Fusion MPH digital gauge not working

**Ollie** · 02-10-2010, 07:00 PM

I have a polaris 600 Fusion and the digtial Gauges stop working. Wondering if anybody had this problem not sure if the Battery controls this or not. when you first strat the sled in the morning it works for a couple of seconds. Headlights and tail lights work fine. Anybody have some suggestion

**gbruner** · 03-22-2010, 08:20 AM

my gague cluster went out completly. Head light works but no digatal gauge or mechanical speedo/Tach

**Wiscdave** · 03-30-2010, 07:23 AM

Confusion about the Fusion?

Unfortunately those sleds have way too many issues.

**RMKrick** · 01-02-2011, 12:38 PM

Have you looked to see if your bearing is out? Or the little electronic speedo is out. They are both down by the secondary clutch..

**PAULARIS600** · 01-03-2011, 03:13 AM

Originally Posted by Wiscdave

Confusion about the Fusion?

Unfortunately those sleds have way too many issues.

6,000 trouble free miles on mine.

**crush4size** · 01-03-2011, 05:16 PM

mine is an 06 600 HO Switchback, I think it shares common hardware in the analog/digital gauge cluster. I have traced mine to either a harness connection, or voltage regulator, or both.
This started earlier in the week, the gauge would work on start-up then quit after engine RPM's were raised high enough to engage the clutch. So I drove around with no tach or speedo, however the high beam, reverse, and brake indicator lamps function normally, as well as all the lighting.
I started troubleshooting this morning, and first off managed to make it not work at all. After re-seating some harness connections got it to power up again. With the RPM's being displayed on the LCD the display would jump around at idle. By holding the hood to chassis harness connector I could get the display to settle, but it as engine RPM's increased to about 3k the display would go dark, and come back to life when the engine returned to idle.
Does anyone out there have the test procedure for the voltage regulator? It acts as though the voltage regulator is clamping current for the display, however I don't have a service manual, and don't know for sure what the voltage level should be for the display. I have to start eliminating possibilities...

**crush4size** · 01-03-2011, 06:10 PM

I forgot to mention the brake indicator lamp on the MFD (multi-function display) or "gauge" is always on. I attributed this to a malfunctioning brake switch, which I have learned to be WRONG.
I should also mention I have since referenced the wiring diagrams and the brake tail lamp function is normal.
The brake tail lamp and voltage regulator are wired in parallel???!??!! Yes, it sounds odd, the schematics label the voltage regulator with something called "AC Brake Signal" and "DC Brake Signal". The ac brake signal comes from the brake lever switch, the dc brake signal goes to the MFD brake lamp. AC input from switch, DC output to gauge.
I wish I had smaller hands and wrists so I could reach the voltage regulator easier...
Time to plod out into the cold and do some chassis diagnostics...stay tuned folks, this is getting interesting!

**sjm700** · 01-03-2011, 09:52 PM

I have both a 600 and 700 fusion and they are both giving me problems but diferent ones. My wifes 600 cluster stated acting up but havent looked at it yet. Need to get my 700 back together first from the stator change. Let us know what you find out. I cant believe polaris put out these junk sleds. I have been finding all kinds of problems with them both that shouldnt happen with under 3000 miles on them

**crush4size** · 01-05-2011, 11:12 PM

I finally got back out into the shop tonight. After some minor dis-assembly (air box, pipe & muffler) I was able to get my hands and a side cutter into the chassis to snip some zip ties and unlatch some wiring loom holder downer thingys.
Careful review of the schematics pointed me in the direction of dc power and/or ground to the MFD, both of which are spliced withing the wiring loom. The splices were not the problem, but there location within the loom helped me find the problem.
The chassis harness loom "branches" to the regulator, that branch was covered with the standard flexible loom tubing. The "tee" where the branch connected to the main harness was rubbing against the motor mount strap. The loom had pushed away and allowed 3 wires to contact the mount strap, wearing through the insulation and conductors. One wire was the DC ground wire - that is why the MFD would intermittently work - it was worn completely through. Another was the AC brake signal - the brake switch opens and closes the path to ground for the lamp and the brake signal - that was obviously grounded. The third was AC power, that wire was still in tact, but it was grounding to the strap.
The connection point of the main harness and tee to the voltage regulator is behind the coolant line to the heat exchanger. It took a bit of work to get these wires exposed for repair.
I re-routed the voltage regulator connector so the wires pass between the cooling line and the bulkhead rather than the cooling line and the motor mount strap. I will have to keep a close eye on this as it is closer to the muffler routed this way.
Sjm700 I Hope this helps you troubleshoot your MFD woes.
I have posted some pictures of this on my profile.

**Ollie** · 01-16-2011, 09:00 PM

I finally took the fusion in to the dealer to have the speedo fixed. The Tech at the dealership said there were problems with wiring being zip tied to the frame and wires to get rubbed through. that wasn't the trouble the box went out only on the side that supplied the power to the speedo. they replace the box and all is fine. I bought this Fusion new and have 7,000 miles on and this was the only problem that I had with it.