Hi everyone, I just picked up a 05 fusion 900, I have heard a lot of horror story's about the fusion, but it was to good of a deal to pass up ($1500 with 2000miles) the sled has had all the updates done and seems to be in perfect mechanical, and physical condition, besides one thing, I am always ready empty for fuel. The sled has a few mods, I was just wondering if there is anything I should look for to make sure it stays running well. Also what belt should I use with it? The Polaris one is out of my range right now, but was thinking g about a HPX? Any info would be awesome.
New to me fusion 900
- Thread starter MicahBS
- Start date
there are horror stories out there for all platforms
The 900 is a GREAT sled, people who talk bad about them likely never owned one
Things for you to check out
oiler cable, the factory setup uses a small oiler cable that goes from the side of the throttle body to the oil pump. Bad design, they break and jam up causing all kinds of problems, They are also a real PITA to install. So the fix is a FBF cable, basically a throttle cable that splits into two upstream and drives the throttle bodies and the oil pump at the same time. Way easier to install and less problematic.
Intake boots dry rot and crack from the under hood heat, when they crack they leak and must be replaced.
Front spindles in 05-06 suck the geometry is all wrong. Change to 08+ spindles for a much better ride
VENT galore, get some air flowing through that hood and console
Better boards, the factory runners collect slush like no other, some board inserts work wonders
DIET
the 900 is really easy to lose some weight from, they are HEAVY from the factory. Trust me get stuck 6-12 times in a day and see how you feel after digging it out all day, or lose some pounds! makes it way less likely to trench/stuck and way easier to move around /lift when it does
plastic chaincase cover, known to melt. Cover with heat tape, make a heat guard, last thing you want is a bunch of melted plastic and a leaky chaincase on the trail!
front radiator delete, I am sure its already been done on your sled, but most people choose to ditch the front mount cooler or at least run it in series instead of parallel like the stock setup
flywheel separation, the flywheel can come apart inside and cut the wires for your stator, causing a dead sled. Good idea to look into the flywheel issue now before you are 12 miles from your truck
read all the stickies on top of this forum
Enjoy! and get us some pictures!
we love 900's here, we know the horror stories are just that....stories
truth is its 146hp two stroke stock torque monster sled, with an IQ chassis (dragon) that can be made into a real monster for CHEAP!!
The 900 is a GREAT sled, people who talk bad about them likely never owned one
Things for you to check out
oiler cable, the factory setup uses a small oiler cable that goes from the side of the throttle body to the oil pump. Bad design, they break and jam up causing all kinds of problems, They are also a real PITA to install. So the fix is a FBF cable, basically a throttle cable that splits into two upstream and drives the throttle bodies and the oil pump at the same time. Way easier to install and less problematic.
Intake boots dry rot and crack from the under hood heat, when they crack they leak and must be replaced.
Front spindles in 05-06 suck the geometry is all wrong. Change to 08+ spindles for a much better ride
VENT galore, get some air flowing through that hood and console
Better boards, the factory runners collect slush like no other, some board inserts work wonders
DIET
the 900 is really easy to lose some weight from, they are HEAVY from the factory. Trust me get stuck 6-12 times in a day and see how you feel after digging it out all day, or lose some pounds! makes it way less likely to trench/stuck and way easier to move around /lift when it does
plastic chaincase cover, known to melt. Cover with heat tape, make a heat guard, last thing you want is a bunch of melted plastic and a leaky chaincase on the trail!
front radiator delete, I am sure its already been done on your sled, but most people choose to ditch the front mount cooler or at least run it in series instead of parallel like the stock setup
flywheel separation, the flywheel can come apart inside and cut the wires for your stator, causing a dead sled. Good idea to look into the flywheel issue now before you are 12 miles from your truck
read all the stickies on top of this forum
Enjoy! and get us some pictures!
we love 900's here, we know the horror stories are just that....stories
truth is its 146hp two stroke stock torque monster sled, with an IQ chassis (dragon) that can be made into a real monster for CHEAP!!
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I did 60 miles the other day. Absolutely love the sled, low end is awesome, and comparied to my last sled ( 03 rx1 ) it rides amazing. Front rad was deleted, pipe and can, clutched. What vents sould I get for the sled, and where do I get them?
SLP makes nice vents for those plastics
but honestly I am more of the home depot fab type guy so if you want to save $$$ just get a sheet of ABS plastic, some cardboard to make templates, a rivet gun, multifunction tool, hole saw, and some screen door material from hardware store and have at it...
nose vents to let it in, console vents (up high) to let it out vent the clutch side big time, these 900's can build some heat!!! heat kills everything under the hood
I have a ton of vents on my sled, some I bought from SLP, some came from a parts sled, and then some I made. Making them is fun and easy
here's my baby I am in the process of a total refab on this sucker:
You can see vents in the nose on the sides, vents in front of the primary clutch and magneto on the other side, then vents on the side panels, then more vents on the console and rear of the plastics to hopefully let the heat out. Most of the black plastic ones I built. I get sheets of abs plastic in town 4'x8' for $40 a piece and use them for all sorts of things around the shop....
but honestly I am more of the home depot fab type guy so if you want to save $$$ just get a sheet of ABS plastic, some cardboard to make templates, a rivet gun, multifunction tool, hole saw, and some screen door material from hardware store and have at it...
nose vents to let it in, console vents (up high) to let it out vent the clutch side big time, these 900's can build some heat!!! heat kills everything under the hood
I have a ton of vents on my sled, some I bought from SLP, some came from a parts sled, and then some I made. Making them is fun and easy
here's my baby I am in the process of a total refab on this sucker:
You can see vents in the nose on the sides, vents in front of the primary clutch and magneto on the other side, then vents on the side panels, then more vents on the console and rear of the plastics to hopefully let the heat out. Most of the black plastic ones I built. I get sheets of abs plastic in town 4'x8' for $40 a piece and use them for all sorts of things around the shop....
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I might give that a shot, always enjoy doing my own fab work. Do you have any idea what could be going on with my fuel gauge? It shows it always empty, and flashes non-stop.
I always get my vents, hoods and now his gauge lifter..from my buddy bill at mountain fit hoods. Best prices imo.
http://stores.mountainfithoods.net
The fuel level issue is most likely the float. It can fall off the fuel pump assembly inside the tank. U will have to remove the tank to fix it. Just shine a light inside the neck and see if it's attached. It should have a flat white float attached (if it's black and round it's the old one and needs updated anyways cause they fall apart)
Sent from my iPhone using Tapatalk
http://stores.mountainfithoods.net
The fuel level issue is most likely the float. It can fall off the fuel pump assembly inside the tank. U will have to remove the tank to fix it. Just shine a light inside the neck and see if it's attached. It should have a flat white float attached (if it's black and round it's the old one and needs updated anyways cause they fall apart)
Sent from my iPhone using Tapatalk
