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95' XLT Running on 1 cylinder
started by pross63
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October 7th 2009 at 12:24 PM
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pross63
New Member
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52 Posts 
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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I have a pretty odd problem that I cannot seem to figure out. I have a 1995 XLT Special, all stock with 7600 miles on it. The sled started running rough last year at the end of the season and appeared to be running on two cylinders. I thought it was a bad coil, changed it...no difference. So far this week I have checked compression (115 across the board), checked for spark...all seem to have it. Removed, disassembled and cleaned the carbs, checked fuel pump, changed plugs...you name it. Nothing seems to help. When it is idling I can remove the mag side and middle plug wires and the engine is not phased. Put those back on and pull the pto side wire though and she quits.
It is possible the module is going bad even though I have spark? I am stumped because all indications is that this thing should run correctly...
Anyone had this happen to them?
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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Site Supporter
Group: Site Supporters
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October 7th 2009 at 12:31 PM
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Zippi
Average Member
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537 Posts 
Group: Members
Member Since: November 7th 2005
Location: Groton, NY, USA
2008-2009 Miles: 1300
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what color is the spark ? same in all three?
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October 7th 2009 at 1:15 PM
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ACEXLT
THREE FOR ALL
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5668 Posts 
Group: Members
Member Since: September 17th 2002
Location: Greenfield, WI, USA
Current Sled: '01 XCR 800
2008-2009 Miles: 1326
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Start it up and spray starting fluid behind the primary clutch on the crank seal.
see if rpm rises. sure does sound like a bad crank seal symptom.
'01 XCR 800
'00 Indy Triumph
TRIPLES RULE!!
TWINS HAVE NO BALLS!!
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October 7th 2009 at 1:46 PM
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Sledman74
CANDU is the right choice for Ontarios Power needs
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115 Posts 
Group: Members
Member Since: November 17th 2008
Location: Kitchener, ON, Canada
Current Sled: 2004 XC 800
2008-2009 Miles: 1100
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having spark and having a good strong spark are two different things, might want to check to see how strong it is.
Toys Own and Owned
1985 Indy Trail 440 - sold with 7500 miles
1987 Indy 600 - sold with 5800 miles
1997 XC 600 - sold with 6500 miles
2002 Edge X 700 - sold with 6000 miles
2004 XC 800
1995 Polaris SL 750 PWC
2000 Polaris Sportsman 500 ATV
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October 7th 2009 at 2:11 PM
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Ugly_old_Poo_kid
techno-bumpkin
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1079 Posts 
Group: Members
Member Since: March 18th 2007
Location: Walworth, NY, USA
Current Sled: 05 Edge & Frankenstorm II
2008-2009 Miles: 165
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Replace the plug wires..
95 - Storm 800 - Modded - AKA: FrankenStorm - Totalled near 100mph at Tug Hill!
96 - XLT/SP with Storm 800 trip/trip and now EFI - FrankenStorm II lives...
95 - RXL -- Sale Pending --
05 - Edge 800 long track - Stayin' stock for now..
---------------------------------------------
It made me more compassionate, more empathetic, more nurturing...
I FEEL LIKE I'M TRAPPED IN MY OWN WORST NIGHTMARE!!!
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October 7th 2009 at 2:12 PM
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pross63
New Member
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52 Posts
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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The spark strength is what I was concerned about...just seems dull though when I put a tester on it all three wires made the reter react the same. Spark color is a light yellow/white color. I thought about seals but I have not tested that because the last sled I had with that problem wanted to drive itself away not die out...so I have ignored that in hopes I don't have to do those on this sled.
The best answer I have it so buy a new one...but my wife does not agree with me on that.
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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October 7th 2009 at 2:37 PM
[ Modified October 7th 2009 at 2:40 PM
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Polaris_Parts_MN
Junior Member
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200 Posts
Group: Members
Member Since: October 8th 2008
Location: NW minneapolis suburbs, Minnesota, USA
Current Sled: 1999 XC 500
2008-2009 Miles: 450
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do you have compression in all cylinders?
check fuel system again- check fuel lines to see if they are rotted. when you cleaned the carbs did you clean both the pilot jet and the main jet? a lot of people dont know about the pilot jet because its small and hidden, and thats always the one that gets clogged up with gunk
1999 Polaris XC 500
-holeshot skid plate
-fox reservoir front track shock
-fox front shocks
-xenon low-beam bulb (very helpful at night)
Just add gas and snow!
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October 7th 2009 at 3:16 PM
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pross63
New Member
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52 Posts
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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Lines are good and I did check both jets. One pilot (middle cylinder) was clogged up...so I thought I had it licked until I started it up last night and there was no real change.
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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October 7th 2009 at 4:23 PM
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mrholmquist
Junior Member
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500 Posts
Group: Members
Member Since: December 15th 2003
Location: cobourg, on, Canada
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October 7th 2009 at 5:16 PM
[ Modified October 7th 2009 at 5:18 PM
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1SethW
Im not Judging... I'm just sayin
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132 Posts
Group: Members
Member Since: January 15th 2009
Location: Wahkon, Minnesota, USA
Current Sled: 2002 Edge X 700
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I had the same problem with my old xcr. The magneto was loose and only sparked at first "same exact problem" also i had to replace the magneto after that
Thanks,
Seth W
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October 7th 2009 at 7:26 PM
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pross63
New Member
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52 Posts
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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You guys have all given me good avenues to try. Thanks for the input so far. One thing I just noticed was that the headlight dims and brightens once in a while...bad chassis ground perhaps. I am digging in.
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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October 7th 2009 at 9:06 PM
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mvvette97
Junior Member
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433 Posts
Group: Members
Member Since: December 13th 2005
Location: Leon, iowa, USA
Current Sled: 1995 Indy XLT
2008-2009 Miles: over 100
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Like said above check the skirts on the pistons so see if they have broken off. You can pull the carbs and look in and also pull the exhaust manifold and look in there. Also check to see if the crank is still in phase. Mine slipped and was doing the same thing you are describing. Pull all the spark plugs and run the middle piston up to the top, the two outer pistons will both be down but more important make sure they are at the same distance down. You can stick something down the holes to measure to see if the are the same depth
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October 8th 2009 at 7:38 AM
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pross63
New Member
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52 Posts
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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Thanks mvvette97. I exhausted all other options last night what you describe is exactly what I am going to check tonight. All you guys have been a great help. I'll update what I find out.
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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October 8th 2009 at 9:56 PM
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stormrider62033
wally
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4729 Posts
Group: Members
Member Since: December 25th 2004
Location: Gillespie, IL, USA
Current Sled: 99xcr 800
2008-2009 Miles: 500
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on all the xlts we have worked on always the needles and seats bad ,but you could have a differnt problem
mid Il alway's waiting for snow,moving north(way north)2001 thundercat 99xcr 800 97SPX ULTRA 96 zrt 600&800,92 doo plusX 92 v max 4 750
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October 9th 2009 at 4:53 PM
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Dman
Average Member
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528 Posts
Group: Members
Member Since: February 13th 2004
Location: Shell Lake, WI
Current Sled: 98 XC600's (2)
2008-2009 Miles: 150
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Get it running with the airbox off. Put your hand over the suspect carbs and see if there is any suction at all to the cylinders that are not running. If not, you have an air leak somewhere. Compression can be fine and spark but if it's sucking air somewhere, it might cause your problem. Could be a MAG crank seal or bad carb boots on those two carbs, or some other air leak. Get
Are the 2 cylinders firing at all? Put your hand on the exhaust header coming off the cylinder and check if they are warm. Are you saying that you can remove the MAG and middle plug caps and it will still run on 1 cylinder? Never seen a triple do that to me personally. 2 yes, 1 no.
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October 11th 2009 at 7:54 PM
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pross63
New Member
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52 Posts
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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I got a little further this weekend. Checked the timing and everything was ok. I have sprayed the engine down with starting fluid and it never made the rpms rise at all. I do have suction on all 3 cylinders however it is stronger on the pto side. If I cover that one the engine quits completely, the other two it does not phase. The plugs are wet...like they are not burning at all though when I do a spark check they all fire. I can pull the mag side and pto side plug wires off at the same time and it runs on one cylinder. I am thinking of buying a used CID just to see. Funny thing is this sled fires right up first pull every time. Run it for a minute and then start it again with 1/2 pull. Just pisses me off...I am so glad I am starting the process now.
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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October 12th 2009 at 7:38 AM
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Ugly_old_Poo_kid
techno-bumpkin
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1079 Posts
Group: Members
Member Since: March 18th 2007
Location: Walworth, NY, USA
Current Sled: 05 Edge & Frankenstorm II
2008-2009 Miles: 165
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Pull the spark plugs and pull the engine over for several pulls, then toss a new set of plugs in and see if the 2 cylinders fire for a while before they quit. If so, the 2 carbs might just be dumping fuel and flooding.
95 - Storm 800 - Modded - AKA: FrankenStorm - Totalled near 100mph at Tug Hill!
96 - XLT/SP with Storm 800 trip/trip and now EFI - FrankenStorm II lives...
95 - RXL -- Sale Pending --
05 - Edge 800 long track - Stayin' stock for now..
---------------------------------------------
It made me more compassionate, more empathetic, more nurturing...
I FEEL LIKE I'M TRAPPED IN MY OWN WORST NIGHTMARE!!!
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October 12th 2009 at 8:07 AM
[ Modified October 12th 2009 at 8:08 AM
]
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polaris1man
Average Member
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738 Posts
Group: Members
Member Since: December 22nd 2007
Location: Nashwauk, Minnesota, USA
Current Sled: Polaris SKS700
2008-2009 Miles: not many
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I know you said you cleaned the carbs and pilot jets, but did you ever align the choke plungers on the carbs? Sounds like two of the carbs are spewing too much Gas into the chamber. Also, the float height can play a big role in your problem
Three-1999 Polaris SKS700's
2000 Polaris SKS700
2000 Polaris Ranger 6x6
2007 Polaris Sportsman 800 EFI X2
2000 Yamaha YZ 250
1996 Yamaha WR250
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October 12th 2009 at 8:26 AM
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pross63
New Member
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52 Posts
Group: Members
Member Since: September 6th 2006
Location: Freedom, Wisconsin
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I did align the choke plungers when I took the carbs apart. I will check the floats again. I am getting closer I can feel it...thanks to all you guys. Wintery mix expected today/tonight! First snowmobile club meeting of the year for us as well tonight...the fever is starting to kick in!
Pross63
1995 XLT Special
1995 RXL
1996 Ultra SP
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October 12th 2009 at 9:54 AM
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mrholmquist
Junior Member
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500 Posts
Group: Members
Member Since: December 15th 2003
Location: cobourg, on, Canada
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did you look at those piston skirts? one broken skirt will affect the cyl beside it
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October 12th 2009 at 12:54 PM
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picman
Junior Member
picman is off to bag his buck. I hope. Skunked so far.
Updated Wednesday at 1:17 PM
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308 Posts
Group: Members
Member Since: January 15th 2009
Location: Marinette, WI, USA
Current Sled: 1998 Polaris Ultra
2008-2009 Miles: 1145
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Quote originally posted by pross63
The spark strength is what I was concerned about...just seems dull though when I put a tester on it all three wires made the reter react the same. Spark color is a light yellow/white color. I thought about seals but I have not tested that because the last sled I had with that problem wanted to drive itself away not die out...so I have ignored that in hopes I don't have to do those on this sled.
The best answer I have it so buy a new one... but my wife does not agree with me on that.
Don't they ALWAYS?
Find the line between respect and fear....then flirt with it
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