06 Fusion 600 -explanation for blown engine...does this make sense?

[Hoosier]

My sled locked up a few weeks back, and I had it repaired by a Polaris mechanic that my father-in-law knows well. The engine needed pretty much a total rebuild. Below is the explanation I got from the mechanic. I'm not the most mechanical guy, so I wanted to put this out there to see if it makes sense:

There's a part called a carb adaptor, which is a rubber boot that attaches to the cylinder. This cracked and allowed an air leak into the cylinder. Air cause the sled to run lean which ate away at piston and ring broke. Debris got down into crank, causing bearing to fail. Bottom line, crank needed to be rebuilt.

Does that all make sense?

By the way, the carb adaptor is now an updated part (as was the voltage regulator I replaced earlier in the season). All these updated parts that aren't recalled makes me really down on Polaris. Love riding it, but if you're going to update the part, you might want to recall it also.

[dab102999]

Yep that will do it for sure.

[vic_junior]

Sounds right! It sucks that this happens, I replaced mine immediately when I started seeing signs of cracking. Didn't matter, a while later the crankseal went and the motor was sucking in more air and I burnt down a piston that way. Good time to add some mods or replace just about everything in the motor, so she is good as new.

[tgun]

Your boot shsould have been part of the updates. I check my carb boots everytime I clean the carbs. Give everything the once over.

I had to replace my VR as well. Funny thing is you talk to alot of people who have replaced thier VR's but the dealers I talked to said they have never sold one.

[Hoosier]

That's funny tgun - I called two different dealers about the VR, and it's like they had no idea it's a common problem.

Just gotta laugh about the Fusion and Polaris in general. I've never rode a sled so fun, but I don't think Polaris gives a hoot about the consumer.

[xcr440]

but I don't think Polaris gives a hoot about the consumer.

Really, a cracked carb boot causes a burn down and Polaris don't give a hoot?

Huh.

[Hoosier]

Question about the update - my sled has been at a few different dealers in the time I've owned it. The first time, I called the dealer it came from right after I bought it to see if any updates needed to be done. The second time, for the gas tank update (different dealer). The third time, for the chain case bracket update (another dealer). I know that each checked for updates. The carb boot never came up. I just googled the problem, and it's obvious this has been a problem and that an update existed.

I'll ask the dealer where it's now at, but since the update never came up, does this likely mean that the update was already done? I can't imagine all three dealers passed up the service money. I doubt I have any recourse against anyone, but I thought I should check.

[ybpigs]

iusmit,
The carb boot was a replacement part along with the gas neck filler and the chaincase bracket. I had all three done to my sled.
I did have the same problem as you right before Christmas of this year where my sled went down and it was the piston. My dealer told me it was caused by a bad carb boot leaking air. I didnt have the crank go bad on me, but it was still $850 to have fixed. I think next time I might try fixing it myself.

[doomsman]

Polaris "nothing wrong with the boots, VR's"
Toyota "nothing wrong with the accelerators"

They do nothing till there is a screaming uprising.

[indy_500]

exact same flippin thing that happened to my 99 indy 500. chunk of the ring is broken off, cylinders nice and scratched up. except for my crank seal went out instead of a carb boot. basically the same concept...to hold in air.

[Hoosier]

Indy - did you have to get the crank rebuilt?

[indy_500]

Indy - did you have to get the crank rebuilt?

i forgot to add, my crank bearing went shot, the crank needs to be rebuilt, the cylinders need to be bored out, and needs 2 new pistons and a crank seal and it would be good to go. but i dont' have the money to stick into a backup sled so i'm going to part it out. it's not for sale on craigslist anymore because some dumbazz flagged my ad and it got removed

[Skylar]

I would keep checking on the update/recall for the carb adapters, or carb boots as I call them. I had them replaced on my 07, and my buddy had them replaced on his 06 Switchy. Always check them before every season, I just put another set on mine in January.

By the way, I had to replace them on my 05 Renegade 600sdi, twice, and so did my brother on his 04 600SDI.

[tgun]

Skylar

Did your replacements crack or do you replace every year to be safe? Thanks

[Skylar]

Yep, replacements cracked, well I would call it delaminating. The rubber was peeling away from the metal that they are glued to.

[polarisrider1]

I have a 1972 Polaris with original carb boots, they look like new. I had carb boots cracked to the edge of thru on a 06 IQ RMK after one yr. I caught it while under warranty. What gives with that? Dealer said no recall on them, yet they are changing a lot of them. The way it has been explained to me as "Updates" are things that need to be fixed and they come out on Manufacturers service bullitens and are not required to notify consumers. "Recalls" are of a safety issue and MUST contact consumers of it. So I ask every time I step into the dealership, "Are there any new updates on my sled?" But it does tick me off about the carb boots, this is a guarenteed "melt down" if tear goes all the way through and sled "leans out".

[elf]

Funny timmg for this thread. I was just changing the jetting back on my 06 600 to get it ready to sell to a friend and I notiiced the boot was cracked. Mine did have the update done in 07 but I guess it's time to do them again. Glad I noticed it before I sold it as I think it would have had problems soon.

[indy_500]

my carb boots on my indy 500 have cracks all over them but not tears that leak any air. my old indy trail had the same miles and never had a crack on the carb boot. What exactly besides your guys' 06 poo problem would cause a carb boot to go bad? just because of how old it is?

[toolie]

Funny timmg for this thread. I was just changing the jetting back on my 06 600 to get it ready to sell to a friend and I notiiced the boot was cracked. Mine did have the update done in 07 but I guess it's time to do them again. Glad I noticed it before I sold it as I think it would have had problems soon.

I wouldn't be surprise if the dealers are putting on the old carb boots and not the updated one's cause their to stupid to look at the updated PN#'s

[Hoosier]

I understand stuff breaks. What I don't understand is how I've had two trips screwed up this year because of parts that have been updated. The first was with the voltage regulator, then the 2nd was because of the carb boot. Maybe I'm just repeating myself, but Polaris has to do a better job of helping to get known problems fixed ahead of time.

The two guys I ride with each have over 9000 miles on their sleds - one is an 02 XC600, and the other is an 05 Saberkitty 700. Mine has about 2900. Neither of them had any issues. Oh well. There's always next year.

[sxrron]

A good way to check to see if your carb boots are leaking is to spray starting fluid around them with the sled running. If the idle increases you most likely have a leak.

[jimfsr]

my carb boots on my indy 500 have cracks all over them but not tears that leak any air. my old indy trail had the same miles and never had a crack on the carb boot. What exactly besides your guys' 06 poo problem would cause a carb boot to go bad? just because of how old it is?

lots of factors... on the ski doo 600's it was a weight issue with the carbs and airbox not supported real well. Also corrosion of the alum mount plate at the rubber boot joint on the 800's. The ethanol in the fuel is a killer on rubber too. Mostly heat and vibration though, and the thinner boots compared to the old days when they were 1/4" thick.

[indy_500]

lots of factors... on the ski doo 600's it was a weight issue with the carbs and airbox not supported real well. Also corrosion of the alum mount plate at the rubber boot joint on the 800's. The ethanol in the fuel is a killer on rubber too. Mostly heat and vibration though, and the thinner boots compared to the old days when they were 1/4" thick.

of course, lets make everything weaker eh!

[srt20]

I had the intake boot come apart on my 08 700 last year. Polaris basically put a new motor in my sled. One head was reused. The rest was new. All on Polaris's dime. Oh and I got the updated intake boots. Dont worry this happens to SKI-DOO's also.

[toolie]

I had the intake boot come apart on my 08 700 last year. Polaris basically put a new motor in my sled. One head was reused. The rest was new. All on Polaris's dime. Oh and I got the updated intake boots. Dont worry this happens to SKI-DOO's also.

So in other words polaris has not learned from there mistakes. Why offer an update if they still fall apart. I am confused.