Target Audience:
Owners and technicians seeking detailed maintenance and repair information for the 1996 Polaris Indy XLT Touring snowmobile.
Value Proposition:
Provides factory-level repair data at a fraction of the cost of dealership service, empowering owners to perform their own maintenance and repairs.
Illustrations:
Hundreds of detailed illustrations and diagrams to guide repair procedures.
Readability:
Easy-to-read text presented in a clear, step-by-step format.
Factory Trained Knowledge:
Imparts knowledge typically held by factory-trained technicians.
Covered Systems:
Engine, Fuel System, Ignition System, Clutching, Drivetrain, Suspension, Steering, Brakes, Electrical System, Bodywork, Track System, Cooling System
Type:
Service/Shop Repair Manual
Engine:
Detailed specifications, disassembly, assembly, troubleshooting, and repair procedures for the 1996 Polaris Indy XLT Touring engine.
Fuel System:
Carburetor adjustment, fuel pump operation, fuel line routing, and fuel tank maintenance.
Ignition System:
CDI unit testing, stator and coil specifications, spark plug selection, and ignition timing.
Clutching:
Primary and secondary clutch inspection, roller and spring replacement, belt selection, and clutch calibration.
Drivetrain:
Chaincase lubrication, chain adjustment, bearing inspection, and driveshaft service.
Suspension:
Front and rear suspension component inspection, shock absorber service, and slider rail maintenance.
Steering:
Handlebar adjustment, steering post inspection, tie rod and spindle service.
Brakes:
Brake caliper service, brake pad replacement, brake fluid bleeding, and hydraulic system troubleshooting.
Electrical System:
Wiring diagrams, lighting system troubleshooting, starter motor service, and battery maintenance.
Bodywork:
Panel removal and installation, seat upholstery, windshield replacement, and decal application.
Track System:
Track inspection for damage, tension adjustment, and hyfax slider maintenance.
Cooling System:
Radiator inspection, coolant type and capacity, and thermostat operation.
Maintenance:
Oil changes, spark plug replacement, air filter cleaning/replacement, chain lubrication, track tension adjustment, and general inspection procedures.
Troubleshooting:
Step-by-step diagnostics for common starting issues, power loss, braking problems, and electrical malfunctions.
Repair:
Complete disassembly and reassembly instructions for all major components, including engine rebuilds, transmission overhauls, and suspension repairs.
Technical Specifications:
Detailed torque specifications, clearances, fluid types and capacities, electrical resistance values, and performance data.
Depth:
Comprehensive, covering from basic maintenance to in-depth engine and drivetrain overhauls, suitable for both novice and experienced mechanics.
Engine Type:
Liquid-Cooled, 2-Stroke, Reed Valve
Displacement:
Approx. 698cc (exact configuration varies by specific model variant, typically dual cylinders)
Bore X Stroke:
Not specified in product data, but typically around 72.3 mm x 73 mm for engines of this era/type.
Horsepower:
Approx. 90-100 HP (estimated for the XLT model range of this era)
Torque:
Not specified in product data.
Carburetion:
Twin Mikuni VM34SS Carburetors (typical for this engine configuration)
Fuel Type:
Unleaded gasoline with proper oil mix (pre-mix or Autolube system)
Oil System:
Autolube Oil Injection System (standard for XLT models)
Overall Length:
Not specified in product data, but typically in the range of 105-115 inches.
Overall Width:
Not specified in product data, but typically around 46-48 inches.
Dry Weight:
Not specified in product data, but estimated around 480-530 lbs.
Fuel Capacity:
Not specified in product data, but typically around 8-10 gallons.
Oil Change:
Refer to manual for specific engine oil change intervals based on operating hours or mileage. Typically every 50-100 hours or annually.
Spark Plugs:
Inspect and replace as needed, typically every 1,000-1,500 miles or annually. Consult manual for correct type (e.g., NGK BR9ES or equivalent).
Clutch Inspection:
Inspect primary and secondary clutches annually or every 500-1000 miles for wear on rollers, buttons, springs, and belt.
Track Tension:
Check and adjust track tension before each riding season and periodically during use. Refer to manual for specific adjustment procedures and tolerances.
Engine Oil Type:
2-stroke, high-performance, synthetic or semi-synthetic snowmobile oil, specifically for liquid-cooled engines. Consult manual for recommended brands and API/TCW3 ratings.
Chaincase Oil Type:
SAE 80W-90 GL-4 or GL-5 Gear Oil (check manual for specific viscosity and GL rating). Capacity approx. 8-10 oz.
Coolant Type:
Ethylene glycol-based antifreeze suitable for cold weather, typically a 50/50 mix with distilled water. Consult manual for specific type and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (check manual for precise specification).
Clutch Wear:
Wear on primary and secondary clutch components (rollers, bushings, springs) can lead to poor performance and belt slippage. Regular inspection and maintenance are key.
Carburetor Icing:
Common in cold, humid conditions, leading to rough running or stalling. Ensure proper ventilation and consider carburetor heat kits if issues persist.
Exhaust Valves:
If equipped with powervalves, carbon buildup can cause them to stick, affecting engine performance. Regular cleaning as per the service manual is recommended.
Polariscraft:
Polaris Industries, founded in 1954, is a well-established American manufacturer of powersports vehicles, including snowmobiles, ATVs, and motorcycles.
Indy Series:
The Indy series was a highly successful line of Polaris snowmobiles, known for their performance and versatility. The XLT represented a premium touring model within this lineup.
Manufacturing Location:
USA (Roseau, Minnesota)
Production Period:
The Indy XLT was produced through the mid to late 1990s, with the 1996 model being a significant iteration.
