Snowmobile Polaris 600 Fusion (2006 year). Manual - part 26

104

MAINTENANCE

General Maintenance

Brake Fluid

The brake fluid level can be seen through a plastic sight glass in the 

brake reservoir.  If the fluid is sufficient, the sight glass will be black.  If 

the sight glass is any color other than black, add brake fluid.

Replace brake fluid at least every two years with Polaris DOT 4 high 

temperature brake fluid.  See page 124 for the part numbers of Polaris 

products.

WARNING

After opening a bottle of brake fluid, always discard any unused portion.  

Never store or use a partial bottle.  Brake fluid is hygroscopic, meaning it rap-

idly absorbs moisture from the air.  The moisture causes the boiling tempera-

ture of the brake fluid to drop, which can lead to early brake fade and the 

possibility of accident or serious injury.

WARNING

Keep the master cylinder cover free of dirt and debris. The vent slits allow for 

diaphragm movement, and if they become plugged, movement of brake fluid 

below the diaphragm may be restricted, altering brake function.

CAUTION

Brake fluid will damage decals, paint and some plastics.  Always wipe up 

spills immediately.

105

MAINTENANCE

General Maintenance

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.  

Bleed the system before operating the snowmobile.

During the bleeding procedure, keep the brake handle as level as possi-

ble.  The reservoir must be in this position to minimize the possibility of 

air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX 

marks or 1/4-5/16I (.6-.8 cm) below the lip of the reservoir open-

ing.  Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the 

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke.  Then unscrew the bleeder 

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a 

solid stream free of air bubbles.

7. After bleeding is complete, refill the reservoir to the proper level.  

See page 104. 

8. Reinstall the gasket and cover.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes, 

which could cause an accident and lead to serious injury or death.  Never 

operate the vehicle with a spongy-feeling brake lever.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may 

cause the brakes to lock, resulting in serious injury or death.  Always add 

brake fluid to the fill line as recommended.

106

MAINTENANCE

General Maintenance

NOTE: Do not touch a halogen bulb with bare fingers.  Oil from skin 

leaves a residue, causing a hot spot that will shorten the life of 

the lamp. If fingers do touch the bulb, clean it with an alcohol-

moistened towel.

Headlight Bulb Removal

1. Remove the plenum covering 

from the headlight assembly.

2. Lift the rubber boot to expose 

the bulb.

3. Push down on the spring (1) 

to release it from the housing.

4. With the wire harness (2) 

attached to the bulb (3), with-

draw the bulb from the hous-

ing.

5. Grasp the bulb by its metal base and carefully separate the bulb 

from the harness.

Headlight Bulb Installation

1. Hold the bulb by its metal base and install it into the wire harness.
2. Insert the bulb into the housing.
3. Connect the spring to the housing.
4. Carefully flip the spring back into the housing, placing it around the 

wire harness.

5. Reinstall the plenum covering on the headlight assembly.
6. Verify headlight aim.

1

2

3

107

MAINTENANCE

General Maintenance

Taillight/Brakelight Replacement

1. Open the rear storage compart-

ment.

2. Reach into the compartment and 

locate the socket assembly above 

the door opening.

3. Turn the socket counterclockwise 

1/4 turn.

4. Carefully pull the socket assembly 

away from the taillight.

5. Replace the bulb and reinstall the socket assembly.
6. Secure the storage compartment door.