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Fusion owners
started by 800storm
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October 14th 2009 at 1:28 PM
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scooter8416
Fanatic.
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104 Posts 
Group: Members
Member Since: February 20th 2005
Location: Middleport, NY, USA
Current Sled: 2006 Fusion 600
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Ok heres a few pic of what cracked. Don't know why...
So my best bet is to drill and zip tie? No plactic weld/
Also, my foam started to burn up on exhast side panel. The heat tape was all burnt up too. Was running stock can. Here is what I did to fix it. Used some high temp silcone and I put it in the "hole" where the foam burnt up and then recoverd it with some heat tape. I used the silcone becasue the tape didn't stick to the foam very well. We'll see how it hold up this season.
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Site Supporter
Group: Site Supporters
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October 14th 2009 at 3:27 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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Quote originally posted by nomerc
Still tring to figure this site out.
My ? is where to mount a spare belt on my 900 fusion. Any idies would me great..
The stock spare belt holder is over on the shock tower by the exhaust. I installed the timbersled intake system and moved my spare belt from the shock tower to the clutch cover.
Polaris is my way out - Other people just use a door.
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October 14th 2009 at 3:36 PM
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xcr440
Sundowners Trail Coordinator
xcr440 icefish's because having feeling in your fingertips is overrated.
Updated Yesterday at 10:49 PM
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12582 Posts 
Group: Members
Member Since: February 1st 2003
Location: St.Germain/Edgerton, Wisconsin, USA
Current Sled: 03prox700/97xcr440
2008-2009 Miles: 610
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Quote originally posted by scooter8416
Ok heres a few pic of what cracked. Don't know why...
So my best bet is to drill and zip tie? No plactic weld/
belly pan is cracked, did ya hit something. I would do the tip tie trick.
a good beer drinker isnt a picky beer drinker
Loggers.... Working their ass off so you can wipe yours!
"Steep ground is when your cutting a notch and notice a mountain goat looking at you like you are crazy." - Hexan
woodbooga: (WOOD-boog-ah), n. regional dialect, common to areas of New Hampshire and Maine including the towns of Ossipee, Alton, Farmington, Acton, and Lebanon; one who attempts to obtain free firewood to fuel woodburning appliances in an effort to mitigate expenses related to home heating with fossil fuels. Frequently used as a term of derision by non-woodburners who mock the presence of loose bark and other wood waste in the beds of their pickup trucks.
2003 Pro x 700 almond/blue,10-66 black/red team 719 T-flow, 440 mains
1997 xcr440 my clutch kit, 380 mains,T-flow
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October 14th 2009 at 4:16 PM
[ Modified October 14th 2009 at 4:17 PM
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triple650
Advanced Member
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1068 Posts 
Group: Members
Member Since: February 10th 2008
Location: Ramore, Ontario, Canada
Current Sled: 05 fusion 900
2008-2009 Miles: 1630
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Quote originally posted by PolarisEdge
Quote originally posted by triple650
i run the 1115 belt the 080 is garbage lasts about 400 miles and shreds i got 600 hard hot miles on the 1115 belt still going.
If you have your clutching is correct and you get the hot air out... 1080's are as good as any, I'm 350lbs dressed and use only 1080's.
theres nothing wrong with my clutching, if i trail rided they would last all year. but i dont i ditch bang all day no air flow makes realy hot clutches i have the slp hot air elimination kit as well. i havnt had a problem with the 1115 belt yet so well see. and i dont just ditch bang once and a while its all the time. Quote originally posted by xcr440
Quote originally posted by scooter8416
Ok heres a few pic of what cracked. Don't know why...
So my best bet is to drill and zip tie? No plactic weld/
belly pan is cracked, did ya hit something. I would do the tip tie trick.
mines like that to, check the rivets that hold it on mine are all lose from pulling on that stupid plastic bumper, i gotta re-rivet mine.
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October 16th 2009 at 1:40 PM
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scooter8416
Fanatic.
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104 Posts
Group: Members
Member Since: February 20th 2005
Location: Middleport, NY, USA
Current Sled: 2006 Fusion 600
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No never hit anyting that I know of.
What rivets are you taking about in specific. Mine seem to be still tight. The one you can see in the picture, the plastic can move a little side to side but, the rivit is tight in the metal. My guess is the hole in the plastic is bigger than the hole in the metal.
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October 18th 2009 at 5:53 PM
[ Modified October 18th 2009 at 5:53 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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drill diff. hole and refasten.
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October 18th 2009 at 10:49 PM
[ Modified October 18th 2009 at 10:50 PM
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Redd
New Member
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71 Posts 
Group: Members
Member Since: October 11th 2009
Location: Rosville, Michigan, USA
Current Sled: 2005 Fusion 900
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He who dies with the most toys wins!
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October 19th 2009 at 4:16 PM
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Redd
New Member
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71 Posts
Group: Members
Member Since: October 11th 2009
Location: Rosville, Michigan, USA
Current Sled: 2005 Fusion 900
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Ok, I called the dealer today and gave them my vin. #'s and they said all recalls but 1 is done! I guess they have 1 that the chain case cover need some attention, seems to leak so they put a special "washer" imo!
What ever it is it's free! He said $50 for the SLP flash..shop time too.
What does that exactly do? This is a bone stock 900 so far. I just want the biggest bang for my buck. Think I should put the cold air intake on first, then have it flashed? And then the "almond" spring?
He who dies with the most toys wins!
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October 19th 2009 at 6:16 PM
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scooter8416
Fanatic.
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104 Posts
Group: Members
Member Since: February 20th 2005
Location: Middleport, NY, USA
Current Sled: 2006 Fusion 600
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Post #579 has your answers for the reflash.
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October 19th 2009 at 7:03 PM
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triple650
Advanced Member
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1068 Posts
Group: Members
Member Since: February 10th 2008
Location: Ramore, Ontario, Canada
Current Sled: 05 fusion 900
2008-2009 Miles: 1630
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Quote originally posted by scooter8416
No never hit anyting that I know of.
What rivets are you taking about in specific. Mine seem to be still tight. The one you can see in the picture, the plastic can move a little side to side but, the rivit is tight in the metal. My guess is the hole in the plastic is bigger than the hole in the metal.
the rivet that holds the bumper on, grab the bumper and lift up and see if it moves. check under the exhaust in front by the bumper theres like 4 rivets there check to see if there tight mine are all loose.
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October 22nd 2009 at 6:19 PM
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freedomrider
Master of POO
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318 Posts
Group: Members
Member Since: October 7th 2007
Location: NY., USA
Current Sled: '06, Fusion 900
2008-2009 Miles: impatient
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Thinking seriously about opening a ATV , motorcycle and Sled repair/ Mod shop. Based out of Sodus Point NY. Also thinking, Usede atv/sled/cycle sales.,,,,, O.K. Planning shop.
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October 23rd 2009 at 4:50 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 freedomrider
Thinking seriously about opening a ATV , motorcycle and Sled repair/ Mod shop. Based out of Sodus Point NY. Also thinking, Usede atv/sled/cycle sales.,,,,, O.K. Planning shop.
great idea i will come check it out
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October 23rd 2009 at 7:39 PM
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Ugly_old_Poo_kid
techno-bumpkin
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1079 Posts
Group: Members
Member Since: March 18th 2007
Location: Walworth, NY, USA
Current Sled: 05 Edge & Frankenstorm II
2008-2009 Miles: 165
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Gonna compete with Jimmy? Or did he close up shop and stick with his school work?
95 - Storm 800 - Modded - AKA: FrankenStorm - Totalled near 100mph at Tug Hill!
96 - XLT/SP with Storm 800 trip/trip and now EFI - FrankenStorm II lives...
95 - RXL -- Sale Pending --
05 - Edge 800 long track - Stayin' stock for now..
---------------------------------------------
It made me more compassionate, more empathetic, more nurturing...
I FEEL LIKE I'M TRAPPED IN MY OWN WORST NIGHTMARE!!!
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October 23rd 2009 at 7:55 PM
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xcr440
Sundowners Trail Coordinator
xcr440 icefish's because having feeling in your fingertips is overrated.
Updated Yesterday at 10:49 PM
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12582 Posts
Group: Members
Member Since: February 1st 2003
Location: St.Germain/Edgerton, Wisconsin, USA
Current Sled: 03prox700/97xcr440
2008-2009 Miles: 610
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Quote originally posted by Redd
I guess they have 1 that the chain case cover need some attention, seems to leak so they put a special "washer" imo!
The chaincase recall we did was a stiffner on the outside of the cover. Helps it from not warping.
a good beer drinker isnt a picky beer drinker
Loggers.... Working their ass off so you can wipe yours!
"Steep ground is when your cutting a notch and notice a mountain goat looking at you like you are crazy." - Hexan
woodbooga: (WOOD-boog-ah), n. regional dialect, common to areas of New Hampshire and Maine including the towns of Ossipee, Alton, Farmington, Acton, and Lebanon; one who attempts to obtain free firewood to fuel woodburning appliances in an effort to mitigate expenses related to home heating with fossil fuels. Frequently used as a term of derision by non-woodburners who mock the presence of loose bark and other wood waste in the beds of their pickup trucks.
2003 Pro x 700 almond/blue,10-66 black/red team 719 T-flow, 440 mains
1997 xcr440 my clutch kit, 380 mains,T-flow
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October 23rd 2009 at 9:56 PM
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the_need_4_speed
Starting Member
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3 Posts
Group: Members
Member Since: January 3rd 2009
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Ok, I serious;ly hear old man winter waking up and now's the time to get the beast out.
Yes, I own one of those infamous 2005 Fusion 900's. Last year I got maybe 200 miles on it due to me being a truck driver, however, this year, I will have much more time.
My remarks from last year's rides:
-Blew an Ultimax XS belt after 50 miles. The belt was hot as hell, I suspect that big stupid dumb airbox being in the way or proper air distribution as well as sucking in hot under hood ait. How air seems to be a huge problem.
-I broke a bold on the clutch changing the primary spring for an almond/red spring.
-For some reason, now, everytime I take off when already in motion, there is some sort of "clonk". It feels like something is sticking or something takes too long to grab the belt.
-I got well over 125MPH on hard pack.
-Oil consumption feels rather low while gas consumption feels rather high. Yeah I drive it like it's the last ride of the year all the time I might add 1/4 of oil per gas refill (I always keep it topped off). I only use 91 or more octane.
Seems like I lose power at top end, max RPM shows 7880, I know it's a bit high...
I cam down with a few things I'll need to make it like I want it...
-The famous 719 helix
-Increase cold air flow under the hood
-Get rid of the dumb, stupid, ridiculous air box
-A minumum of 78 gram weights to a maximum of 85 (from what I read)
-Skis!! Are C&A's worth the money over slydog's?
-A loud, sweet sounding pipe, stock sounds just uhm... I don't want a 900 that sounds like a 500 fan.
-The handling is horrible. My steering always seems to want to follow the "other one's" tracks...
-Tailwhipping is nasty to. It's hard to keep'er steady. At 100 MPH, seems to be the best control speed.
-Deep snow performance is very respectable on a stock track with 96 studs.
-At -30 celcius, it's not a fun sled to crank. Since I'm looking for weight reduction, lets not go for an electric start.
-Seems like the fave RPM is around 6500, where it pulls the hardest.
-Everything else feels and runs great.
-Work out that thumb! It gets sore fast.
Now, most my experience has been on my XLT 600 Special '99 and '03 ProXR 440. XLT is easy to work on because of the size of the chassis, same with the 440. The Fusion, well, lets say it wasn't fun putting in the almond spring in.
Overall, I love that sled. I'ts fast and mean. However, the hot underhood air seems to be raining on my parade.
Any suggestions??
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October 24th 2009 at 1:07 PM
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triple650
Advanced Member
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1068 Posts
Group: Members
Member Since: February 10th 2008
Location: Ramore, Ontario, Canada
Current Sled: 05 fusion 900
2008-2009 Miles: 1630
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Quote originally posted by the_need_4_speed
Ok, I serious;ly hear old man winter waking up and now's the time to get the beast out.
Yes, I own one of those infamous 2005 Fusion 900's. Last year I got maybe 200 miles on it due to me being a truck driver, however, this year, I will have much more time.
My remarks from last year's rides:
-Blew an Ultimax XS belt after 50 miles. The belt was hot as hell, I suspect that big stupid dumb airbox being in the way or proper air distribution as well as sucking in hot under hood ait. How air seems to be a huge problem.
-I broke a bold on the clutch changing the primary spring for an almond/red spring.
-For some reason, now, everytime I take off when already in motion, there is some sort of "clonk". It feels like something is sticking or something takes too long to grab the belt .Thats the sound of the team secondary there all like that.
-I got well over 125MPH on hard pack. ya good one buddy, it wont do that even if its life depended on it.
-Oil consumption feels rather low while gas consumption feels rather high. Yeah I drive it like it's the last ride of the year all the time I might add 1/4 of oil per gas refill (I always keep it topped off). I only use 91 or more octane. It doesnt use much oil.
Seems like I lose power at top end, max RPM shows 7880, I know it's a bit high... once you get passed the proper rpm 7450rpm i think it is the power dramaticaly drops especialy reving that high.
I cam down with a few things I'll need to make it like I want it...
-The famous 719 helix
-Increase cold air flow under the hood
-Get rid of the dumb, stupid, ridiculous air box. You do realize that that air box works very well. get the slp hot air elimination kit.
-A minumum of 78 gram weights to a maximum of 85 (from what I read)
-Skis!! Are C&A's worth the money over slydog's?
-A loud, sweet sounding pipe, stock sounds just uhm... I don't want a 900 that sounds like a 500 fan.
-The handling is horrible. My steering always seems to want to follow the "other one's" tracks...
-Tailwhipping is nasty to. It's hard to keep'er steady. At 100 MPH, seems to be the best control speed.
-Deep snow performance is very respectable on a stock track with 96 studs.
-At -30 celcius, it's not a fun sled to crank. Since I'm looking for weight reduction, lets not go for an electric start.
-Seems like the fave RPM is around 6500, where it pulls the hardest.
-Everything else feels and runs great.
-Work out that thumb! It gets sore fast.
Now, most my experience has been on my XLT 600 Special '99 and '03 ProXR 440. XLT is easy to work on because of the size of the chassis, same with the 440. The Fusion, well, lets say it wasn't fun putting in the almond spring in.
Overall, I love that sled. I'ts fast and mean. However, the hot underhood air seems to be raining on my parade. Your gonna always have alot of heat no matter what unless you get like a mesh hood, but its so tight in there that there will be always lots of heat. Just getting an aftermarket silencer will help alot with air flow, since there alot smaller and you lose about 16 lbs.
Any suggestions??
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October 24th 2009 at 3:51 PM
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Redd
New Member
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71 Posts
Group: Members
Member Since: October 11th 2009
Location: Rosville, Michigan, USA
Current Sled: 2005 Fusion 900
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Triple650...
I was going to put the SLP air box and pipe w/ VForce3 reeds.
The hot air elinination kit is a must right? (got a pic?)
This is the first Fusion I've owned so I need to get it right before
I hit the white stuff!
He who dies with the most toys wins!
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October 24th 2009 at 7:59 PM
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freedomrider
Master of POO
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318 Posts
Group: Members
Member Since: October 7th 2007
Location: NY., USA
Current Sled: '06, Fusion 900
2008-2009 Miles: impatient
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Quote originally posted by Redd
Triple650...
I was going to put the SLP air box and pipe w/ VForce3 reeds.
The hot air elinination kit is a must right? (got a pic?)
This is the first Fusion I've owned so I need to get it right before
I hit the white stuff!
DYNOPORT,DYNOPORT,DYNOPORT,DYNOPORT,DYNOPORT,
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October 24th 2009 at 10:08 PM
[ Modified October 24th 2009 at 10:17 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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you need to get rid of the air box. It will save on the belts and the clutches getting to hot . The under the hood heat is a huge problem. you can take off the compartment doors by your feet and cover with screen works good. i have a timber sled intake witch dropped some pounds and let the air move around the clutches and belts. The problem I
Now i have a question
I have a timber sled intake . If I were to take off the filter and some how attach it to my console with a flex tube would that work or does it need forced air.
The idea of it is so the filter sucks cold air from the outside not warm air from under the hood.
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October 24th 2009 at 10:44 PM
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Redd
New Member
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71 Posts
Group: Members
Member Since: October 11th 2009
Location: Rosville, Michigan, USA
Current Sled: 2005 Fusion 900
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Quote originally posted by freedomrider
Quote originally posted by Redd
Triple650...
I was going to put the SLP air box and pipe w/ VForce3 reeds.
The hot air elinination kit is a must right? (got a pic?)
This is the first Fusion I've owned so I need to get it right before
I hit the white stuff!
DYNOPORT,DYNOPORT,DYNOPORT,DYNOPORT,DYNOPORT,
I see that yer a fond owner of one! No flash? Flash? If not why? And is it "DNR" friendly? I love the way it looks. I used to be into three wheelers many moons ago and most pipes were so close that you could hardly tell. Never put one on a sled, rest assure in a week or two one will be on!
He who dies with the most toys wins!
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October 25th 2009 at 2:55 PM
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Ugly_old_Poo_kid
techno-bumpkin
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1079 Posts
Group: Members
Member Since: March 18th 2007
Location: Walworth, NY, USA
Current Sled: 05 Edge & Frankenstorm II
2008-2009 Miles: 165
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Mixing a DynoPort pipe with the SLP re-flash, burns down the 900's. It clearly says so on the DynoPort website.
Get a DynoPort pipe and stay away from SLP for the fusions pipes, as the DynoPort pipe runs circles around the SLP pipe AND flash combo..
Seeing what F/R's fusion did going from stock to where it is, and having discussed with Rich from DynoPort about it in person, I can say that the dynoport is the way to go. (all the facts are published, you just have to read them and not believe the SLP hype)
95 - Storm 800 - Modded - AKA: FrankenStorm - Totalled near 100mph at Tug Hill!
96 - XLT/SP with Storm 800 trip/trip and now EFI - FrankenStorm II lives...
95 - RXL -- Sale Pending --
05 - Edge 800 long track - Stayin' stock for now..
---------------------------------------------
It made me more compassionate, more empathetic, more nurturing...
I FEEL LIKE I'M TRAPPED IN MY OWN WORST NIGHTMARE!!!
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October 25th 2009 at 4:00 PM
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Redd
New Member
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71 Posts
Group: Members
Member Since: October 11th 2009
Location: Rosville, Michigan, USA
Current Sled: 2005 Fusion 900
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I am learning alot about the Fuse's.... I'm most likely goin' with the DynoPort,
I've been reading up on alot about both pipes and got with my brother inlaws good friend that drag races sleds on black top all around the East coast and he runs Ski-Doo, and he said that the guys that are doin' "hot runs" have DynoPort, among total custom pipes on the Polaris's.
He who dies with the most toys wins!
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October 25th 2009 at 5:51 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 800storm
you need to get rid of the air box. It will save on the belts and the clutches getting to hot . The under the hood heat is a huge problem. you can take off the compartment doors by your feet and cover with screen works good. i have a timber sled intake witch dropped some pounds and let the air move around the clutches and belts. The problem I
Now i have a question
I have a timber sled intake . If I were to take off the filter and some how attach it to my console with a flex tube would that work or does it need forced air.
The idea of it is so the filter sucks cold air from the outside not warm air from under the hood.
?
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October 26th 2009 at 5:13 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 800storm
Quote originally posted by 800storm
you need to get rid of the air box. It will save on the belts and the clutches getting to hot . The under the hood heat is a huge problem. you can take off the compartment doors by your feet and cover with screen works good. i have a timber sled intake witch dropped some pounds and let the air move around the clutches and belts. The problem I
Now i have a question
I have a timber sled intake . If I were to take off the filter and some how attach it to my console with a flex tube would that work or does it need forced air.
The idea of it is so the filter sucks cold air from the outside not warm air from under the hood.
?
help anyone?
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October 26th 2009 at 5:28 PM
[ Modified October 26th 2009 at 5:28 PM
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scooter8416
Fanatic.
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104 Posts
Group: Members
Member Since: February 20th 2005
Location: Middleport, NY, USA
Current Sled: 2006 Fusion 600
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