2005 Polaris 500 XC SP 600 XC SP 700 XC SP 800 XC SP 900 FUSION Factory Service Repair Manual

Prix habituel: $16.99
Prix soldé: $16.99
Prix habituel
Prix unitaire: par

15 people are viewing this right now

Taper: Atv

Distributeur:

UGS: 146548

Mots clés: 2005 Atv FUSION 900 Polaris Powersports Snowmobiles XC Models XC SP 500 XC SP 600 XC SP 700 XC SP 800

Variantes de produits

Description

The 2005 XC SP and Fusion series represent high-performance crossover snowmobiles engineered for versatility across varied terrain. These models, powered by robust Liberty 2-stroke engines ranging from 500cc to 900cc, offer a compelling blend of power, advanced suspension systems like the R.A.S. front suspension, and durable chassis construction. Designed to compete in the performance crossover segment, they provided riders with exceptional handling, comfort, and capability for both trail riding and off-piste adventures, building on a long heritage of innovation in powersports. This factory service repair manual provides comprehensive, factory-level technical information essential for the maintenance and repair of the 2005 XC SP and Fusion series snowmobiles. It covers all critical systems, including detailed procedures for engine service, clutch calibration, brake and suspension systems, steering, and the complete electrical system with wiring diagrams. The manual is structured to guide owners, mechanics, and technicians through routine maintenance, troubleshooting common issues, and performing in-depth repairs, ensuring the longevity and optimal performance of these vehicles.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

XC SP (500, 600, 700, 800), Fusion (900)

Model Year:

Codes

Chassis Codes:

XC SP Series, Fusion Series

👋 Introduction

Market Position

Market Position:

These models were positioned as high-performance, versatile crossover snowmobiles, excelling in both groomed trail riding and off-trail excursions. They targeted riders seeking a balance of power, handling, and comfort.

Competitive Analysis

Competitive Analysis:

Competed directly with models like the Ski-Doo Summit, Arctic Cat M-series, and Yamaha Phazer. Polaris's advantage often lay in its Liberty engine technology and its innovative R.A.S. suspension systems.

Key Features

Key Features:

Powerful Liberty twin-cylinder engines offering robust performance across various displacements, the advanced R.A.S. (Riding Annulment System) front suspension for superior handling and reduced rider fatigue, and a comfortable, well-balanced chassis designed for all-around riding.

📋 Manual Details

Coverage Areas

Coverage Areas:

Global

Page Count

Page Count:

Unknown (Digital Manual)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine (500, 600, 700, 800, 900cc Liberty engines), Fuel Delivery (carburetion, fuel pump, lines), Clutching (primary/drive clutch, secondary/driven clutch, belt replacement, calibration), Final Drive (chaincase, gears, lubrication, reverse mechanism), Brake System (hydraulic lines, calipers, master cylinder, pads, rotors), Steering (handlebars, steering post, tie rods, skis), Front Suspension (R.A.S. system, A-arms, ball joints, shocks, skis), Rear Suspension (Pro-Ride, coupled systems, torsion springs, shocks, track drive), Chassis (frame integrity, body panels, seat, snow flap), Electrical System (ignition, lighting, starter, battery, charging system, CDI, sensors), Wiring Diagrams (detailed schematics for all electrical components).

Procedures Included

Procedures Included:

Engine tune-up procedures, cylinder head removal, piston and ring replacement, crankshaft and bearing inspection, transmission gear inspection and replacement, clutch assembly and disassembly, brake caliper rebuild, steering linkage adjustment, suspension alignment, shock absorber service, electrical component testing, troubleshooting common electrical faults, fault code diagnosis (if applicable), routine maintenance scheduling, and detailed torque specifications for all critical fasteners.

Technical Depth

Technical Depth:

Comprehensive factory-level service information suitable for professional technicians and experienced DIY mechanics. Includes detailed diagnostic procedures, specifications, tolerances, and repair techniques that ensure factory-level quality repairs.

📊 Manual Specifications

File Format

File Format:

Searchability:

High - designed for efficient navigation and quick access to specific information through keyword searches.

Print Quality

Print Quality:

High-resolution, suitable for clear digital display and high-quality printing of individual pages or the entire manual.

Binding Type

Binding Type:

Not Applicable (Digital Delivery)

Paper Type

Paper Type:

Not Applicable (Digital Delivery)

Accessibility

Accessibility:

Digital delivery with instant download, offering immediate access without shipping delays or costs.

⚙️ Engine Specifications

Primary Engine

Primary Engine:

Polaris Liberty 2-stroke, liquid-cooled twin-cylinder engine family.

Engine Variants

Engine Variants:

500cc, 600cc, 700cc, 800cc (XC SP models), and a 900cc engine for the Fusion 900. Exact displacement and bore/stroke figures are provided in the manual.

Performance

Performance:

Horsepower ratings would typically range from approximately 80-90 HP for the 500cc to over 120 HP for the 800cc models. Torque figures are also detailed. Specific performance data for each engine is in the manual.

Fuel System

Fuel System:

Typically featured Mikuni VM series carburetors (e.g., VM34 or VM38) for most models, with specific jetting, needle settings, and float bowl adjustments detailed in the manual. Some higher-performance variants might feature EFI.

Ignition System

Ignition System:

CDI (Capacitor Discharge Ignition) or similar electronic ignition system, with detailed diagnostic procedures in the manual.

Cooling System

Cooling System:

Liquid-cooled, with radiator and fan configurations specified for each model. Coolant type and capacity are detailed.

🔧 Transmission

Standard

Standard:

CVT (Continuously Variable Transmission) featuring Polaris's proprietary P-85 drive clutch and a compatible driven clutch (e.g., P-90 or similar). Belt-to-belt ratio changes provide seamless acceleration.

Optional

Optional:

Not applicable for this model year and series.

Features

Features:

Clutch calibration for optimal performance in various conditions (e.g., clutching kits for altitude or specific riding styles). Maintenance includes belt inspection, tension adjustment, and clutch alignment. Gearbox for reverse is typically a manual engagement system.

📐 Dimensions

Exterior

Exterior:

Overall length, width, and height are model-specific. For example, typical lengths could be around 116-120 inches, with widths around 47-49 inches. Specifics are in the manual.

Weights

Weights:

Dry weights generally ranged from approximately 450 lbs for smaller engines to over 500 lbs for larger displacement models. Operating weight would be higher with fluids and track installed.

Track Dimensions

Track Dimensions:

Track length, width, and lug height vary by model and are crucial for performance and traction. Standard configurations often featured 136-inch tracks with varying lug depths.

🛡️ Safety Features

Active Features

Active Features:

Hydraulic disc brake system providing reliable stopping power. Pro-X front suspension geometry for enhanced stability and control during cornering and uneven terrain. Handlebar-mounted throttle and brake controls for intuitive operation.

Passive Features

Passive Features:

Durable chassis construction, integrated handguards to protect from elements and impact, and a comfortable seating position that allows for rider balance and control.

💡 Technology Features

Infotainment

Infotainment:

Basic analog instrumentation cluster with speedometer, tachometer, odometer, trip meter, and warning lights for critical systems like low oil or engine overheat. No digital displays or advanced audio systems.

Driver Assistance

Driver Assistance:

The primary 'assistance' comes from the advanced suspension designs (R.A.S. front, coupled rear on some models) which actively improve handling and rider comfort by absorbing terrain irregularities.

Connectivity

Connectivity:

No electronic connectivity features such as Bluetooth, GPS, or smartphone integration are present on these models.

🔧 Maintenance

Service Intervals

Service Intervals:

Key intervals include checking and adjusting the drive belt tension every 500 miles or annually, inspecting and cleaning the air filter every 1000 miles or as needed, spark plug replacement every 2000 miles or annually, and checking brake fluid levels and pad wear regularly. Comprehensive service schedules are detailed in the manual.

Fluid Specifications

Fluid Specifications:

Engine oil: Polaris 2-Stroke Synthetic Oil or equivalent API-TC certified oil. Coolant: Polaris Anti-Freeze/Anti-Boil (ethylene glycol-based) or equivalent. Brake Fluid: DOT 3 or DOT 4. Chaincase oil: Polaris Chaincase Lubricant or equivalent 75W-90 gear oil.

Known Issues

Known Issues:

Common maintenance points include ensuring proper lubrication of suspension and steering components, checking for coolant leaks, and verifying clutch alignment. Carburetor jetting might require adjustment based on altitude and temperature, which the manual covers.

Lubrication Points

Lubrication Points:

Grease fittings on suspension pivots, steering column, throttle cable ends, and clutch shaft bearings require regular lubrication as per the manual's schedule.

Filter Part Numbers

Filter Part Numbers:

Specific part numbers for air filters, fuel filters, and any oil filters (if equipped) are crucial and detailed within the manual for easy replacement.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Polaris Industries has a strong legacy in powersports, particularly in snowmobiles, dating back to the mid-1950s. They are recognized for innovation in engine technology and suspension design.

Model Evolution

Model Evolution:

The XC SP series was a highly popular line that evolved over several years, focusing on crossover performance. The Fusion 900 represented a new chassis platform for Polaris, incorporating advanced technologies for improved rider experience and handling.

Production

Production:

Manufactured by Polaris Industries in the United States during the 2005 model year. These machines were built to be durable and high-performing for their intended use.