1995-2003 Polaris Xplorer 4010 L ATV service manual

Table of Contents

General Product Information

1. Publications

   • Available Publications
   • Usage Instructions

2. Model Identification

   • VIN and Serial Number Locations
   • Model Year Identification

3. Service Tools Description

   • Required Tools for Maintenance
   • Special Tools for Service

4. Service Tools & Supplies List

   • Recommended Supplies
   • Tool Kits and Availability

5. Specifications

   • 1985 Models
   • 1986 Models
   • 1987 Models
   • 1988 Models
   • 1989 Models
   • 1990 Models
   • 1991 Models
   • 1992 Models
   • 1993 Models
   • 1994 Models
   • 1995 Models

6. Accessory Fit Chart

   • Compatible Accessories
   • Installation Guidelines

7. Routing Diagrams

   • Electrical Routing
   • Cable Routing

8. How to Handle a Service Complaint

   • Reporting Procedures
   • Customer Service Contacts

9. Service Tips

   • Best Practices
   • Common Maintenance Errors

10. Warranty Policy

    • Coverage Details
    • Claim Procedures

Body, Steering and Suspension

1. Frame and Body Panels

   • Inspection and Repair
   • Removal and Installation

2. Steering System

   • Steering Mechanism Overview
   • Power Steering System

3. Front and Rear Suspension

   • Suspension Types and Maintenance
   • Shock Absorber Replacement

4. Tires and Wheels

   • Specifications and Maintenance
   • Tire Pressure and Wear

Brake Service

1. Brake System Overview

   • Hydraulic and Mechanical Systems
   • Brake Fluid Specifications

2. Front and Rear Brakes

   • Disc and Drum Brake Maintenance
   • Brake Pad and Shoe Replacement

3. Parking Brake

   • Adjustment and Maintenance
   • Component Replacement

4. Troubleshooting

   • Brake Noise and Vibration
   • Inadequate Braking Performance

Transmission Service

1. Transmission Types

   • Manual and Automatic Transmissions
   • Specifications and Fluid Types

2. Transmission Maintenance

   • Fluid Change Procedures
   • Component Inspection and Replacement

3. Troubleshooting

   • Common Transmission Issues
   • Diagnostic Procedures

Final Drive System Service

1. Drive System Overview

   • Front and Rear Differentials
   • Chain and Sprocket Maintenance

2. Driveshaft and U-Joints

   • Inspection and Replacement
   • Lubrication Procedures

3. Axle Service

   • Front and Rear Axle Maintenance
   • Seal and Bearing Replacement

PVT System (Polaris Variable Transmission)

1. PVT System Overview

   • System Components and Function
   • Maintenance and Adjustment

2. Clutch System

   • Clutch Inspection and Replacement
   • Belt Maintenance

3. Troubleshooting

   • PVT System Noise and Performance Issues
   • Common Problems and Solutions

Engines

1. Engine Mechanical

   • Engine Removal and Installation
   • Engine Disassembly and Assembly

2. Engine Cooling System

   • Radiator and Cooling Fan
   • Water Pump and Thermostat

3. Fuel System

   • Fuel Tank and Lines
   • Fuel Pump and Fuel Filter

4. Exhaust System

   • Exhaust Manifold and Muffler
   • Emission Control Systems

5. Engine Electrical

   • Ignition System Components
   • Starter and Alternator

Electrical

1. Electrical System Overview

   • Battery and Charging System
   • Fuses and Relays

2. Lighting Systems

   • Headlights and Taillights
   • Interior and Indicator Lights

3. Instrument Panel

   • Gauges and Warning Lights
   • Instrument Cluster Replacement

4. Audio and Communication Systems

   • Radio and Sound System
   • Communication Equipment

5. Wiring Diagrams

   • Complete Vehicle Wiring Diagram
   • Component-Specific Diagrams

6. Troubleshooting

   • Electrical Diagnostic Procedures
   • Common Electrical Issues