Snowmobile Polaris 600 Fusion (2006 year). Manual - part 21

84

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow 

recommended regular maintenance and perform service checks as out-

lined in this manual. Record maintenance and service in the Mainte-

nance Log beginning on page 138.

The recommended maintenance schedule on your snowmobile calls for 

service and maintenance inspections at 150 miles (240 km), 500 miles 

(800 km) and 1000 miles (1600 km).  These inspections should be per-

formed by a qualified service technician.  For continued optimum per-

formance and component life, continue maintenance checks at 1000 

mile (1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception 

of authorized warranty repairs, become the responsibility of the regis-

tered owner.  If, during the course of the warranty period, part failures 

occur as a result of owner neglect in performing recommended regular 

maintenance, the cost of repairs are the responsibility of the owner. 

Personal safety is critical when attempting to service or make adjust-

ments to your snowmobile.  If you're not familiar with safe service or 

adjustment procedures and the use of tools, or if you don't feel comfort-

able performing these tasks yourself, contact an authorized Polaris 

dealer for service.

CAUTION

Hot components can cause damage to plastic.  Always make sure the 

exhaust system and engine have cooled before tipping the snowmobile on its 

side for service or inspection.

85

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions.  You 

may need to increase frequency based on riding conditions.  When 

inspection reveals the need for replacement parts, always use genuine 

Polaris parts, available from your Polaris dealer.

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean

R - Replace

L - Lubricate

Item

See 

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CLUTCH

Clutch Alignment Offset 

(without belt)

108

I

I

I

Drive Belt Condition

109

I

I

I

I

Clutches (disassemble)

108

C

C

C

Belt Tension

--

I

I

I

I

Clutch Sheaves

108

I

I

I

I

ENGINE/COOLING

Engine Mounts

--

I

I

I

I

Recoil Rope

--

I

I

I

I

Engine Torque Stop

111

I

I

I

I

Cylinder Head Bolts

--

I

I

I

Cylinder Base Nuts

--

I

I

I

I

Ignition Timing BTDC

--

I

I

I

VES System

--

C

C

C

I

Coolant Level

98

I

I

R

I

Coolant Hose

--

I

I

I

I

Heat Exchangers

100

I

I

I

I

I

Coolant Circulation

--

I

I

I

Coolant Leaks

--

I

I

I

I

Spark Plug Condition

93

I

I

I

R

I

Exhaust Pipe

101

I

I

Exhaust Retaining 

Springs

101

I

I

I

I

86

MAINTENANCE

Periodic Maintenance Interval Table

Item

See 

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

BRAKES

Hose Routing

--

I

I

I

I

Hose Condition

--

I

I

I

I

Fluid Leaks

--

I

I

I

I

Brake Pads

103

I

I

I

I

Brake Disc

--

I

I

I

I

Parking Brakes

65

I

I

I

I

Brake System

64, 

103

I

Brake Fluid

104

R

FUEL MANAGEMENT

Pilot Air Screws

--

I

I

I

Carburetor 
(synchronize)

96

I

I

I

Idle RPM

--

I

I

I

Throttle Lever

79

I

I

I

I

I

Oil Pump Lever 
(synchronize)

--

I

I

I

Throttle Cable

89

L

L

L

Choke Cable

89

L

L

L

Choke

89

I

I

I

Vent Lines

--

I

I

I

I

Throttle Position 
Sensor

--

I

I

I

Fuel Lines

95

I

I

I

I

I

Fuel Filter

95

R

R

Oil Filter

94

R

R

Oil Lines

94

I

I

I

Air Box

--

I

I

I

I

I

Drain and Water Traps

97

I

I

I

ELECTRICAL

Auxiliary Shut-Off 

Switch

68

I

I

I

I

I

Throttle Safety Switch

78

I

I

I

I

I

Ignition Switch

--

I

I

I

I

I

Taillight

68

I

I

I

I

I

Brakelight

68

I

I

I

I

I

Headlight

68

I

I

I

I

I

87

MAINTENANCE

Periodic Maintenance Interval Table

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean

R - Replace

L - Lubricate

Item

See 

Page

Frequency

150 mi.

(240 km)

500 mi.

(800 km)

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

CHASSIS

Ski Toe Alignment

--

I

I

I

Suspension Mounting 

Bolts

--

I

I

I

I

I

Steering Fasteners

--

I

I

I

I

C

Rear Suspension Fas-

teners

--

I

I

I

I

I

Suspension Shock Oil

--

I

I

I

I

Cooling Fins and 

Shroud

--

I

I

I

I

Drive Shaft Bearing

89

L

L

L

I

Jackshaft Bearings

122

L

L

L

I

Skags (Wear Bars)

119

I

I

I

I

I

Ski Saddle/Spindle 

Bolts

--

I

I

I

I

I

Drive Chain Tension

102

I

I

I

I

I

Hood Latches

67

I

I

I

I

I

Rear Wheel Idler Bolts

115

I

I

I

I

I

Idler Bolt Jam Nut

115

I

I

I

I

I

Rear Suspension Pivot 

Shafts

88

L

L

L

Camber Alignment

--

I

I

I

Handlebar Centering

--

I

Tether Switch and Strap

68

I

I

I

I

I

Track Alignment

116

I

I

I

I

I

Track Tension

114

I

I

I

I

I

Front Limiter Strap

--

I

I

I

I

I

Rail Slide Condition

120

I

Chaincase Oil

90

I

I

I

R

I