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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #1 ·
**AS OF Dec. 5, 2005:

All the parts for Fusion updates have been shipped, but some in limited quantity. Additional Filler Neck kits, and replacement Fuel tanks have more parts due to be available.

Replacement spindles for those that need them are also available.
***

I hope I will not be sorry for presenting this information, please take it the right way. I have seen much misunderstanding with regard to the fixes and recalls Polaris has for the '05 900 Cleanfire sleds.

Polaris has released a checklist to help dealers explain the recalls, fixes, tips and maintenance operations for the '05 900 Fusion, Switchback and RMK models.

Individual snowmobiles (based on their VIN#) will not need each one of these performed. A lot of the problems/improvements were caught early and later machines had the fix in place, or improved part or assembly before they went into the crate at the factory.

Recalls involve notification of the customer and required activity.

Service Bulletins are fixes that Polaris wants to have done.

Team Tips are simply observations and notes about maintenance and operational activities.
an example is S-04-10-02. It simply explains the need for a cooler protection kit when a Fusion is equipped with studs, and points out the Part number and availabilty of the kit. Sometimes they draw attention to a problem that might be covered by warranty, depending on the situation.


Safety Recalls – Covered Under Warranty
* S-04-03A Fuel Line Clamp Installation (3) 7081256
* S-04-05 Fusion Drive Shaft Replacement 2202954
* S-05-03 Handlebar Wiring Harness Routing 2203073
* S-05-08 Spindle Inspection/ Replacement 2203123
spindles: LH 1822724 red 1822722 blue
spindles: RH 1822725 red 1822723 blue
* S-05-09 IQ Fuel System Update 2203097
* S-05-12 Fuel Filler Neck Update/Replace 2203178 (all 05 900's) parts 12/05/05
* S-05-12A Fuel Tank Replace 2203220 (as needed) parts 12/09/05

Service Bulletins – Covered Under Warranty
* S-04-04 Fusion Shock Rod Replacement 2202953
* S-04-07 Oil Hose Fastening Procedure 4010589
* S-04-08 ECU Reflash Procedure
* S-05-01 RMK Heat Shield Kit
* S-05-02 RMK Side Panel Vent Kit
* S-05-04 RMK / Switchback Headlight Seal
* S-05-05 Engine Mount Update Kit *Registered* 2203074 parts 12/23/05
* S-05-06 Torque Stop Update Kit *Not Registered* 2203079 parts 12/23/05
* S-05-11 High Performance Belt pn 3211111 parts 12/05/05

Team Tips – Not Covered Under Warranty
* S-04-10-02 IQ Fusion 121 Cooler Protection Kit 2874687
* S-04-10-10 900 Drive Clutch Install: Ream, 96 ftlb, run, retorque to 96 ftlb
* S-04-11-02 Fusion Track Tension s/be 7/8 to 1 1/8" @ 10 lb.
* S-04-11-04 Head O-Ring Replacement
* S-04-11-11 Torque Stop Adjustment .010- .030"
* S 05-01-03 Erratic Fuel Gauge Readings
* S-05-02-02 Exhaust Temp Probe Spec/Test
* S-05-02-03 Installing Heavy Torsion Spring on Fusion
* S-05-02-06 Rear Track Shock Top Mount Loose
* S-05-03-03 Air Intake Boot Seal Replacement 5412761
* S-05-03-04 Series 11 Drive Clutch Weights
* S-05-09-02 Engine Cylinder Bolt Washer (8) 7556234

Pre-Season Tune-Up (See Maintenance Chart in Service/Owners Manual) – Not Covered Under Warranty
* Clutch
* Engine
* Brakes
* Fuel Management
* Electrical
* Chassis

Please be considerate of your dealer in having these operations performed. Check with them in advance to make sure that all the kits, and tools they need are available, as well as properly trained technicians. It is your responsibility to have the machine in good running order, this might be an opportunity for a fall tuneup and prep. You should have fresh fuel in the tank, between 2 and 5 gallons for S-05-01-03 Erratic Fuel Gauge Readings.

These warranty operations are basically setup for flat rate labor compensation, and it is not easy to get the job done in the amount of time allowed. Having the dealer install studding, carbides or other accessories can give them a chance to make some money for their effort.
 

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Thanks for your time and effort. You answered alot of questions I had for my dealer. :div20:
 

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Originally posted by ExcursionPSD@Oct 3 2005, 10:26 PM
* S-04-05 Fusion Drive Shaft Replacement  2202954 
 
* S-05-08 Spindle Inspection/ Replacement  2203123 
What do they means by drive shaft replacement? In any case i have been advise by the factory or my dealer.

Thanks in advance
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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6,144 Posts
Discussion Starter · #10 ·
Originally posted by Mid-Range@Oct 10 2005, 03:38 PM
Sorry.....you should have read that i have NOT been advised
<div align="right">index.php?act=findpost&pid=920205
[/quote]
Third paragraph of my post.

Individual snowmobiles probably will not need each one of these performed. A lot of the problems/improvements were caught early and later machines had the fix in place, or improved part or assembly before they went into the crate at the factory.
 

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Thanx Excursion PSD........good post by the way.We bought them Xmas eve last year and they are running great and we did have the reflashes
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #12 ·
I am not at all happy to note that on October 14, 2005 I had to add the line:

S-05-12 Fuel Filler Neck Update/Replace 2203178

which applies to ALL '05 900s and some '06 IQ sleds. The fuel filler neck has to be reinforced.

Call your dealer first, the repair kits are not yet available.
 

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got letter today given new belt checkin spindle fasteners fuel tank chafin replace feul pump and remappin for better fuel milelige :beerchug:
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #15 ·
Originally posted by ExcursionPSD@Oct 15 2005, 12:50 AM
I am not at all happy to note that on October 14, 2005 I had to add the line:

S-05-12 Fuel Filler Neck Update/Replace    2203178

which applies to ALL '05 900s and some '06 IQ sleds.  The fuel filler neck has to be reinforced.

Call your dealer first, the repair kits are not yet available.
<div align="right">index.php?act=findpost&pid=930901
[/quote]

If you check the date of the CPSC safety recall, you will find, the forum was notified pretty quickly. The repair kit is not yet available. Parts availability from Polaris is around 10/28/05 at this time.
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #17 ·
Originally posted by twitch54@Oct 25 2005, 03:45 PM
Has anybody out their with a NEW 2006 600HO been part of the "fuel neck" problem ????
<div align="right">index.php?act=findpost&pid=955099
[/quote]

Check with your dealer, several models of the 06 600HO Fusions are involved depending on the VIN number. The fix kit is not yet available. Polaris says it will be available Nov. 2, 2005
 

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I HAVE A CHANCE OF GETTING A HOLDOVER (RED) 2005 FUSION 900 FOR 6,200 SHOULD I OR SHOULDN,T I HE SAYS ALL UPDATES DONE?? OH YA IT,S NOT FROM A DEALER BUT THE DEALER HE GOT IT FROM HAS DONE ALL UPDATES IT IS BRAND NEW HE BOUGHT DEALERS OVER STOCK AND SELLS ON THE NET
 

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MY21 650 SBA 146, ES, ICE Storm 1.5
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Discussion Starter · #19 ·
Originally posted by thunderbird@Oct 30 2005, 08:56 AM
I HAVE A CHANCE OF GETTING A HOLDOVER (RED) 2005 FUSION 900 FOR 6,200 SHOULD I OR SHOULDN,T I HE SAYS ALL UPDATES DONE?? OH YA IT,S NOT FROM A DEALER BUT THE DEALER HE GOT IT FROM HAS DONE ALL UPDATES IT IS BRAND NEW HE BOUGHT DEALERS OVER STOCK AND SELLS ON THE NET
<div align="right">index.php?act=findpost&pid=966461
[/quote]

When I said in the prior post...

'The fix kit is not yet available. Polaris says it will be available Nov. 2, 2005'

That was/is accurate. Either me, or the guy you're buying from is not telling the truth. You decide.

If the sled is not warranty reqistered with Polaris by Oct. 31, it may not be eligible for some of the updates, such as the 3211111 belt. Who knows what updates it really has had done on it. If the sled has not been setup correctly, you may have some problems with warranty.
 
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