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Old 04-03-2005, 06:31 PM   #1 (permalink)
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1996 Polaris XLT Touring no power

I bought a 1996 Polaris XLT Touring (600cc triple) about 2 months ago and it hasn't run properly from day 1. Initially it would run great one day and produce lots of power the next day I couldn't get it to go over 30 km/h. It finally got so bad that it can't even pull me now. I've changed the fuel filter, cleaned out the carbs, changed all the plugs a couple of times. It's producing good spark on all 3 plugs and the compression is 117 - 120 on all cylinders. It seems to be burning a lot of oil and it's a real hog on gas when it was running ok (about 10 gallons of gas for 50 miles of trail riding). Anyone have any idea's of what could be the problem??

I almost forgot to mention that it starts and idles great.\
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Old 04-03-2005, 08:36 PM   #2 (permalink)
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Obviously an overfuel problem. Try rebuilding the fuel pump(s)?
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Old 04-04-2005, 07:29 AM   #3 (permalink)
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Forgot to mention I rebuilt the fuel pump last week, still no change.
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Old 04-04-2005, 10:00 AM   #4 (permalink)
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Did you set the float height in the carbs when you cleaned them?
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Old 04-04-2005, 01:14 PM   #5 (permalink)
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I didn't set the float height. How do I set them, and what should they be set to? I'm also going to try removing the muffler and see if that helps. I figure the muffler might be plugged from burning too much oil, thereby robbing me of power. Thanks for all the help.
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Old 04-04-2005, 02:03 PM   #6 (permalink)
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Remove the carb. Take the bowl off and measure from the gasket surface to the brass flapper thing that the floats touch while the carb is upside down. There should be 23 to 25 mm from the gasket surface to that flap.
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Old 12-09-2005, 10:44 PM   #7 (permalink)
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I finally got back to working on my sled. I reset the floats and it hasn't helped much. The floats were set too rich. It's able to pull me now but not much about 10 mph. Where's the next logical thing to check? I'm looking at changing out the needle jet next. Any one have any other ideas. Thanks for the help.
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