How to adjust the chain on an 06' 900 Fusion

Louharle · 02-13-2012, 07:54 PM

ok, I'll admit it - I'm not the most handy with a set of tools but can someone, anyone, share with me how you get to the adjusting bolt to adjust the chain? Something must move out of the way, right???

Thanks,

Lou

michahicks · 02-13-2012, 08:09 PM

You need to pull the exhaust to do that, and if you're going into it that far, I'd go ahead and pull the chain case cover to change the oil. While the cover is off adjust the chain so you can see exactly what's going on.

Louharle · 02-13-2012, 08:11 PM

wow, what a massive pain in the butt - all that work to just adjust the chain......

sloan188 · 02-13-2012, 08:11 PM

on my 05 900, I usually remove the pipe and can. Pipe removal requires removal of 7 springs: 3 on the y-pipe, 2 on the corner outside, 2 where it meets the can. To remove the muffler there are 2 nuts that have to come off. Then just pull out the pipe (also remove exhaust probe: either 9/16 or 14mm wrench to remove) and pull out the muffler. Can removal/install can be a pain; it's much easier if the can-side side console screw is out, then just pop out bottom of console (much easier this way).

To adjust, back off the jam nut, turn adjuster bolt by hand until tight (you might have to rotate your track a little to remove the slack), back off 1/4 turn and tighten.

Put can/pipe back and you're done.

To remove the pipe springs, I built a spring removal tool out of a coat hanger.

Suspect the 06 is pretty much the same. You might be able to get at the adjuster bolt without removing can but I do mine at maintenance time so can is off.

Louharle · 02-13-2012, 08:16 PM

Many thanks to both of you - do you know what size the jam/adjuster nut is? My kid's hand will fit down there so that's what we are gonna try....

sloan188 · 02-13-2012, 08:17 PM

michahicks is right about chaincase oil but I would avoid the cover removal. First - you can drain the chaincase oil with a hex head drain screw on the bottom, second - many of these leak despite the recall and require silicone in addition to the gasket that is there (maybe this is only an 05 issue), third - it's no problem to tighten if you do what I said above.

On the other hand if you've never had the chaincase cover off and don't know where your sled has been it might be better to pull the chaincase cover.

sloan188 · 02-13-2012, 08:17 PM

9/16 or 14mm

02-13-2012, 07:54 PM	#1 (permalink)
Louharle Member Join Date: Mar 2010 Posts: 12	How to adjust the chain on an 06' 900 Fusion ok, I'll admit it - I'm not the most handy with a set of tools but can someone, anyone, share with me how you get to the adjusting bolt to adjust the chain? Something must move out of the way, right??? Thanks, Lou

02-13-2012, 08:09 PM	#2 (permalink)
michahicks Super Advanced Member Join Date: Feb 2005 Posts: 5,074 Current Sled(s): 06 600 HO Fusion Previous Sled(s): 07 600 IQ carb Location: Waterford and Gaylord Mi. Favorite Riding Area: Northern Lower and UP 10-11 Mileage: 1500 Age: 62 Riding Since: 1969	You need to pull the exhaust to do that, and if you're going into it that far, I'd go ahead and pull the chain case cover to change the oil. While the cover is off adjust the chain so you can see exactly what's going on. __________________ 600HO Fusion w/4 valve Air 2.0, HRP spindles, .359 torsion springs, X-Clicks, Retro graphics by ArcticFX, and Tempaflo

02-13-2012, 08:11 PM	#3 (permalink)
Louharle Member Join Date: Mar 2010 Posts: 12	Pita wow, what a massive pain in the butt - all that work to just adjust the chain......

02-13-2012, 08:11 PM	#4 (permalink)
sloan188 Advanced Member Join Date: Oct 2008 Posts: 84 Current Sled(s): 2005 Polaris Fusion 900,2009 Yamaha Nytro XTX Location: Vaudreuil, QC 12-13 Mileage: 1000km 11-12 Mileage: 1500 km Age: 43	on my 05 900, I usually remove the pipe and can. Pipe removal requires removal of 7 springs: 3 on the y-pipe, 2 on the corner outside, 2 where it meets the can. To remove the muffler there are 2 nuts that have to come off. Then just pull out the pipe (also remove exhaust probe: either 9/16 or 14mm wrench to remove) and pull out the muffler. Can removal/install can be a pain; it's much easier if the can-side side console screw is out, then just pop out bottom of console (much easier this way). To adjust, back off the jam nut, turn adjuster bolt by hand until tight (you might have to rotate your track a little to remove the slack), back off 1/4 turn and tighten. Put can/pipe back and you're done. To remove the pipe springs, I built a spring removal tool out of a coat hanger. Suspect the 06 is pretty much the same. You might be able to get at the adjuster bolt without removing can but I do mine at maintenance time so can is off.

02-13-2012, 08:16 PM	#5 (permalink)
Louharle Member Join Date: Mar 2010 Posts: 12	Many thanks to both of you - do you know what size the jam/adjuster nut is? My kid's hand will fit down there so that's what we are gonna try....

02-13-2012, 08:17 PM	#6 (permalink)
sloan188 Advanced Member Join Date: Oct 2008 Posts: 84 Current Sled(s): 2005 Polaris Fusion 900,2009 Yamaha Nytro XTX Location: Vaudreuil, QC 12-13 Mileage: 1000km 11-12 Mileage: 1500 km Age: 43	michahicks is right about chaincase oil but I would avoid the cover removal. First - you can drain the chaincase oil with a hex head drain screw on the bottom, second - many of these leak despite the recall and require silicone in addition to the gasket that is there (maybe this is only an 05 issue), third - it's no problem to tighten if you do what I said above. On the other hand if you've never had the chaincase cover off and don't know where your sled has been it might be better to pull the chaincase cover.

02-13-2012, 08:17 PM	#7 (permalink)
sloan188 Advanced Member Join Date: Oct 2008 Posts: 84 Current Sled(s): 2005 Polaris Fusion 900,2009 Yamaha Nytro XTX Location: Vaudreuil, QC 12-13 Mileage: 1000km 11-12 Mileage: 1500 km Age: 43	9/16 or 14mm

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