Model Variants:
Explorer 4x4
Applicable Model Years:
1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Segment:
Utility ATV segment, known for its four-wheel-drive capability and versatility
Competitors:
Competed with other utility ATVs from manufacturers like Honda (e.g., FourTrax), Yamaha (e.g., Moto-4), and Suzuki during its production run.
Distinguishing Features:
Four-wheel drive capability, robust utility focus, Polaris's early entry into the ATV market.
Primary Users:
Farm and ranch owners, hunters, recreational riders requiring off-road capability
Primary Coverage:
Complete service and repair for Polaris ATV Explorer 4x4
Specific Models Covered:
Polaris ATV Explorer 4x4 (all model years 1985-1995)
Estimated Page Count:
Likely 500+ pages (typical for comprehensive service manuals of this era)
Type:
Factory Service Manual / Repair Manual
File Format:
PDF / WINRAR
Delivery Method:
Instant Download
Engine:
Detailed diagnostics, repair, and overhaul of engine components
Transmission:
Service, repair, and troubleshooting of the transmission system
Final Drive:
Service and repair of the final drive system (e.g., differentials, axles)
Pvt System:
Coverage for the Polaris Variable Transmission (PVT) system, including belt inspection and replacement
Steering:
Inspection, adjustment, and repair of the steering system
Suspension:
Service and repair of front and rear suspension components
Brakes:
Comprehensive brake service, including inspection, pad replacement, fluid changes, and hydraulic system repair
Electrical:
Wiring diagrams, electrical component testing, troubleshooting, and repair
Body:
Information on body panels, seat removal, and other cosmetic/structural components
General Product Info:
Overview of the vehicle, specifications, and general maintenance guidelines
Preventative Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements
Troubleshooting:
Diagnostic procedures for identifying and resolving common and uncommon issues
Repair Procedures:
Step-by-step instructions for component removal, installation, and repair
Component Overhaul:
Detailed instructions for complete engine, transmission, and other major component rebuilds
Adjustments:
Procedures for adjusting brakes, clutch, carburetor (if applicable), and other systems
Depth:
Comprehensive, factory-level detail suitable for professional technicians and experienced DIY enthusiasts
Diagnostic Tools:
Mentions required tools and specifications for accurate diagnostics
Torque Specifications:
Precise torque values for all critical fasteners
Clearances And Tolerances:
Specifications for component clearances and operating tolerances
Quality:
Bookmarked and searchable PDF for easy navigation and information retrieval
Searchability:
Complete searchable text, allowing users to quickly find specific topics
Printability:
All pages are printable, enabling users to create hard copies for use in workshops
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Operating Systems:
Win95/98/ME/XP/vista/7/Linux/MAC
Engine Type:
Likely a 2-stroke or 4-stroke, air-cooled or liquid-cooled gasoline engine. Specific displacement varies by year and exact model variant.
Engine Displacement Range:
Typically ranged from 250cc to 400cc during this era for similar models.
Bore Stroke:
Specific values are detailed within the manual for each applicable engine variant.
Compression Ratio:
Specific values are detailed within the manual for each applicable engine variant.
Horsepower Range:
Estimated 15-30 HP, depending on engine size and tuning. Exact figures in manual.
Torque Range:
Estimated 15-25 lb-ft, depending on engine size. Exact figures in manual.
Fuel Delivery:
Likely carburetor-based. Specific carburetor models and jetting details are in the manual.
Fuel Type:
Unleaded gasoline. Octane rating as specified in manual (likely 87 or 89 octane).
Oil Type:
Specific engine oil viscosity (e.g., SAE 10W-40 or 20W-50) and API service classification detailed in manual.
Cooling Method:
Air-cooled or liquid-cooled, depending on the specific engine variant. Manual provides details.
Type:
Polaris Variable Transmission (PVT) - Automatic CVT
Drive System:
Shaft-driven 4WD. Manual covers operation and maintenance of drive shafts.
Gear Selection:
Typically High, Low, Neutral, Reverse. Manual details operation and adjustments.
Transmission Fluid Type:
Specific CVT fluid type and capacity detailed in the manual. May require specialized fluids.
Length Range:
Approx. 70-80 inches. Exact dimensions vary by year. Manual provides specific figures.
Width Range:
Approx. 40-45 inches. Exact dimensions vary by year. Manual provides specific figures.
Height Range:
Approx. 40-45 inches. Exact dimensions vary by year. Manual provides specific figures.
Dry Weight Range:
Approx. 450-550 lbs. Exact dry weights vary by year. Manual provides specific figures.
Ground Clearance Range:
Typically 5-8 inches. Manual provides specific clearance figures.
Towing Capacity:
Capacity varies, check manual for specific year's rating (often around 500-1000 lbs).
Tire Size Front:
Commonly 22x7-10 or 23x8-11. Manual confirms specific sizes.
Tire Size Rear:
Commonly 22x10-10 or 24x11-10. Manual confirms specific sizes.
Wheel Bolt Pattern:
Typically 4/110 or 4/115 mm. Manual will confirm.
Crash Test Data:
ATVs of this era did not undergo standardized crash testing like passenger vehicles. Safety recommendations focus on rider behavior and protective gear.
Braking System:
Hydraulic disc brakes (front and/or rear) depending on model and year. Manual details system operation and maintenance.
Operator Protection:
Emphasis on rider training, use of helmets, eye protection, and appropriate riding gear. Manual provides safety warnings.
Features:
Basic by modern standards. Typically featured a simple digital display for odometer, trip meter, and possibly basic indicator lights.
Features:
No electronic driver assistance features. Focus is on mechanical systems and rider control.
Features:
No connectivity features. Purely mechanical and electrical systems.
Oil Change Interval:
Typically every 3-6 months or 1,000-2,000 miles, but annual inspections are crucial. Manual provides precise intervals.
Air Filter Cleaning:
Recommended every few rides or monthly, depending on usage conditions. Manual details inspection and cleaning.
Spark Plug Replacement:
Typically every 12-24 months or as needed based on inspection. Manual specifies type and gap.
Brake Fluid Type:
DOT 3 or DOT 4 as specified by Polaris. Manual confirms specific requirement.
Coolant Type:
If liquid-cooled, a specific ethylene glycol-based coolant mixture (e.g., 50/50) as per manual.
Gearcase Oil:
Specific gear oil viscosity (e.g., SAE 80W-90 GL-5) for front and rear differentials, and transmission/gearbox. Manual lists capacities.
Common Wear Items:
PVT belt wear, brake component wear, suspension bushing wear, and carburetor gumming from infrequent use are common for ATVs of this age.
Carburetor Maintenance:
The manual will likely include detailed instructions for carburetor cleaning and adjustment, a common task for older carbureted engines.
Electrical Connections:
Corrosion on electrical connectors can be an issue; the manual's electrical section will guide diagnosis.
Polaris History:
Polaris has a long history in powersports, starting with snowmobiles and expanding into ATVs, becoming a dominant force in the industry.
Explorer Series:
The Explorer series was a key part of Polaris's early ATV lineup, focusing on ruggedness and 4x4 capability to meet the demands of utility users.
Manufacturing Location:
Primarily manufactured in the USA by Polaris.
