06 Fusion 600HO
- Thread starter tundrahog
- Start date
Dealer in munising had 2 when I called a few weeks ago. I didn't end up needing it.
Good to know. Those stupid things got pricey didn't they! I replaced mine right when Polaris introduced the updated part - they offered it for about $90 then - I think because they knew the original one was junk. Now I think they are about $230.
Is the one you are replacing the one behind the motor or on the belt guard? If on the belt guard, let me know. I could use the plastic electrical clips off your dead one, since they are broke on mine (belt blew and broke the clips).
indy_500
Well-known member
Yup polaris has us by the balls. Thats why I try to build or make my own of anything I can really getting quite sickening.
polarisrider1
New member
I bought one in 97. It cost $12.85 for a voltage regulator back then.
Since we're complaining, it seems like the price has gone up so it can power the fancy gauges. All I really need is a temp gauge, tach and odometer. The better lights are part of that too, I guess, and those are nice.
I'm going to assume the regulator on your 06 RMK is the original and is the same as an 06 Fusion. The original regulator is mounted behind the engine/in front of the gas tank. It has 2 electrical clips coming down off it on the chaincase side. Disconnect those. These are automotive-type clips. You might need a small screw driver or an adjustable pliers to disconnect them. You WON'T be removing the old regulator - it is far too buried anyway.
The new regulator installs on the aluminum belt guard. The instructions should show you about where to put it - you want to try to position it so you can still also carry a spare belt there. It installs with 2 bolts, I think. I can't remember, but it may have come with rivets and I may have gone out and bought small bolts to install it. So to install this, assuming it comes with bolts, you'll need a drill to drill 2 holes and then something to tighten the bolts with. You then have to route the wiring harness through the engine/carb area to plug it back into the sled. Watch where you run them to keep them away from the exhaust.
I think the instructions indicated you should remove the old regulator but I saw no reason to do that - you're talking quite a bit of work to do so. Also, the instructions may have said to relocate the spare belt clip to a different spot on the belt guard, but I don't think I did that either. I didn't take the exhaust out of the way, but that might make it easier.
So for tools I think you need a small screwdriver, pliers, wrenches to tighten down the bolts on the regulator (not sure on size), and possibly but probably not a rivet gun. You might want some tie straps to keep the wiring harness ran where you want it. Overall, very simple job.
allen_shores
New member
Ok new to me 06 Fusion 600. it has been fine all winter. start it up this morning and no lights or speedometer, but sled runs fine. Pull into garage and turn hand warmers off and everything comes back on. I can see that if I turn hand warmers on high that the lights dim. I'm guessing it the regulator. It already has the one on the belt guard.
I don't know but I wouldn't be surprised. For me the lights and gauge cut out. Can't remember if warmers were affected.
One way to check is to unplug the regulator at idle. If everything comes back on OK, it is the regulator. Don't rev it unplugged though, you will blow something
Had almost the exact thing happen but only the lights went dim. Found out I had a short in the wiring on the right side handwarmer. replace handwarmer and have'nt had a problem since.
how did you find the short ?heading up north this weekend to install new voltage regulator
i had brought it to a dealer and the first thing they did was replace the controller unit on the left side handle bar area but did not fix the problem. They finally pulled the hand warmers off and found the short. Apparently it burnt a very small hole thru the rubber sheath around the wiring on the handle bar itself. They replaced it and I was good to go. Hope this helps. Also my hand warmers were not getting very warm. Luke warm at best.
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Did you just put a new belt on it? Sounds like you might need to adjust your belt deflection.
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Did you have to buy the new left hand control unit? Do you still have the old one?