Polaris ATV Xplorer 4X4 User Manual

OWNER’S MANUAL SUPPLEMENT
2002 XPLORER 4X4
PN 9916984

IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s manual at all

times.

Capacities

Body Style Gen IV

Gross Vehicle Weight 1 100

Fuel Capacity 3.5 Gallons

Gearcase Oil 27 Ounces

Engine Oil Capacity 2 Quarts

Front Rack (Maximum ­Capacity)

Rear Rack 180 Lbs.

Tongue Weight 30 Lbs.

Tow Hitch Std

Tow Capacity 850 Lbs.

Turn Radius 60〉

Ground Clearance 6〉

Height 46”

Length 76.5”

Seat Height 34

Dry Weight 49.75”

Wheel Base 49.75”

Width 45.5”

90 Lbs.

Drive System

Drive System Type PVT

Shift Type Side Lever (Hi/Low-

N-R)

Gear Reduction - Low 6.69/1

Gear Reduction - Reverse 5.17/1

Gear Reduction - Foward 3.34/1

Front Drive (ratio) 2:1

Final Drive (ratio) 12/42 80P

Center Drive (ratio) Not Applicable

Drive Chain 520 O-Ring

Front Tire 23 x 7-10

Rear Tire 24 x 11-10

Tire Pressure (front) 4

Tire Pressure (rear) 3

Suspension and Brakes

Front Susp. - Mac Strut 6.7

Rear Susp. - Progresseive
Rate Swing Arm

Shock Adjustment CAM

Front Brake Fixed disc, hydraulic

Rear Brake Hydraulic, opposed

Auxiliary Brake Hydraulic, opposed pis-

Park Brake Hydraulic lock, all wheel

9.0

floating caliper

piston caliper, rear axle
fixed disc

ton caliper, rear axle
fixed disc

Engine & Cooling

Engine Model Number EC-25PFE-15

Engine Type 2 Cycle, Single Cylinder

Lubrication Oil Injection

Bore x Stroke 72 x 60

Displacement 244

Compression Ratio 6.1/1 Effective

Engine Cooling Air

Alternator Output (watts) 150

Carburetion 1/VM30SS

Main Jet 130

Pilot Jet 40

Needle Jet 0-4 (169)

Cutaway 2.0

Air Screw 1.0

Jet Needle 5DP7-3

Ignition CDI

Timing 25 @ 3000

Spark Plug Gap .7 mm/.028 in.

Spark Plug Type NGK BR8ES

Exhaust USFS Approved

IMPORTANT: After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank
has dropped, indicating that the oil pump is functioning properly. If the level has not dropped, see your dealer
for oil pump bleeding and repeat the pre-mix procedure.

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Features

Headlight (watts) 2 Headlights (30/30)

Taillight (watts) 8.26

Brake Light (watts) 26.9

Battery 12V 14 AH

DC Plug In - Rear Accessory

DC Socket - Forward Accessory

Electric Start Standard

High Beam Indicator Standard

High Temp Indicator Not Available

Windshield Accessory

Low Oil Light Standard

Neutral Indicator Standard

Reverse Indicator Standard

Speedometer Accessory

Tool Kit Standard

Carburetor Jetting Clutching Chart

Altitude Ambient

Meters

(Feet)

Temperature

0-900

(0-3000)

900-1800

(3000-6000)

1800-2700

(6000-9000)

2700-3700

(9000-1200

0)

- Drop Jet Needle one position (raise E-Clip) PN 9916984 Rev 01 6/01

Below 0F

(Below -- 18C)

150 140

140 130 120 110

125

115

0 to 40F

(--18CtoΗ5C)

Η40 to Η 80F

(Η5CtoΗ26C)

130 120

120 110 100

110 100 95

Η80F & Abov e

(Η26C&

Above)

Alti-

tude

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Shift

Weight

F

5630515

16

5630279

Drive
Clutch
Spring

Blue/Green

7041157

Blue/Green

7041157

Driven
Clutch
Spring

Red

7041198

Red

7041198

Turn air screw out 1/2 turn (counterclockwise) E 2001 Polaris Sales Inc.

Printed in U.S.A.

Driven

Helix

40

5131446

2+2

40

5131446

2+2

2