Polaris 2002 ATV Xplorer 4X4 - Manual

1
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 1100
Fuel Capacity 3.5 Gallons
Gearcase Oil 27 Ounces
Engine Oil Capacity 2 Quarts
Front Rack (Maximum -
Capacity)
90 Lbs.
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”
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
9.0
Shock Adjustment CAM
Front Brake Fixed disc, hydraulic
floating caliper
Rear Brake Hydraulic, opposed
piston caliper, rear axle
fixed disc
Auxiliary Brake Hydraulic, opposed pis-
ton caliper, rear axle
fixed disc
Park Brake Hydraulic lock, all wheel
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.