Target Audience:
Owners, mechanics, and enthusiasts seeking to maintain, repair, or troubleshoot their Polaris Xpedition ATVs.
Rival Models:
Competed with other utility ATVs from brands like Honda (FourTrax), Yamaha (Grizzly), and Kawasaki (Prairie).
Utility Focus:
Designed for work, hauling, and trail riding, emphasizing durability and capability.
Accessibility:
Instant download for immediate access to repair information.
Durability Of Format:
PDF format is resistant to grease and dirt compared to paper manuals, with a lifetime protection policy against loss or damage.
General Information:
True
Routine Maintenance:
True
Engine Removal Installation:
True
Lubrication Cooling System:
True
Engine Specifications:
True
Transmission Drive Chain Sprockets:
True
Advanced Troubleshooting:
True
Estimated Pages:
Variable (typical for digital manuals, not specified)
Type:
Downloadable PDF Repair Manual
Format:
Digital PDF (Downloadable)
Engine:
Comprehensive coverage including disassembly, assembly, tuning, and diagnostics.
Fuel System:
Carburetor adjustment, fuel pump, fuel lines, and fuel tank service.
Cooling System:
Radiator, coolant, fan operation, and thermostat service.
Lubrication System:
Oil change procedures, oil filter replacement, and lubrication points.
Transmission Drivetrain:
Automatic transmission service, drive chain adjustment/replacement, and sprocket inspection.
Steering And Suspension:
Handlebar steering, tie rod ends, ball joints, and shock absorber service.
Electrical System:
Wiring diagrams, battery maintenance, lighting, ignition system, and starter motor.
Brakes:
Hydraulic brake system, caliper service, brake pad replacement, and fluid bleeding (if applicable).
Body And Frame:
Plastic panel removal/installation, fender service, and chassis inspection.
Exhaust System:
Muffler inspection, exhaust pipe service, and gasket replacement.
Maintenance:
Scheduled maintenance checks, fluid changes, filter replacements, and general upkeep.
Repair:
Step-by-step instructions for component repair and replacement.
Diagnostics:
Troubleshooting common problems with diagnostic flowcharts and symptom-based solutions.
Rebuilding:
Detailed procedures for engine and transmission rebuilding.
Installation:
Guidance on installing new components or accessories.
Depth:
Comprehensive, covering from basic maintenance to in-depth mechanical and electrical repairs.
Engine Type:
4-stroke, SOHC, 2-valve
Engine Type:
4-stroke, SOHC, 2-valve
Horsepower Approx 325:
Approx. 19-20 HP (estimated, varies by tuning)
Horsepower Approx 425:
Approx. 25-26 HP (estimated, varies by tuning)
Carburetor Type:
Keihin (likely CV type, specific model number found in manual)
Fuel Type:
Unleaded gasoline (minimum octane rating specified in manual)
Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Drive System:
Shaft Drive (likely to rear axle, front axle engagement might be selectable or automatic based on model)
Transmission Fluid:
Polaris AGL Synthetic Gearcase Lubricant or equivalent (specific viscosity found in manual)
Length Approx:
Approx. 81 inches (205.7 cm)
Width Approx:
Approx. 45 inches (114.3 cm)
Height Approx:
Approx. 47 inches (119.4 cm)
Dry Weight Approx 325:
Approx. 590 lbs (267.6 kg)
Dry Weight Approx 425:
Approx. 615 lbs (278.9 kg)
Ground Clearance Approx:
Approx. 10 inches (25.4 cm)
Rear Rack Capacity Lbs:
90 lbs (40.8 kg)
Front Rack Capacity Lbs:
50 lbs (22.7 kg)
Towing Capacity Lbs:
1500 lbs (680 kg)
Rollover Protection:
ATVs are not designed with roll cages; emphasis on rider training and safe operation.
Braking System:
Hydraulic disc brakes, front and rear.
Lighting:
Dual headlights, tail light/brake light.
Rider Training:
Manual emphasizes the importance of reading the owner's manual and seeking ATV safety training.
Features:
Basic instrumentation (speedometer, odometer, fuel gauge). No advanced infotainment systems typical of modern vehicles.
Features:
Focus on mechanical systems and rider input. No electronic driver-assistance features.
Features:
No electronic connectivity features.
Oil Change Interval:
Typically every 100 hours or 6 months (refer to manual for exact specification).
Air Filter Cleaning:
Recommended to check/clean at shorter intervals, especially in dusty conditions (e.g., every 25 hours).
Spark Plug Replacement:
Typically at 100-200 hours or annually.
Engine Oil Type:
SAE 10W-40 Synthetic (Polaris brand or equivalent, specific API rating in manual)
Engine Oil Capacity:
Approx. 1.7 US quarts (1.6 liters) (refer to manual for precise amount)
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water, specific freeze point in manual)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for specific recommendation)
Pvttemperaturesensor:
Early PVT systems could be prone to heat-related issues, though this manual would cover diagnostics and potential fixes.
Drive Belt Wear:
Regular inspection of the drive belt for cracks, fraying, or excessive wear is crucial.
Carburetor Cleaning:
Carburetors may require periodic cleaning due to fuel varnish or debris, especially if the ATV is stored for extended periods.
Polarissnowmobiles:
Polaris has a long history in motorsports, beginning with snowmobiles in the 1950s.
Xpedition Line:
The Xpedition line was Polaris's foray into larger-displacement, more utility-focused ATVs, building on their Ranger utility vehicle platform.
Year Introduction:
The Xpedition line was introduced around the early 2000s.
