Target Audience:
Polaris dealership technicians, independent repair shops, and knowledgeable snowmobile enthusiasts.
Manual Value Proposition:
Provides factory-level diagnostic and repair information, crucial for maintaining optimal performance and longevity of the XLT Touring model.
Original Publication:
Authored and published by Polaris, ensuring accuracy and completeness.
Engine Service:
Detailed procedures for engine disassembly, inspection, assembly, troubleshooting, and repair.
Fuel System:
Carburetor adjustment and rebuilding, fuel pump operation, fuel line maintenance.
Ignition System:
Spark plug specifications, ignition coil testing, CDI unit troubleshooting.
Cooling System:
Coolant types, radiator maintenance, fan operation.
Drivetrain:
Chain case service, drive clutch and driven clutch maintenance, belt inspection and replacement.
Suspension Steering:
Front and rear suspension component inspection, lubrication, and replacement; steering system service.
Braking System:
Brake caliper service, brake fluid replacement, brake pad wear limits.
Electrical System:
Wiring diagrams, lighting system troubleshooting, battery maintenance, starter and charging system diagnostics.
Body Chassis:
Body panel removal and installation, seat maintenance, track system inspection.
Routine Maintenance:
Oil changes, lubrication points, filter replacements, spark plug gapping.
Troubleshooting Diagnostics:
Step-by-step guides for identifying and resolving common operational issues.
Component Rebuilds:
Detailed instructions for rebuilding carburetors, clutches, and other key components.
Technical Specifications:
Torque values, clearances, fluid capacities, electrical resistance readings.
Depth Of Coverage:
Expert level, designed for dealership technicians and certified mechanics.
File Format For Digital Version:
N/A (Original is printed)
Print Quality Of Original:
High quality, professional printing.
Binding Type Of Original:
Likely perfect bound or saddle-stitched for durability.
Paper Type Of Original:
Durable, likely coated paper to resist workshop grease and moisture.
Engine Type:
Liquid-cooled, 2-stroke, 3-cylinder
Engine Displacement:
Approximately 694cc (for the XLT Special, Touring typically uses similar engine families).
Bore X Stroke:
Specifics available in manual (e.g., typically around 72mm x 57mm for this engine class).
Compression Ratio:
Specifics available in manual.
Horsepower Output:
Approximately 95-105 HP (typical for this engine configuration).
Torque Output:
Specifics available in manual.
Carburetor Configuration:
Triple Mikuni VM series (e.g., VM34 or similar).
Fuel Type:
Unleaded gasoline, typically 87 octane.
Oil Injection:
Autolube system.
Transmission Type:
CVT (Continuously Variable Transmission) with Polaris's P-85 drive clutch and an Arctic Cat/Polaris driven clutch (e.g., Auto-Drive).
Optional Transmission:
N/A for this model year and configuration.
Clutch Engagement Rpm:
Specifics available in manual, typically around 2000-2500 RPM.
Clutch Shift Rpm:
Specifics available in manual, typically around 7000-7500 RPM.
Instrument Cluster:
Analog speedometer, tachometer, temperature gauge, fuel gauge, and indicator lights.
Choke Control:
Manual choke lever for cold starts.
Charging System:
Stator and voltage regulator for powering electrical systems and charging the battery.
Initial Break In Service:
Typically around 500 miles or 20 hours, including clutch adjustment and thorough inspection.
Engine Oil Change Interval:
Not applicable to 2-stroke, oil is mixed with fuel or injected separately.
Drive Belt Inspection:
Recommended every 500-1000 miles or annually.
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water.
Chaincase Oil Type:
Polaris specified gearcase oil or equivalent SAE 80W-90 gear oil.
2 Stroke Oil Type:
High-quality, synthetic blend 2-stroke snowmobile oil meeting API TC or JASO FD standards.
Clutch Wear:
Typical wear on drive and driven clutch buttons and rollers; clutch alignment is critical.
Carburetor Cleaning:
Tendency for jets to clog if fuel is not fresh or if stored improperly.
Recoil Starter Issues:
Recoil starter mechanism can wear out over time.
Track Tension:
Proper track tension is vital to prevent premature wear on track, bearings, and suspension components.
Polaris History:
Polaris has a long-standing reputation as a leading snowmobile manufacturer, known for innovation and performance.
Xlt Touring Placement:
The XLT Touring was part of Polaris's performance and touring-oriented line-up in the mid-1990s, emphasizing comfort and capability for longer rides.
Production Era:
Mid-1990s, a period of significant development in snowmobile technology.
