2005 polaris 600 xc sp snowmobile service repair manual

service repair manual

1. 500 XC SP
600 XC SP
700 XC SP
800 XC SP
900 FUSION
2005 PERFORMANCE
SERVICE MANUAL
PN99193039919303
2005 PERFORMANCE SERVICE MANUAL
CVR_9919304 9/2/04 8:37 AM Page 1

2. i
2005PERFORMANCE
MANUAL
SPECIFICATIONS
1
GENERAL 2
MAINTENANCE 3
FUEL DELIVERY 4
ENGINE 5
CLUTCHING 6
FINAL DRIVE 7
BRAKE SYSTEM 8
STEERING 9
FRONT SUSPENSION 10
REAR SUSPENSION 11
CHASSIS / HOOD 12
ELECTRICAL SYSTEM 13
WIRING DIAGRAMS 14
Foreword
This manual is designed primarily for use by certified
Polaris snowmobile service technicians in a properly
equipped shop. Persons using this manual should have
a sound knowledge of mechanical theory, tool use, and
shop procedures in order to perform the work safely and
correctly. The technician should read the text and be fa-
miliar with service procedures before starting the work.
Certain procedures require the use of special tools. Use
only the proper tools, as specified. Cleanliness of parts
and tools as well as the work area is of primary impor-
tance.
All references to left and right side of the vehicle are
from the operator’s perspective when seated in a normal
riding position.
This manual includes 2005 Model Year information,
along with service specifications. A table of contents is
placed at the beginning of each chapter, and an
alphabetic index is provided at the end of the manual for
location of specific page numbers and service
information. Keep this manual available for reference
in the shop area.
At the time of publication allinformation contained in
this manual was technically correct. However, all
materials and specifications are subject to change
without notice.
Comments or suggestions about this manual may be
directed to:
Polaris Sales Inc.
Snow Engineering Publications Department
2100 Hwy 55 Medina, Minnesota 55340.
2005 PERFORMANCE MANUAL
(PN9919303)
Copyright 2004 Polaris Sales Inc. Printed in U.S.A.

3. 500 XC SP 1.2 -- 1.3...........................................
600 XC SP 1.4 -- 1.5...........................................
700 XC SP 1.6 -- 1.7...........................................
800 XC SP 1.8 -- 1.9...........................................
900 FUSION 1.10 -- 1.11.........................................

4. SPECIFICATIONS
1.2
MODEL: 500 XC SP..............
MODEL NUMBER: S05NE(P)5CS(A,B)....
ENGINE MODEL: S2715--5044--PI5C.....
ENGINE CARBURETION
Engine Type Libertyt Type TM38
Engine Displacement cc 500 Main Jet 410
Bore in / mm 2.78/70.5 Pilot Jet 45
Stroke in / mm 2.52/64 Jet Needle 9DFH6--57/2
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearance
in / mm
.0045” -- .0059”
0.115 -- 0.149mm
Throttle Gap UnderCutaway
in / mm
0.079”/2.0mm
Piston Ring End Gap in / mm
.014” -- .020”
0.356 -- 0.508
Cutaway 1.5
Piston Marking N/A Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 145
Operating RPM±200 8250--8500 Fuel Screw 3.0
Idle RPM±200 1500 Pilot Air Jet N/A
Engagement RPM±300 4200 Air Screw 1.25
Exhaust Valve Spring Pink/Yellow Fuel Octane 87 min non--oxygentaed
AMBIENT TEMPERATURE
Altitude Below-30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_ FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_ C
0--600 (0--2000)
440
#3
430
#3
410
#2
390
#2
380
#2
360
#2
600--1200
(2000--4000)
420
#3
400
#2
390
#2
370
#2
350
#2
340
#1
1200--1800 390 380 360 340 330 3101200--1800
(4000--6000)
390
#2
380
#2
360
#2
340
#2
330
#1
310
#1
Meters
1800--2400
(60008000)
370 350 340 320 300 290
Meters
(Feet)
(6000--8000)
370
#2
350
#2
340
#2
320
#1
300
#1
290
#1
2400--3000
(800010000)
340 330 310 300 280 260
(8000--10000)
340
#2
330
#2
310
#1
300
#1
280
#1
260
#1
3000--3700
(1000012000)
320 300 290 270 250 240
(10000--12000)
320
#2
300
#1
290
#1
270
#1
250
#1
240
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1056Bhd 56/4236ER 224074
0-900
(0-3000)
10--56 Bushed 56/42--36 ER 22:40--74
Mt
900-1800
1054Bhd 56/4236ER 224074Meters
(Feet)
900-1800
(3000-6000)
10--54 Bushed
Blk/G 7043058
56/42--36 ER 22:40--74
(Feet)
1800-2700
10Bhd
Black/Green 7043058
56/4236ER 214074
1800-2700
(6000-9000)
10 Bushed 56/42--36 ER 21:40--74
2700-3700
10MBBhd 56/4236ER 214074
2700-3700
(9000-12000)
10MB Bushed 56/42--36 ER 21:40--74

5. SPECIFICATIONS
1.3
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92”
Shift Weights 10--56 Bushed Gearing : Chain 22:40--74
Drive Spring Black/Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads 2202202
Type Team Roller Reverse
BrakeType Type81
Spring Red/Black
BrakeType Type81
Helix Angle 56/42--36 ER CAPACITIES
BELT Fuel Tank 11.8 gal / 44.7 l
Belt Part Number 3211080 Oil Tank 3.25 qts. / 3.1 l
Belt Width (Projected) 1.438” Coolant 5.6 qts. / 5.3 l
Side Angle (Overall) 28_ Chain Case Oil 9 oz. / 266 ml
Outside Diameter 46.625” SLED DIMENSION
Center Distance 11.50”
Unit Length / Height /
Widthin/cm.
113 / 46 / 48
287 / 117 / 122
FRONT SUSPENSION REAR SUSPENSION
Type Edge Type Edge / M--10
IFS Shocks
M10/STD 7043082
F/O 7042211
Stock FTS
STD / F/O 7041975
M107042224
StockIFSSpringRate
M10/STD 68/160
StockFTS
M--107042224
StockIFSSpringRate
M10/STD68/160
F/O 90/180
IFS Spring Pre--Load
M--10/STD (Inst. length)
10.56”
F/O .625”
FTS Spring Rate
STD / F/O 160/VAR
M--10 160
Front Vertical Travel 10.28”/26cm.
FTSPreLoad
STD / F/O N/A (eyelet to re-
tainer)350”
TRACK
FTSPre--Load tainer)3.50”
M--10 .90”
Width 15”
StockRTS
STD 7042129
F/O7042212
Length 121”
StockRTS F/O7042212
M--10 7042216
Lug Height
STD/F/O .91” / 1.25”
M--10 1.0”
Torsion Spring .375(sq.)
TrackTension Seepage310
M--10 RTS Springs 7041935/7041936
TrackTension See page3.10
Optional Torsion Springs found on page 11.7-- 11.8
ELECTRICAL
Flywheel I.D. 4010677 SparkPlug/Gap RN57YCC / .70mm/.025”
CDI Marking 4010829 Voltage Regulator N/A
Alternator Output 280w Magneto Pulses 6
Ignition Timing(see conver-
25_@2500RPM ElectricStart
STD/M--10 AccessoryIgnitionTiming(seeconver
sion chart on page 13.4)
25_@2500RPM ElectricStart
STD/M10Accessory
F/O / M--10 F/O Standard

6. SPECIFICATIONS
1.4
MODEL: 600 XC SP..............
MODEL NUMBER: S05N(A,E,P)6E(E,S)(A,B)....
ENGINE MODEL: S2761--6044--PI6E.....
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 38
Engine Displacement cc’s 599 Main Jet 440
Bore in / mm 3.04” / 72.25mm Pilot Jet 45
Stroke in / mm 2.52” / 64mm Jet Needle 9DFH7--60 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence
in / mm
.0045 -- .0059”
.115 -- .149mm
Throttle Gap UnderCutaway
in / mm
0.079”
2.0 mm
Piston Ring End Gap
in / mm
.014”-- .020”
.356 -- .508mm
Cutaway 2.5
Piston Marking 3021308 Valve Seat 1.5
Piston Ring Marking N/A Starter Jet 140
Operating RPM±200 8100 Fuel Screw 2.5 Turns
Idle RPM±200 1200 Pilot Air Jet N/A
Engagement RPM±300 4000 Air Screw 1.0 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#4
440
#3
420
#3
400
#3
390
#2
600--1200
(2000--4000)
450
#4
430
#4
410
#4
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
Mt
1200--1800
(4000--6000)
420
#4
400
#4
390
#3
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(60008000)
400 380 360 340 330 310(Feet)
(6000--8000)
400
#4
380
#3
360
#2
340
#2
330
#2
310
#2
2400--3000
(800010000)
370 350 330 320 300 280
(8000--10000)
370
#3
350
#2
330
#2
320
#2
300
#2
280
#2
3000--3700
(1000012000)
340 330 310 290 270 260
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#1
260
#1
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1058 584236ER 2339:74P
0-900
(0-3000)
10-58 58--42--.36 ER23--39: 74P
Mt
900-1800
1056 584236ER 2339:74PMeters
(Feet)
900-1800
(3000-6000)
10-56
DarkBlue/White Red/Blue
58--42--.36 ER23--39 : 74P
(Feet)
1800-2700
1054
Dark Blue/White Red / Blue
584236ER 2239:74P
1800-2700
(6000-9000)
10--54 58--42--.36 ER22--39 : 74P
2700-3700
10 584236ER 2239:74P
2700-3700
(9000-12000)
10 58--42--.36 ER22--39 : 74P

7. SPECIFICATIONS
1.5
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm
Shift Weights 10--58 Gearing : Chain 23--39 : 74 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring Red / Blue
BrakeType LiquidCooled
Driven Helix Angle 58--42--.36 ER CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected)1.438” / 3.65cm Coolant 5.6 Qts / 5.3 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48” 287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks STD (F/O)
7043082 (7042211)
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate160#/in
Front Vertical Travel10.28” / 26cm FTS Pre--Load .25” / .635 cm
TRACK M--10 FTS Pre--Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
Lug Height (M--10/F/O)
.91” / 2.3 cm (1” / 2.54 cm / 1.25”/3.175cm)
M--10 RTS Fox IFP Res PN 7042216
TkTi SP310
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension SeePage3.10
Torsion Springs .375(Sq.) 77_
Optional M--10 Springs see page 11.7-- 11.8
ELECTRICAL
Flywheel I.D. 4010677 SparkPlug/Gap RN57YCC / .028” / .70mm
CDI Marking 4010830 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-
24_@3500RPM±15_ ElectricStart Accessory
IgnitionTiming(seeconver
sion chart on page 13.4 )
24_@3500RPM±1.5_ ElectricStart Accessory

8. SPECIFICATIONS
1.6
MODEL: 700 XC SP..............
MODEL NUMBER: S05N(E,P)7CS(A,B)....
ENGINE MODEL: S2469--7070--PR7C.....
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc’s 701 Main Jet 440
Bore in / mm 3.19” / 81mm Pilot Jet 45
Stroke in / mm 2.68” / 68mm Jet Needle 9DGN--57 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence
in / mm
.0044-- .0058”
.111-- .147mm
Throttle Gap UnderCutaway
in / mm
0.079”
2.0 mm
Piston Ring End Gap
in / mm
.012-- .018”
.304 -- .457mm
Cutaway 1.5
Piston Marking 3021307 Valve Seat 1.8
Piston Ring Marking N/A Starter Jet 145
Operating RPM±200 8000 Fuel Screw 2.5 Turns
Idle RPM±200 1400 Pilot Air Jet N/A
Engagement RPM±300 3500 Air Screw 1.25 Turns
Exhaust Valve Spring Green/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
480
#4
460
#3
440
#3
420
#3
400
#3
390
#2
600--1200
(2000--4000)
450
#3
430
#3
410
#3
400
#3
380
#2
360
#2
1200--1800 420 400 390 370 350 330
Mt
1200--1800
(4000--6000)
420
#3
400
#3
390
#3
370
#2
350
#2
330
#2
Meters
(Feet)
1800--2400
(60008000)
400 380 360 340 330 310(Feet)
(6000--8000)
400
#3
380
#3
360
#2
340
#2
330
#2
310
#2
2400--3000
(800010000)
370 350 330 320 300 280
(8000--10000)
370
#3
350
#2
330
#2
320
#2
300
#2
280
#2
3000--3700
(1000012000)
340 330 310 290 270 260
(10000--12000)
340
#2
330
#2
310
#2
290
#2
270
#2
260
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1062 624246ER 2541:76P
0-900
(0-3000)
10-62 62--42--.46 ER25--41: 76P
Mt
900-1800
1060 624246ER 2541:76PMeters
(Feet)
900-1800
(3000-6000)
10-60
Black/Green 7043063
62--42--.46 ER25--41: 76P
(Feet)
1800-2700
1058
Black/Green 7043063
624046ER 2339:74P
1800-2700
(6000-9000)
10--58 62--40--.46 ER23--39 : 74P
2700-3700
1056 624046ER 2339:74P
2700-3700
(9000-12000)
10--56 62--40--.46 ER23--39 : 74P

9. SPECIFICATIONS
1.7
DRIVE CLUTCH CHAINCASE
Type P--85 Center DIstance 7.92” / 20.12cm
Shift Weights 10--62 Gearing : Chain 25--41 : 76 P
Drive Spring Black / Green Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring 7043063
BrakeType LiquidCooled
Helix Angle 62--42--.46 ER CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm Coolant 5.2 Qts / 4.9 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48”
287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks STD (F/O)
7043082
(7042211)
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate 68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate 160#/in
Front Vertical Travel 10.28” / 26cm FTS Pre--Load .25” / .635 cm
TRACK M--10 FTS Pre--Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
Lug Height (M--10/F/O)
.91” / 2.3 cm (1” / 2.54 cm / 1.25”/3.175cm)
M--10 RTS Fox IFP Res PN 7042216
TkTi SP310
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension SeePage3.10
Torsion Springs .375(Sq.) 77_
Optional M--10 Springs see page 11.7-- 11.8
ELECTRICAL
Flywheel I.D. 4010677 SparkPlug/Gap RN57YCC / .028” / .70mm
CDI Marking 4010839 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-
20_@2000RPM±15_ ElectricStart
AccessoryIgnitionTiming(seeconver
sion chart on page 13.4 )
20_@2000RPM±1.5_ ElectricStart
Accessory
STD M--10

10. SPECIFICATIONS
1.8
MODEL: 800 XC SP..............
MODEL NUMBER: S05N(E,P)8CS(A,B)....
ENGINE MODEL: S2774--8070--PI8C.....
ENGINE CARBURETION
Engine Type Libertyt Type
Mikuni
TM 40
Engine Displacement cc’s 794 Main Jet 460
Bore in / mm 3.35” / 85mm Pilot Jet 40
Stroke in / mm 2.76” / 70mm Jet Needle 9DGN5--57 / 3
Cylinders 2 Needle Jet P--8
Piston / Cylinder Clearence
in / mm
.006 -- .0074”
.152-- .188mm
Throttle Gap UnderCutaway
in / mm
0.079”
2.0 mm
Piston Ring End Gap
in / mm
.016-- .022”
.406 -- .559mm
Cutaway 1.5
Piston Marking 3021315 Valve Seat 1.8
Piston Ring Marking N/A Starter Jet 135
Operating RPM±200 7900 Fuel Screw 2.5 Turns
Idle RPM±200 1500 Pilot Air Jet N/A
Engagement RPM±300 3500 Air Screw 1.5 Turns
Exhaust Valve Spring Pink/Yellow Fuel Octane (R+M/2)
87 Oct. NonOxy /
89 Oct. Oxy
AMBIENT TEMPERATURE
Altitude Below -30°F -30_to --10_F -- 1 0_to +10_F +10_to +30_F +30_to +50_F Above +50_FAltitude Below-30F
Below -34°C
-30_to--10_F
-34_to -23_C
--10_to+10_F
-23_to --12_C
+10_to+30_F
-12_to --1_C
+30_to+50_F
-1_to +10_C
Above+50_F
Above +10_C
0--600
(0--2000)
500
#4
480
#4
460
#3
440
#3
420
#2
400
#2
600--1200
(2000--4000)
470
#4
450
#3
430
#3
410
#2
400
#2
380
#2
1200--1800 440 420 400 390 370 350
Mt
1200--1800
(4000--6000)
440
#3
420
#3
400
#2
390
#2
370
#2
350
#2
Meters
(Feet)
1800--2400
(60008000)
410 400 380 360 340 320(Feet)
(6000--8000)
410
#3
400
#2
380
#2
360
#2
340
#2
320
#2
2400--3000
(800010000)
390 370 350 330 310 290
(8000--10000)
390
#2
370
#2
350
#2
330
#2
310
#2
290
#2
3000--3700
(1000012000)
360 340 320 300 290 270
(10000--12000)
360
#2
340
#2
320
#2
300
#2
290
#2
270
#2
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1064 624646ER 2541:76P
0-900
(0-3000)
10-64 62--46--.46 ER25--41: 76P
Mt
900-1800
1062 624246ER 2541:76PMeters
(Feet)
900-1800
(3000-6000)
10-62
Dark Blue/
7043063
62--42--.46 ER25--41: 76P
(Feet)
1800-2700
1060
DarkBlue/
White
7043063
624046ER 2339:74P
1800-2700
(6000-9000)
10--60
White
62--40--.46 ER23--39 : 74P
2700-3700
1058 624046ER 2339:74P
2700-3700
(9000-12000)
10--58 62--40--.46 ER23--39 : 74P

11. SPECIFICATIONS
1.9
DRIVE CLUTCH CHAINCASE
Type P--85 Center Distance 7.92” / 20.12cm
Shift Weights 10--64 Gearing : Chain 25--40 : 76 P
Drive Spring Dark Blue / White Reverse Electronic Reverse
DRIVEN CLUTCH Brake Pads Type 81
Type Team Roller Reverse
BrakeType LiquidCooled
Driven Spring 7043063
BrakeType LiquidCooled
Helix Angle 62--46--.46 CAPACITIES
BELT Fuel Tank 11.8 Gal. / 45 Liters
Belt Part Number 3211080 Oil Tank 3.25 Qts / 3 Liters
Belt Width (Projected) 1.438” / 3.65cm Coolant 5.6 Qts / 5.3 Liters
Side Angle (Overall) 28_ Chain Case Oil 9 fl. oz. / 266 ml
Outside Diameter 46.625” / 118.4cm SLED DIMENTIONS
Center Distance 11.5” / 29.2cm
Unit Length / Height /
Widthin/cm
113” / 48” / 48”
287 / 122 / 122 cm
FRONT SUSPENSION REAR SUSPENSION
Type EDGE Type EDGE
IFS Shocks STD (F/O)
7043082
(7042211)
Stock FTS IFP / PN 7041975
Stock IFS Spring Rate 68/160#/in. FTS Spring Rate 160#/in Var
F/O IFS Spring Rate 90/180#/in. M--10 FTS (ACE) Fox IFP / PN 7042224
Stock IFS Spring Pre--Load (F/O) 3.25” / 8.26cm (.625” / 16 mm)
M--10 FTS Spring Rate 160#/in
Front Vertical Travel 10.28” / 26cm FTS Pre--Load .25” / .635 cm
TRACK M--10 FTS Pre--Load .90” / 23mm
Width 15” / 38 cm Stock RTS Fox PS / PN 7042129
Length 121” / 307 cm F/O RTS Fox PS / CA PN 7042212
Lug Height (M--10/F/O)
.91” / 2.3 cm (1” / 2.54 cm / 1.25”/3.175cm)
M--10 RTS Fox IFP Res PN 7042216
TkTi SP310
M--10 RTS Spring Rate (M--10 ACE Spring Rate)210/278 #/in. (220/1140)
Track Tension SeePage3.10
Torsion Springs .375(Sq.) 77_
Optional M--10 Springs see page 11.7-- 11.8
ELECTRICAL
Flywheel I.D. 4010677 SparkPlug/Gap RN57YCC / .028” / .70mm
CDI Marking 4010842 Voltage Regulator T1
Alternator Output 280 watts Magneto Pulses 6
Ignition Timing(see conver-29_@3250 RPM±1.5_
ElectricStart Accessory
IgnitionTiming(seeconver
sion chart on page 13.4 )
29@3250RPM±1.5
w/TPS disconnected
ElectricStart Accessory

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13. SPECIFICATIONS
1.10
MODEL: 900 FUSION..............
MODEL NUMBER: S05MP8D(E,S)(A,B,C)....
ENGINE MODEL: S2883--8686--PI8D.....
ENGINE FUEL SYSTEM
Engine Type Libertyt Type Clean Fire Injection
Engine Displacement cc 866 Regulator Pressure 4 Bar (58psi)
Bore in / mm 3.46”/ 83mm THROTTLE BODY
Stroke in / mm 3.15” / 80mm Throttle Body Bore Size in/cm 2” / 51mm
Cylinders 2 TPS voltage @ idle .92 -- .94
Piston / Cylinder Clearance
in / mm
.0045” -- .0098”
.114 -- .249
Throttle Body Manufacture Mikuni
Piston Ring End Gap in / mm
.016” -- .022”
.406--.56
DRIVE CLUTCH
Piston Marking 3021327 Type P--85
Piston Ring Marking N/A Center Distance in/cm 11.5” / 29.2
Operating RPM±200 7500 Spring Dark Blue / White
Idle RPM±200 1700 Shift Weight 10--74
Engagement RPM±300 3700 DRIVEN CLUTCH
Exhaust Valve Spring Purple Type TEAM
CHAINCASE Spring 7043063
Center Distance in/cm 11.35” / 28.83cm Helix 62/46--36 ER
Gearing 25 : 37 -- 92P BELT
Reverse Electronic Width in/cm 1.438” / 3.652cm
Brake Pads 2202727 Length in/cm 46.625” / 118.4275cm
Brake Type Type 94 (DOT 4) Part Number 3211080
CAPACITIES DIMENSIONS
Fuel Tank gal./l 10.8 / 40.9 Length in/cm 112.5 / 286
Oil Tank qts./l 3 / 2.8 Height in/cm 47 / 119
Coolant qts. / l 6.7 / 6.3
Widthin/cm 4725/120
Chain Case Oil oz. / ml 11 / 325.3
Widthin/cm 47.25/120
DRIVE CLUTCH DRIVEN CLUTCH
Altitude Shift Clutch Clutch Driven ChaincaseAltitude Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Chaincase
Gearing
0-900
1074 253792
0-900
(0-3000)
10--74 25:37--92
900-1500
1070 253792
900-1500
(3000-5000)
10--70 25:37--92
1500-2100
1068 223992
Meters
1500-2100
(5000-7000)
10--68
Dark Blue/
7043063 62/4636ER
22:39--92
Meters
(Feet) 2210-2700
1066
DarkBlue/
White
7043063 62/46--36 ER
223992
(Feet) 2210-2700
(7000-9000)
10--66
White
22:39--92
2700--3350
(9000--11000)
10--64 22:39--92
3350--4000
(11000--13000)
10--62 22:39--92

14. SPECIFICATIONS
1.11
FRONT SUSPENSION REAR SUSPENSION
Type IQ Type IQ
Stock IFS Shocks 7042258 Stock FTS 7042327
F/O IFS Shocks 7043095 F/O FTS 7043096
Stock IFS Spring Rate 100# Stock FTS Spring Rate 170#
F/O Spring Rate 120# F/O FTS Spring Rate 190#
Stock Spring Pre--Load10.25”/26cm installed lengthStock Spring Pre--Load 7.25 installed length
F/O Spring Rate 11.17”/28cm installed lengthF/O FTS Spring Pre--Load7.25 installed length
Front Vertical Travel 10in / 25.4cm Stock RTS 7042218
TRACK F/O RTS 7043097
Width in/cm 15/38.1 TORSION SPRINGS
Length in/cm 121/307.34 Stock Torsion Spring .359/80_ 12.5#
Lug Height in/cm 1.25/3.175 Light Torsion Spring .359/80_ 11.25#
Track Tension Seepage3.10 Heavy Torsion Spring .405/80_ 16.25#
ELECTRICAL
Flywheel I.D. 4011119 SparkPlug/Gap
Champion RN57YCC /
.025mm(.003”)
Base ECU 4011081 Voltage Regulator 4010866
Alternator Output 400watts Stator 4010727
Ignition Timing(see conver-
14_@3000RPM ElectricStart TBD
IgnitionTiming(seeconver
sion chart on page 13.4)
14_@3000RPM ElectricStart TBD