Model Years Covered:
1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
Product Type:
Factory Service Repair Manual
Engine Code Indication:
Manual covers various engine configurations used across the model years.
Purpose Of Manual:
To provide owners and technicians with the official factory service and repair information for the Polaris ATV Explorer 4x4, enabling comprehensive maintenance and repair.
Manual Quality Comparison:
This manual is equivalent to the documentation used by authorized Polaris dealerships, offering a higher level of detail and accuracy than aftermarket generic repair guides.
Manual Benefits:
Detailed illustrations, step-by-step instructions, comprehensive system coverage, printable pages for workshop use, accurate technical data for efficient troubleshooting and repair.
Primary Coverage Areas:
General Product Information, Body, Steering, Suspension, Brake Service, Transmission Service, Final Drive System Service, PVT System, Engines, Electrical
Estimated Page Count:
While not explicitly stated, a comprehensive factory service manual of this scope and era typically ranges from 300 to 800+ pages.
Manual Type:
Factory Service Manual / Repair Manual
Engine Systems:
Engine overhaul, disassembly, assembly, component testing, cooling system, lubrication system, fuel system (carburetion and fuel delivery), ignition system, exhaust system.
Transmission Systems:
Manual transmission (if applicable), Automatic transmission (if applicable), Polaris Variable Transmission (PVT) system service, belt inspection and replacement, clutch operation, gear case servicing.
Drivetrain Systems:
Four-wheel drive (4x4) system operation, differential service (front and rear), drive shaft maintenance, U-joints, CV joints (if equipped).
Suspension And Steering:
Front and rear suspension component inspection, replacement, and adjustment; steering system diagnosis, tie rod ends, steering column, rack and pinion (if equipped); wheel alignment procedures.
Brake Systems:
Hydraulic brake system service, brake fluid replacement, caliper overhaul, master cylinder service, brake pad/shoe replacement, rotor/drum inspection and service, parking brake adjustment.
Electrical Systems:
Wiring diagrams, component testing (starter, alternator/stator, battery, ignition coil), lighting system, charging system, troubleshooting electrical faults, fuses and relays.
Body And Frame:
Body panel removal and installation, seat components, storage compartments, chassis inspection, plastic component repair/replacement.
Maintenance Procedures:
Routine maintenance checks, oil changes, filter replacements, lubrication points, belt tension checks, battery maintenance, tire pressure monitoring.
Diagnostic Procedures:
Troubleshooting guides for common problems, symptom-based diagnostics, component testing procedures, electrical troubleshooting flowcharts.
Repair Procedures:
Step-by-step instructions for major component repairs, assembly and disassembly of engine, transmission, suspension, brakes, and electrical components.
Overhaul Procedures:
Detailed instructions for complete engine rebuilds, transmission overhauls, and component reconditioning.
Depth Of Information:
Comprehensive. Covers basic maintenance to complete engine and transmission rebuilds, electrical diagnostics, and component-level repairs, mirroring dealer-level service information.
Engine Type Indication:
The Polaris Explorer 4x4 utilized various engine configurations throughout its production run, typically ranging from 250cc to 350cc, often 2-stroke and some early 4-stroke models. Specific engine types and displacements will be detailed within the manual based on the sub-model year.
Horsepower Torque Range:
Horsepower and torque figures varied significantly by engine displacement and configuration. The manual will contain specific data for each engine variant.
Fuel Delivery System:
Primarily carburetor-based fuel systems. The manual will detail specific carburetor models, jetting, adjustment procedures, and troubleshooting.
Cooling Method:
Typically air-cooled, with provisions for oil cooling in some higher-performance variants. Manual will detail specific cooling system components and maintenance.
Transmission Type:
Polaris Variable Transmission (PVT) with belt drive, coupled with a shaft-driven 4x4 system. Manual will detail PVT system servicing, including belt, clutch, and roller maintenance.
Transmission Options:
Some earlier models might have featured manual transmissions, though the Explorer line is predominantly known for its PVT automatic systems. The manual will cover all configurations used.
Pvtsystem Features:
Automatic engagement, high and low range gearing, reverse. Manual will detail operation, maintenance, and repair of the drive clutch, driven clutch, and drive belt.
Overall Dimensions:
Specific dimensions (length, width, height) will vary by model year and specific configuration. The manual will provide detailed chassis specifications.
Dry Weight Range:
Dry weights typically ranged from approximately 450 to 550 lbs (204 to 250 kg) depending on engine size and features. The manual will provide precise weights.
Payload Capacity Indication:
Payload capacity will be detailed within the manual, generally suitable for rider and light cargo.
Safety Standards Adherence:
Designed to meet prevailing ATV safety standards of its production era. The manual will reference relevant safety precautions and operating guidelines.
Braking System Type:
Hydraulic disc brakes, front and rear. Manual covers all aspects of brake system maintenance and repair.
Rollover Protection:
No integrated rollover protection. Emphasis on safe operation and proper riding techniques as outlined in the manual.
Infotainment Features:
Basic functionality, focused on essential controls and instrumentation (speedometer, odometer, fuel gauge, engine warning lights).
Driver Assistance Systems:
None. Focus on mechanical systems and rider control.
Connectivity Options:
N/A. This era of ATV predates widespread electronic connectivity features.
Engine Oil Change Interval:
Typically 100 hours or annual service. Specific intervals for oil, filter, and spark plug changes will be detailed in the manual.
Pvtsystem Belt Inspection:
Regular inspection for wear and damage, with replacement recommended at specified intervals or upon signs of deterioration. Manual will provide detailed inspection criteria.
Lubrication Schedule:
Scheduled lubrication of suspension components, drive shaft U-joints, and steering linkages. Manual will include a detailed lubrication chart.
Engine Oil Specification:
Typically SAE 10W-40 or SAE 20W-50, depending on ambient temperature. The manual will specify the exact grade and API classification required.
Gear Oil Specification:
Specific gear oil grades for front and rear differentials and transmission/gearcase. Manual will list recommended viscosities and types (e.g., API GL-4 or GL-5).
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify the exact type for optimal brake performance and seal compatibility.
Common Wear Items:
PVT belt wear, carburetor jetting issues (especially with ethanol fuels), suspension component wear (bushings, ball joints), electrical connector corrosion, and starter solenoid issues are common in older ATVs. The manual provides diagnostic and repair procedures for these.
Engine Specific Concerns:
Depending on the engine type (2-stroke vs. 4-stroke), common issues might include carbon buildup, piston ring wear, or stator failure. The manual will offer specific troubleshooting for these.
Polaris Atv Legacy:
Polaris has been a pioneering force in the ATV industry since the 1980s, with the Explorer line representing an early iteration of their rugged and capable off-road vehicles.
Explorer Series Development:
The Explorer series evolved from Polaris's earlier ATV models, introducing advancements in 4x4 technology and the PVT system, catering to utility and recreational riders.
Manufacturing Locations:
Polaris ATVs are historically manufactured in the United States.
