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Discussion Starter · #1 ·
Went for a ride yesterday, filled it up and when we stopped at the trail entrance I noticed I had fuel condensation at the base of the filler-neck. I wiped it away, and it was wet again instantly.

I Pulled the fuel cap to make sure the gasket was still in it, everything looked good, I inspected for cracks, and I did not see any cracks on the neck.

So next stop put us at about 1/2 tank of fuel, and it is still wet with fuel down both sides of the tank, under the seat. and I was pretty well covered down my legs too.

Took a real close look and saw what looked like a horizontal crack inside the tank, right where the neck makes the transition into the tank. if you look at the tank from the top the crack is hidden by the large plastic nut on the outside.
And before anyone asks, No I do not let the fuel nozzle hang off the tank when filling it. I always hold the weight of it and keep it in contact with the filler neck to avoid a static electric spark.

Anyone else seen this on a 2006 900 Switchback?

I am waiting for my service appointment for the fuel level float & filter, I hope they can get a tank in before the sled gets there.

keep an eye on this, My sled was outside of the affected VIN numbers that got notices for this.
 

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Here's the info from the TSB on your sled

2006 600 HO Switchback * Model #s S06PS6FS
Serial #s S06PS6FSA 600501 - 600510 / 600712 - 600715 / 617015 - 617388 610215 - 610314 / 616041 - 617014

(REFERENCE LAST 6 DIGITS OF VIN NUMBER)
 

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Here's the info from the TSB on your sled

2006 600 HO Switchback * Model #s S06PS6FS
Serial #s S06PS6FSA 600501 - 600510 / 600712 - 600715 / 617015 - 617388 610215 - 610314 / 616041 - 617014

(REFERENCE LAST 6 DIGITS OF VIN NUMBER)[/b]
Is that a US VIN? My VIN Starts with SN1PS6FS8C. Last numbers 627xxx. I just bought the sled used, and I'm not sure if the work was done or if the TSB even applies to my sled. Can't afford to spill fuel a $1.10/litre!

Anybody got a pix of what the repair looks like?
 

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Mine was cracked at the same location that you described. My sled serial number fell within the range that is covered by the service bulletin. My VIN ends with 620621 and it's a 06' 900 model S06PS8DSA. The dealer did add an insert inside the filler neck to make it stronger, but it did not help with the crackin issue. Mine was cracked at the factory and I discovered the leak when I trailered it home. Below is the entire model list that is impacted and can be found at ---http://www.cpsc.gov/cpscpub/prerel/prhtml06/06503.html

Model Number of Affected Snowmobiles:

Model Model Number
2005 900 Fusion
S05MP8DS (A)(B)©

2005 900 RMK
S05PL8DS (A)(B)©(D)
S05PM8DS (A)(B)
S05PN8DS
S05PN8DE

2005 900 Switchback
S05PS8DS

2006 600 HO Fusion
S06MP6FS (A)(B)
S06MC6FS
S06ME6FS

2006 600 HO RMK
S06PK6FS (A)

2006 600 HO Switchback
S06PS6FS (A)

2006 900 Fusion
S06MP8DS (A)(B)

2006 900 RMK
S06PL8DS (A)(B)
S06PM8DS (A)
S06PN8DS (A)
S06PR8DS

2006 900 Switchback
S06PS8DS (A)

2006 FS Classic
S06PD7ES

2006 FS Touring
S06PT7ES

2006 FST Classic
S06PD7FS

2006 FST Touring
S06PT7FS

2006 FST Switchback
S06PS7FS
 

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Discussion Starter · #7 ·
Thanks for the list IndyBaker,

Did you guys know arctic cat is having the same problems? The get their tanks from the same vendor allegedly. so this isn't a Polaris problem, it is from the plastics company that made the tanks.
 

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GTO,
I also have the 600 HO SB. No problems last year when I put the sled away for the summer. This year when I pulled it out for the first ride of 2007 the filler neck was sure enough leaking gas. I had asked my dealer berore I even picked up the sled to take care of this as a recall item. He told me that my sled vin # was not effected. They also said they don't automatically replace them unless they develope a leak. Went to pick up the sled today and found out electric start was now
finally an option. So I dropped $699.00 for an option I wanted last year. Z-Bart.
 

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Discussion Starter · #10 ·
$700.00 for electric start? Holy schitt!!! I bet you could hire a local kid to start your sled everyime you want to ride for 1/3rd of that cost!! Up until I was 30-years old I never even paid that much for a car or a truck!!


2 yanks on a rope is fine for me, It has always started on the first or second full pull after a slow one to loosen it up when really cold.
 

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$700.00 for electric start? Holy schitt!!! I bet you could hire a local kid to start your sled everyime you want to ride for 1/3rd of that cost!! Up until I was 30-years old I never even paid that much for a car or a truck!!
2 yanks on a rope is fine for me, It has always started on the first or second full pull after a slow one to loosen it up when really cold.[/b]

GTO, That's the out the door cost at the local dealership. $599 + $100 instalation. If I had a heated garage I'm sure I could have handled the instal.
After reading alot of different posts, I see the 900SB seems to be alot easier to start than the 600SB. Hense the need for the electric start. I once had a boss that said " I don't expect you guy's to work any harder...just smarter". I had the joy of a 40 pull morning last year @ -25 degrees.
 

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I have an 06 Switchback that got the filler neck bushing last year. Last week the tank cracked on the trail in Caribou. Had to drive over to Chandler Farms and have a new tank installed. One hour and fifteen minutes to get back on the trail.
 

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Discussion Starter · #13 ·
Sorry Z, I didn't realize you had a carbed sled, This is my 3rd year on a CFI sled. And I do not miss the carb jetting issues due to any 20 degree weather change.

But I still think 7-bills is high for electric start.
 

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Sorry Z, I didn't realize you had a carbed sled, This is my 3rd year on a CFI sled. And I do not miss the carb jetting issues due to any 20 degree weather change.

But I still think 7-bills is high for electric start.[/b]

GTO,
I could not agree with you MORE. $700.00 is way too much. When I went down to pick up my sled my dealer was singing me a sob story how Polaris does not supply the battery for the Switchback electric start. He told me he had to "EAT" the cost of the battery!! I think for 7 bills he did ok!!
Now that I have used the sled with electric start there's no going back for this guy. Love it to death!!
Z-Bart.
 

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I had my 06 Switchback crack a year after they installed the cure-all stiffener bushing. They put in a new tank this year. A week later I had my daughters 2005 600 XC SP crack. They put in a new tank. This past weekend my friends 2004 600 XC SP cracked.
The dealer said all the 2005 and 2006 tanks will eventually crack.
 
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