The 2006 Polaris Fusion 900 is a powerful sled, but with a few modifications, it can become a true trail and off-trail performer. This article details the customizations and performance enhancements done to a 137″ converted 06 Fusion.
Engine and Fuel System
This 06 Fusion runs with stock carbs, utilizing .7 paj (pilot air jets) instead of the factory .6’s, and fuel screws adjusted to 1.25 turns out from the standard 1.5 turns. This richer setting, especially noticeable on the pilot circuit, will be further refined next season. Smaller pilot jets (one size down) and main jets (two sizes down) are planned if the stock exhaust remains. An SLP exhaust system is available, providing noticeable performance gains, however, fitment issues require significant heat shielding modifications to prevent melting surrounding components.
Air Intake
The SLP air box modification, while not adding horsepower, significantly improves ease of installation and eliminates the frustration of wrestling the airbox into place. This $40 upgrade is highly recommended.
Clutching and Ignition
Clutching remains stock, providing optimal performance across various conditions. The ignition timing remains untouched and at factory settings.
Gearing
Switching to a 22/40 gearing ratio is a standout modification, transforming the 06 Fusion into a nimble and responsive machine, especially in corner-to-corner riding.
Cooling System
Despite experimenting with a series configuration, the cooling system retains its parallel setup, showing no significant temperature difference. Relocating the rear cooler to the snow flap resulted in a noticeable decrease in operating temperatures, maintaining a consistent range instead of frequently reaching 140-150 degrees on packed trails.
Suspension and Track
The suspension remains stock, with regular shock servicing every other season to accommodate a rider weight of 350 lbs. A significant upgrade is the 1.6″ x 137″ Ice Cobra track, requiring IQ RMK drivers for installation. This track delivers exceptional performance both on and off-trail.
Skis and Steering
Polaris Gripper skis equipped with Stud Boy Shaper carbides provide excellent handling on and off-trail. Steering enhancements include an ’07 IQ fixed steering post mount and cover, a Powermadd pivoting bar riser adapter with a 4″ riser, Pro-X straight handlebars and bar pad, and Polaris handlebar hooks.
Accessories
Essential accessories include a Polaris tether, a Garmin 62c GPS with a RAM mount attached to the steering post cover, a Skinz windshield bag and knee pads, a Sled Solutions Carry All, and an 11″ black Polaris windshield. These additions enhance both functionality and rider comfort.
Conclusion
This customized 06 Fusion demonstrates how strategic modifications can significantly improve performance and handling. The combination of gearing changes, track upgrade, and thoughtful accessory choices results in a versatile and reliable sled for both trail riding and off-trail adventures. This Fusion remains a top performer and a testament to the platform’s potential for customization.
