Polaris 2002 ATV Xplorer 4X4 User Manual
Polaris Motorcycles
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.