ves800
There is a dealer about 3 miles where we go riding wheelers has 13 of them still siting in crates brand new. He parted 2 out last year and sold 2 others. I am thinking of going and making them an offer on 1 but still love my 800. With porting this thing is a torque monster. just didnt know if i want to sacrifice my well broke in sled for a head ache but sound like most ppl like them and are relaible units when showed the right wrench. There seems to be slew of them around here so it shouldnt be a problem picking one up used either.
what years are they?
what does he want for one or two?
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October 22nd 2008 at 10:02 PM
[ Modified October 22nd 2008 at 10:03 PM
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FireCat59
Senior Member
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3113 Posts
Group: Members
Member Since: February 3rd 2007
Location: Camden, NY, USA
Current Sled: 05 F7 SP
2008-2009 Miles: 800
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The fusion is superior to the xc 800 I think. Such an awesome aggressive trail sled. Going from your 800 to the 900 will be a huge improvement.I would buy the 06 though over the 05. People make the 900 way worse than it really is. Few little tweaks here and there and you'll absolutely fall in love with it. Vibration isn't as bad as people say, vibrates only at idle until 1800 rpms then smooths out. Throw a pipe on it like shnill did, gain hp, have nice sound and lose weight. Get rid of that airbox and get an slp(which I like the best) or the timbersled, buy a slp air kit, and a team 719 helix and you will be set.
These fusion 700's and 900's NEED studs. I spun like crazy last year, so much torque and it would just break the track loose everytime I hit the flipper. I recommened 144 down the center. One more thing you might want to do is take a gander at the oil pump, there is a cable there and it's important that you keep it clean or else it will stick causing fouling. Polaris has a return spring for it but it's too wimpy. That cable gets gunk on it from belt debris and oil and the spring cannot work properly. Easy fix is to put a bit heavier return spring on it.
"Who cares about triples, I could hit myself in the face with a frying pan and feel just as good as riding 10 miles on xtra 10." hahaha
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October 22nd 2008 at 11:08 PM
[ Modified October 22nd 2008 at 11:11 PM
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TriumphoverU
The Sled Guru - Moderator
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2192 Posts 
Group: Moderators
Member Since: June 19th 2001
Location: Saint Johns, MI, USA
Current Sled: 2006 Polaris Fusion 700
2008-2009 Miles: 600
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Max rpm for the fusion should be around 7600. Any more than that, and you are wayyyyy over your power band. Contrary to what most think, the aftermarket pipes dont make the power, its all in the computer reflash. Many have had their ecu's reflashed and report big gains with the stock pipe still in place.
As mentioned above, check the oil pump cable, and check it often. Here is a link to the guy who had a bunch of cables made.
Oil Cable
Also I would recommend inspecting the the throttle body boots at the beginning of the season. They are prone to cracking and could cause a lean burn down. Supposedly polaris has an updated boot, but I havent heard if it is any better than the original ones.
Lots of fusion owners are installing slp's torque and push arms. I believe these to be a band aid for a bigger problem. Poorly designed front motor mounts are the bigger problem. I'd recommend the torque and push arms for those who do not wish to remove their motor to install new mounts. There is a guy over on snowest that goes by the name Compfusion who makes these mounts.
Motor Mounts
If i ever have to pull my motor, i'm definatly going to buy a set of his mounts.
Make sure your clutches are aligned. Many dealerships that set these sleds up didnt bother aligning the clutches properly which is why many are blowing their drive belts. The 420719 team helix is a must, but also you should install some delrin washers in the secondary to help eliminate binding.
Aftermarket air box is a must, but if you insist on running the stock air box, you need to put some reinforcement under the box so that if you blow a drive belt, it will not puncture the airbox and suck belt debris into the motor.
The TPS voltage needs to be checked to make sure you are getting all of the performance possible. Many were set incorrectly from the factory hurting gas mileage and performance. I just built a home made tps tool to check my tps adjustment.
There are a few things I've learned about the Fusions, and i'm still learning on mine.
Polaris is my way out - Other people just use a door.
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October 23rd 2008 at 8:37 AM
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FUSION900PA
Average Member
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942 Posts
Group: Members
Member Since: October 20th 2005
Location: Edinburg, PA, USA
Current Sled: SNOW CHECK 09 D8 SP
2008-2009 Miles: 1100
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the 05 fusion, stock, is recommended by polaris to run at 7500 however many people seem to think 7250-7300 makes the most power. Polaris recommends that a stock 06 900 should be at 7600. These are low reving machines with a lot of torque and the motor likes to be loaded down.
"If you ain't first, you're last" Ricky Bobby
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October 23rd 2008 at 12:44 PM
[ Modified October 23rd 2008 at 12:46 PM
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Quote originally posted by TriumphoverU
Max rpm for the fusion should be around 7600. Any more than that, and you are wayyyyy over your power band. Contrary to what most think, the aftermarket pipes dont make the power, its all in the computer reflash. Many have had their ecu's reflashed and report big gains with the stock pipe still in place.
As mentioned above, check the oil pump cable, and check it often. Here is a link to the guy who had a bunch of cables made.
Oil Cable
Also I would recommend inspecting the the throttle body boots at the beginning of the season. They are prone to cracking and could cause a lean burn down. Supposedly polaris has an updated boot, but I havent heard if it is any better than the original ones.
Lots of fusion owners are installing slp's torque and push arms. I believe these to be a band aid for a bigger problem. Poorly designed front motor mounts are the bigger problem. I'd recommend the torque and push arms for those who do not wish to remove their motor to install new mounts. There is a guy over on snowest that goes by the name Compfusion who makes these mounts.
Motor Mounts
If i ever have to pull my motor, i'm definatly going to buy a set of his mounts.
Make sure your clutches are aligned. Many dealerships that set these sleds up didnt bother aligning the clutches properly which is why many are blowing their drive belts. The 420719 team helix is a must, but also you should install some delrin washers in the secondary to help eliminate binding.
Aftermarket air box is a must, but if you insist on running the stock air box, you need to put some reinforcement under the box so that if you blow a drive belt, it will not puncture the airbox and suck belt debris into the motor.
The TPS voltage needs to be checked to make sure you are getting all of the performance possible. Many were set incorrectly from the factory hurting gas mileage and performance. I just built a home made tps tool to check my tps adjustment.
There are a few things I've learned about the Fusions, and i'm still learning on mine.
I have an 05 900 Fuse coming in to work on and I think I will document and photo set up.
The plan is to install the new oil cable referenced above, I like it as it also allows easier removal of throttle bodies.
We will also be:
- removing SLP exhaust system and re-installing stock pipes
- removing SLP push and pull arms
- installing Compfusion mounts
- adjusting clutch CC and aligning
- TPS set and adjust
- balanced clutches
- 719 helix
- remove Pilots and install USI PX 301's using set back hole in USI plate to fix steeering issue instead of updated spindles.
Sled already has Timbersled intake.
No Brain No Pain
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October 23rd 2008 at 12:50 PM
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FUSION900PA
Average Member
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942 Posts
Group: Members
Member Since: October 20th 2005
Location: Edinburg, PA, USA
Current Sled: SNOW CHECK 09 D8 SP
2008-2009 Miles: 1100
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why are you removing the slp exhaust?
I like how the throttle bodies are towards the front unlike the other cfi sleds. It's going to take some work to get to.
"If you ain't first, you're last" Ricky Bobby
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October 23rd 2008 at 1:26 PM
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Quote originally posted by FUSION900PA
why are you removing the slp exhaust?
I like how the throttle bodies are towards the front unlike the other cfi sleds. It's going to take some work to get to.
No hp gain from aftermarket exhaust and the vibration is worse with it on. HP is made by the reflash not the pipes.
No Brain No Pain
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October 23rd 2008 at 5:30 PM
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800storm
900 fusion
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555 Posts
Group: Members
Member Since: February 19th 2007
Location: webster, ny, USA
Current Sled: 2005 900 fusion
2008-2009 Miles: 600
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Quote originally posted by Thinksno
Quote originally posted by TriumphoverU
Max rpm for the fusion should be around 7600. Any more than that, and you are wayyyyy over your power band. Contrary to what most think, the aftermarket pipes dont make the power, its all in the computer reflash. Many have had their ecu's reflashed and report big gains with the stock pipe still in place.
As mentioned above, check the oil pump cable, and check it often. Here is a link to the guy who had a bunch of cables made.
Oil Cable
Also I would recommend inspecting the the throttle body boots at the beginning of the season. They are prone to cracking and could cause a lean burn down. Supposedly polaris has an updated boot, but I havent heard if it is any better than the original ones.
Lots of fusion owners are installing slp's torque and push arms. I believe these to be a band aid for a bigger problem. Poorly designed front motor mounts are the bigger problem. I'd recommend the torque and push arms for those who do not wish to remove their motor to install new mounts. There is a guy over on snowest that goes by the name Compfusion who makes these mounts.
Motor Mounts
If i ever have to pull my motor, i'm definatly going to buy a set of his mounts.
Make sure your clutches are aligned. Many dealerships that set these sleds up didnt bother aligning the clutches properly which is why many are blowing their drive belts. The 420719 team helix is a must, but also you should install some delrin washers in the secondary to help eliminate binding.
Aftermarket air box is a must, but if you insist on running the stock air box, you need to put some reinforcement under the box so that if you blow a drive belt, it will not puncture the airbox and suck belt debris into the motor.
The TPS voltage needs to be checked to make sure you are getting all of the performance possible. Many were set incorrectly from the factory hurting gas mileage and performance. I just built a home made tps tool to check my tps adjustment.
There are a few things I've learned about the Fusions, and i'm still learning on mine.
I have an 05 900 Fuse coming in to work on and I think I will document and photo set up.
The plan is to install the new oil cable referenced above, I like it as it also allows easier removal of throttle bodies.
We will also be:
- removing SLP exhaust system and re-installing stock pipes
- removing SLP push and pull arms
- installing Compfusion mounts
- adjusting clutch CC and aligning
- TPS set and adjust
- balanced clutches
- 719 helix
- remove Pilots and install USI PX 301's using set back hole in USI plate to fix steeering issue instead of updated spindles.
Sled already has Timbersled intake.
what is the tps?
I didn't understand a word about the steering
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October 23rd 2008 at 6:50 PM
[ Modified October 23rd 2008 at 6:50 PM
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Quote originally posted by 800storm
[what is the tps?
I didn't understand a word about the steering
Throttle position sensor. A low setting can negatively affect performance and fuel economy.
The early IQ sleds had some complaints about heavy steering if set up aggressively. Some people installed newer style spindles which Polaris designed to reduce steering effort- $$$ and time to do it correctly. The common improvement method was to swap out skis. Lots like SlyDog skis, this sled has Pilots on it and we feel USI's are better for ski design and the fact you can move ski pivot point back easily using the USI style ski plates.
I only use USI Skis.
 02 700 Rocket
No Brain No Pain
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October 23rd 2008 at 8:09 PM
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800storm
900 fusion
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555 Posts
Group: Members
Member Since: February 19th 2007
Location: webster, ny, USA
Current Sled: 2005 900 fusion
2008-2009 Miles: 600
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Quote originally posted by Thinksno
Quote originally posted by TriumphoverU
Max rpm for the fusion should be around 7600. Any more than that, and you are wayyyyy over your power band. Contrary to what most think, the aftermarket pipes dont make the power, its all in the computer reflash. Many have had their ecu's reflashed and report big gains with the stock pipe still in place.
As mentioned above, check the oil pump cable, and check it often. Here is a link to the guy who had a bunch of cables made.
Oil Cable
Also I would recommend inspecting the the throttle body boots at the beginning of the season. They are prone to cracking and could cause a lean burn down. Supposedly polaris has an updated boot, but I havent heard if it is any better than the original ones.
Lots of fusion owners are installing slp's torque and push arms. I believe these to be a band aid for a bigger problem. Poorly designed front motor mounts are the bigger problem. I'd recommend the torque and push arms for those who do not wish to remove their motor to install new mounts. There is a guy over on snowest that goes by the name Compfusion who makes these mounts.
Motor Mounts
If i ever have to pull my motor, i'm definatly going to buy a set of his mounts.
Make sure your clutches are aligned. Many dealerships that set these sleds up didnt bother aligning the clutches properly which is why many are blowing their drive belts. The 420719 team helix is a must, but also you should install some delrin washers in the secondary to help eliminate binding.
Aftermarket air box is a must, but if you insist on running the stock air box, you need to put some reinforcement under the box so that if you blow a drive belt, it will not puncture the airbox and suck belt debris into the motor.
The TPS voltage needs to be checked to make sure you are getting all of the performance possible. Many were set incorrectly from the factory hurting gas mileage and performance. I just built a home made tps tool to check my tps adjustment.
There are a few things I've learned about the Fusions, and i'm still learning on mine.
I have an 05 900 Fuse coming in to work on and I think I will document and photo set up.
The plan is to install the new oil cable referenced above, I like it as it also allows easier removal of throttle bodies.
We will also be:
- removing SLP exhaust system and re-installing stock pipes
- removing SLP push and pull arms
- installing Compfusion mounts
- adjusting clutch CC and aligning
- TPS set and adjust
- balanced clutches
- 719 helix
- remove Pilots and install USI PX 301's using set back hole in USI plate to fix steeering issue instead of updated spindles.
Sled already has Timbersled intake.
did you mean vx
and were can you get them at a reasonable $$
their web site wants $$$$$$$$$$$$
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October 23rd 2008 at 9:02 PM
[ Modified October 23rd 2008 at 9:06 PM
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PX =Project X 301 skis, which were on many Polaris race sleds, a little more agressive than the VX 301's on the edges. There are better deals out there all the time. Here is a link, $170 for a pair available in black or blue. You then need to get mounts for your particular sled, again good deals out there. I like the racing handles, think I paid $38 for a pair.
Shapers are awesome but on the VX 301 but may be too agressive for most. Round bars are cheaper and work well with the keel design.
http://cgi.ebay.com/ebaymotors/USI-ski-P...06.c0.m245
That's about half of web site list price.
No Brain No Pain
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October 23rd 2008 at 10:48 PM
[ Modified October 23rd 2008 at 10:48 PM
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FireCat59
Senior Member
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3113 Posts
Group: Members
Member Since: February 3rd 2007
Location: Camden, NY, USA
Current Sled: 05 F7 SP
2008-2009 Miles: 800
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So the pipes do not gain any hp at all? It's just in the reflash? Is that only for slp, because with Dyno port you don't need a reflash and they claim good hp gains..???
Schnill just put one on his 05 900.
"Who cares about triples, I could hit myself in the face with a frying pan and feel just as good as riding 10 miles on xtra 10." hahaha
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October 24th 2008 at 6:43 AM
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800storm
900 fusion
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555 Posts
Group: Members
Member Since: February 19th 2007
Location: webster, ny, USA
Current Sled: 2005 900 fusion
2008-2009 Miles: 600
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Quote originally posted by Thinksno
PX =Project X 301 skis, which were on many Polaris race sleds, a little more agressive than the VX 301's on the edges. There are better deals out there all the time. Here is a link, $170 for a pair available in black or blue. You then need to get mounts for your particular sled, again good deals out there. I like the racing handles, think I paid $38 for a pair.
Shapers are awesome but on the VX 301 but may be too agressive for most. Round bars are cheaper and work well with the keel design.
http://cgi.ebay.com/ebaymotors/USI-ski-P...06.c0.m245
That's about half of web site list price.
what do you think about the tripple threat skis / I do 90% trail riding
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October 24th 2008 at 6:56 AM
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FUSION900PA
Average Member
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942 Posts
Group: Members
Member Since: October 20th 2005
Location: Edinburg, PA, USA
Current Sled: SNOW CHECK 09 D8 SP
2008-2009 Miles: 1100
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There is a thread on HCS that says many people like the sly dog skis for IQ sleds. They decrease steering effort and offer more bite.
"If you ain't first, you're last" Ricky Bobby
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October 24th 2008 at 7:48 AM
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MadMatt900
Junior Member
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129 Posts
Group: Members
Member Since: October 12th 2006
Location: Brooklin, On, Canada
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I've only heard good things about Compfusion Engine Mounts. Does anyone have any bad words to say?
MadMatt900
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