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1995 Polaris XLT Touring
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Discussion Starter #1
Hi all,

Since I'm back into the sport this year with a 25 year old sled, on top of just repairs I knew I'd have to take on, I want to make sure any preventative pre-season maintenance is done.

So far I've:
  • Replaced the hyfax and inspected all idler wheels and replaced every bearing in the rear, adjusted the track tension to spec when re-installed.
  • Cleaned out chaincase, replaced incorrect chain, tensioned and refilled with fluid.
  • Inspected drive and jackshaft bearings, all are tight and spinning smoothly. (have a replacement kit ready in case driveshaft replacement becomes necessary)
  • Flushed coolant & refilled with fresh premix.
  • Replaced in-line fuel filter & inspected pickup line filter in tank.
  • Will be siphoning out old gas previous owner left in the sled.
  • Greased all zerks on skid, steering and clutch side drive bearings.
  • Removed carbs, cleaning this weekend. Replaced fuel lines from fuel pump to carbs while everything was apart.
  • Cleaned up clutch faces.
  • Topped up brake fluid.
  • Checked ski alignment/steering feel.
  • Adjusted front & rear shock preload & set rear springs to desired level.
  • Compression was tested, right at 120 all cylinders, inspected plugs & spares on hand.
  • Visual inspection of brake pads, all bulbs, accessories, belt & spare, inspect all hoses coolant, fuel and oil lines.
  • Make sure all electrical components are secured/in tact and bolted down properly where required.
  • Set up a tool kit including tow rope, etc.
  • Cleaned up air box for any debris/grime over the years.

  • Once the carbs are cleaned, I'll have to adjust the choke on all 3, dial in the idle and throttle free play, though these weren't bad before removing the carbs.
  • The carbides are just OK, should be fine for one season, but will need to be replaced next year.
  • I haven't done any clutch work besides the cleaning, but it seems to engage in the 3500-4000rpm range in the garage, track spins very slightly at idle when raised, all sounds smooth to me.

Is there anything glaring that I'm missing besides "Just Add Snow"?
 

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Nope you've pretty much covered it all it looks like. Engagement is about right for a stock spring on those. I like mine around 4200 but that is just personal preference.
 

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How do you get grease in the zerks, on mine I can only get a few to take it the others won't take the grease and just spit it out where the grease gun connects or it is really hard to pump the handle and just won't go?
 

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1995 Polaris XLT Touring
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Discussion Starter #4
Some zerks might be clogged from not being used. I generally found if I tried hard enough if it won't take the grease it will eventually break free... Other than that, they are removable and pretty cheap to order in bulk so it's an easy replacement. Or could possibly remove and soak them in something to free up. I've never tried that so take that advice with a grain of salt.

I just find it's another one of those things that neglect ends up creating headaches!
 

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Ok, yeah when I pull the rear suspension out I will try to get everything better. How do you grease the jack shaft?
 

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For the jack shaft, the bearing in the chain case gets lube from the chain case oil. The bearing on the clutch side is normally sealed and you can not grease it. You just replace it when it goes.
 

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One thing that sometimes works on stuck grease fittings... take a heat gun and heat up the fitting and the metal around it. Sometimes that will soften the grease inside that is clogging up things. I would try that before removing and soaking, it can save you a step.

There are also tools that you can use to clear the fitting and channels. The tool is filled with grease and you apply the tool and hit it with a hammer. The force is substantially greater than the grease gun and it can blast the fitting and channel free.
 

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1995 Polaris XLT Touring
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545 Posts
Discussion Starter #9
Here's a somewhat related question about pre-season prep that really only applies to myself - the skis that came with my sled are off a 2001 Skidoo Mach Z. A previous owner kept the correct spindle rubbers for the Polaris, but they don't hold all that tight since the mount wasn't made to support them. Is there anything I could put underneath the rubbers to keep them tight to the bottom of the spindles? They probably need about a quarter to a half inch of support below. Easiest would be to just cut down a couple of pieces of wood but that's kind of bush league... Although it would be hidden completely, could be painted black, and I've got plenty of pressure treated scraps around from building a 12x16 shed this spring.

The stock Skidoo rubber dampers definitely don't work for the Polaris spindles. If I can rig something up this year I could always sell them next year and pick up some ride specific skis.
 

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Why in gods name would he put Ski-Doo skis on a Polaris? Not even close to working correctly! Any Polaris Plastic Skis will work and the Camoplast skis are cheap enough with the mounting kit. Now those do take a Ski-Doo carbide but the mounting kit is made for Polaris. Gotta love it when people do that stuff to projects! Enough to drive you crazy!
 

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1995 Polaris XLT Touring
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Discussion Starter #13
Most people just say "ehhhh, it's fine" without thinking. Or he got the skis really cheap. I'll make the best of it for this year because I'm at the point where I'm waiting to see how well the sled runs in the first place before sinking money into it that I wouldn't get back on resale if I decided to get something different.
 

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I will send you a link to a kit later today that has the Camoplast skis, mounting kit and carbides for it, iirc they are around 200-275 for the entire setup with shipping off of eBay.
 

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1995 Polaris XLT Touring
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Discussion Starter #15
Sounds good. I usually manage to find anything here in Canada through Royal Distributing. Exchange rates, import duty and shipping tend to be a b!tch on anything eBay I've found, but I'll definitely keep my options open for anything.
 

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Well they do have ebay.ca so I will check there as well. Have to work on something else really quick and then will work on that. I used that exact same kit on 2 snowmobiles in the touring skis and love them. 20-30lbs off the front end vs steel skis. So glad after '98 or so Plastic Skis were the norm not an option or aftermarket for most snowmobiles unless you wanted to go with aggressive aftermarket skis.
 

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1995 Polaris XLT Touring
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Discussion Starter #17
Here was my makeshift solution for this year... not visually appealing but nobody's gonna see it anyway! 1/2" recycled rubber outdoor stair tread, contact cement and my existing fairly worn dampers. I might want to drill a couple of holes through the ski mount to put a small bolt on both sides of the rubber to hold it in place, but should still be better than before once I put everything back together tonight. Was a good opportunity to clean up the grime on the skis while I had them off too!

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