Vehicle Class:
Utility All-Terrain Vehicle (ATV)
Target Audience:
ATV owners, home mechanics, repair shops, and parts distributors for the Polaris Xpedition 425.
Utility Atv Market:
The Xpedition 425 competed in the utility ATV segment, emphasizing versatility for work, sport, and trail riding. Its design prioritized reliability and ease of maintenance, making it a popular choice for a wide range of users.
Manual Utility:
Provides essential part numbers and visual references crucial for accurate parts ordering and effective DIY maintenance and repairs, saving time and money.
Powertrain:
Engine (Piston, Crankshaft, Crankcase, Cylinder, Carburetor, Oil Pump, Magneto, Starting Motor, Recoil Starter), Exhaust System, Cooling System, Fuel Tank, Oil Tank, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase, Rear Wheel Drive.
Chassis And Body:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, Engine Mounting, Air Box, Front Drive, Front Tightener, Front Strut, CV Joint – BTB, Front Wheel, Front Brake, Swing Arm/Shock Mounting, Center Tightener, Rear Brake, Rear Wheel.
Controls And Electrical:
Controls -- Throttle ASM./Cable, Controls - Master Cylinder/Brake Line, Steering Post, Handlebar and Headlight Pod, Electrical/Taillight, Gear Selector.
Assembly Disassembly:
Detailed exploded diagrams showing part relationships for assembly and disassembly of all major vehicle components.
Part Identification:
Identification of all individual components and assemblies with corresponding part numbers for ordering and replacement.
Routine Maintenance Support:
Supports routine maintenance by clearly illustrating components like air filters, oil filters, spark plugs, and fuel systems.
Depth Of Information:
Highly detailed, focusing on precise part identification and OEM part numbers. Primarily aimed at parts sourcing for repair and maintenance rather than in-depth repair procedures.
Engine Type:
Four-stroke, Single-cylinder, SOHC
Engine Displacement:
425cc
Bore X Stroke:
Information not directly provided, but typical for this class.
Horsepower:
Approx. 25-30 HP (Estimates based on similar models of the era).
Torque:
Information not directly provided.
Fuel Delivery:
Carburetor (specified in contents).
Fuel Type:
Unleaded gasoline.
Oil Type:
Typically SAE 10W-40 or 20W-50 ATV-specific engine oil. Consult specific service manual for exact viscosity and API rating.
Oil Capacity:
Approx. 2.0-2.5 quarts (1.9-2.4 liters). Consult specific service manual for exact capacity.
Cooling Method:
Liquid-cooled (specified in contents).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water.
Coolant Capacity:
Information not directly provided, but typically around 1.5-2.0 liters.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission).
Drive System:
2WD/4WD selectable (likely with front differential lock or automatic engagement).
Gear Selection:
Forward, Neutral, Reverse (specified in contents).
Gearcase Fluid:
Typically Polaris proprietary ATV gearcase lubricant or a high-quality SAE 80W-90 gear oil. Consult specific service manual for exact specification and capacity.
Length:
Information not directly provided, but typically around 80-85 inches.
Width:
Information not directly provided, but typically around 45-48 inches.
Height:
Information not directly provided, but typically around 45-50 inches.
Dry Weight:
Approx. 575-625 lbs (261-283 kg). Exact weight may vary by configuration.
Towing Capacity:
Typically rated for 1500 lbs (680 kg) for towing.
Rack Capacity Front:
Typically around 100 lbs (45 kg).
Rack Capacity Rear:
Typically around 200 lbs (91 kg).
Atv Safety Standards:
Designed to meet industry safety standards for ATVs. Users must always wear appropriate safety gear and follow safe operating practices.
Braking System:
Hydraulic disc brakes front and rear (specified in contents).
Lighting:
Headlights, Taillight (specified in contents).
Body Protection:
Front bumper and rack systems provide some protection (specified in contents).
Ergonomics:
Handlebar and steering post design for control and comfort (specified in contents).
Infotainment System:
Basic ATV design, typically does not feature advanced infotainment systems. Relies on functional controls and indicators.
Driver Assistance Features:
No advanced driver-assistance systems are standard. Focus is on rider control and mechanical functionality.
Connectivity Features:
No onboard connectivity features like Bluetooth or USB ports are standard.
Oil Change Interval:
Typically every 100 hours or 6 months, whichever comes first. Refer to the official Polaris service manual for precise intervals.
Air Filter Service:
Inspect and clean/replace as needed, especially in dusty conditions. Recommended every 20-40 hours of operation.
Spark Plug Replacement:
Recommended every 100-200 hours or annually. Consult the service manual for the correct spark plug type and gap.
Engine Oil Specification:
SAE 10W-40 or 20W-50 ATV engine oil (API SG or higher recommended). Verify with official manual.
Gearcase Lubricant:
Polaris ATV gearcase lubricant or SAE 80W-90 gear oil. Verify with official manual.
Coolant Specification:
50/50 mix of ethylene glycol antifreeze and distilled water.
Common Wear Items:
Drive belts (CVT belts), brake pads, wheel bearings, suspension bushings, and steering components are common wear items on ATVs of this era.
Cv Joint Boots:
CV joint boots are susceptible to damage from debris and require regular inspection to prevent joint failure.
Electrical Connections:
Corrosion or loose connections in the electrical system can lead to intermittent issues. Thorough inspection of wiring harnesses and connectors is recommended.
Polariss Atv Legacy:
Polaris has been a pioneer in the ATV industry, known for its innovation, ruggedness, and performance. The Xpedition line built upon this reputation.
Xpedition Line Introduction:
The Xpedition line, introduced in the early 2000s, offered a blend of utility and comfort, often featuring more integrated storage and rider-focused ergonomics compared to earlier utility ATVs.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States.
