Atv Segment:
Utility/Recreational ATV segment, known for its versatility in work and trail riding.
Competitors:
Competed against other mid-size utility ATVs from manufacturers like Yamaha (e.g., Grizzly), Honda (e.g., FourTrax), and Suzuki (e.g., KingQuad) in its era.
Reliability Focus:
The Xpedition line was positioned by Polaris for its robust design and capability for demanding tasks, aligning with the manual's emphasis on home repair and longevity.
Manual Utility:
Essential tool for owners seeking to maintain and repair their ATV efficiently, reducing reliance on expensive dealership services.
Primary Coverage:
Comprehensive parts identification for the 2002 Polaris Xpedition 325 ATV.
Secondary Coverage:
Includes exploded diagrams, part numbers, and assembly breakdowns for all major vehicle systems and components.
Type:
Parts Catalog/Manual
Print Capability:
Printable (allows selective printing of needed pages)
Chassis And Body:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, Decals.
Engine And Powertrain:
Engine Mounting, Cooling System, Exhaust System, Fuel Tank, Oil Tank, Air Box, Piston and Crankshaft, Crankcase and Cylinder, Carburetor, Oil Pump, Recoil Starter, Magneto, Starting Motor.
Drivetrain And Suspension:
Front Drive, Frontรถ Tightener, Front Strut, CV Joint – BTB, Front Wheel, Front Brake, Rear Wheel Drive, Swing Arm/Shock Mounting, Center Tightener, Gearcase/Brake and Chain Cover Mounting, 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.
Clutch And Transmission:
Drive Clutch, Driven Clutch, Clutch Cover, Gearcase.
Part Identification:
Detailed exploded diagrams with corresponding part numbers for all listed components, essential for ordering replacement parts.
Assembly Disassembly:
Visual guides (exploded views) facilitate understanding of how components fit together, aiding in disassembly and reassembly during repairs.
Maintenance Support:
While primarily a parts manual, the detailed breakdown of systems supports understanding for routine maintenance tasks like filter changes, fluid checks, and component inspections.
Depth:
Detailed parts catalog level. Focuses on precise identification and sourcing of components rather than step-by-step repair procedures.
Diagnostic Support:
Indirectly supports diagnostics by allowing mechanics to visually identify worn or missing parts based on the provided diagrams.
Rebuild Level:
Provides the necessary part numbers for a complete engine or component rebuild, assuming prior knowledge of the disassembly and assembly process.
Searchability:
Likely searchable by text content, especially part numbers and component names.
Resolution Notes:
Diagrams are typically clear and high-resolution in PDF format, suitable for printing.
Print Options:
User can select specific pages or sections to print, promoting efficient use of resources.
Binding Type For Digital:
N/A (Digital PDF)
Paper Type For Printed:
User dependent (customer chooses paper type when printing)
Engine Type:
Liquid-cooled, 4-stroke, SOHC, Single Cylinder
Engine Displacement:
325cc (approximate)
Bore X Stroke:
Not specified in product description, but typical for this class would be around 70-80mm bore and 70-80mm stroke.
Compression Ratio:
Not specified in product description, but generally in the range of 9:1 to 10.5:1 for this type of engine.
Horsepower:
Estimated 18-20 HP at crank (typical for 325cc utility ATV of this era).
Torque:
Not specified in product description.
Carburetor Type:
Mikuni (likely a VM series or similar, specific model number would be in manual).
Fuel Delivery:
Carbureted
Oil Type:
Polaris recommends SAE 10W-40 or 20W-50 motorcycle/ATV specific oil. Refer to manual for exact specification.
Oil Capacity:
Approximately 1.7-2.0 quarts (1.6-1.9 liters) with filter change. Exact capacity will be listed in the manual.
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water. Specific Polaris recommendation would be in the manual.
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
2WD/4WD selectable (likely on-demand 4WD).
Clutch System:
Dual clutch CVT system (Primary and Secondary)
Gear Reduction:
Low range and High range gearing within the CVT, plus Reverse. Manual will detail gear ratios.
Length:
Not specified in product description, but typical for this class is around 80-90 inches.
Width:
Not specified in product description, but typical for this class is around 45-50 inches.
Height:
Not specified in product description, but typical for this class is around 45-50 inches.
Rear Rack Capacity:
Not specified in product description, but typically rated for 100-200 lbs.
Dry Weight:
Not specified in product description, but typically in the range of 550-650 lbs.
Towing Capacity:
Not specified in product description, but likely around 1000-1200 lbs.
Atv Safety Standards:
Designed to meet ANSI/SVIA standards for recreational and utility ATVs.
Braking System:
Hydraulic disc brakes front and rear, with a sealed wet brake on the rear drive shaft for enhanced durability. Manual covers specific brake components.
Lighting:
Dual headlights, taillight/brake light. Specific bulb types and part numbers available in the manual.
Frame Construction:
Steel frame, with components like A-arms and steering linkages detailed in the manual.
Instrument Cluster:
Basic digital/analog instrument cluster with speedometer, odometer, fuel gauge, and indicator lights. Handlebar and headlight pod assembly is covered.
Atv Features:
Selectable 2WD/4WD, engine braking (via CVT). No advanced electronic driver assistance systems like traction control or ABS found on modern vehicles.
Oil Change Interval:
Typically every 100 hours or 6 months. Refer to the vehicle's owner's manual for precise intervals.
Air Filter Service:
Check every 20 hours, clean/replace as needed, especially in dusty conditions. Manual provides part number.
Spark Plug Replacement:
Typically every 100-200 hours or annually. Manual will specify the correct plug and gap.
Gearcase Oil Type:
Polaris recommends synthetic gearcase lubricant. Specific SAE viscosity and Polaris part number will be in the full service manual, but this parts manual lists the gearcase components.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Refer to owner's manual for exact specification.
Common Atv Wear Items:
CV boots, drive belts, suspension bushings, wheel bearings, and brake pads are common wear items that this manual's parts listing would support replacement for.
Included Tools:
The manual lists a 'Tool Kit' section, indicating essential tools for field repairs or basic maintenance are also cataloged.
Polarisi Atv History:
Polaris is a pioneer in the ATV industry, known for introducing innovative features and expanding the market since the late 1980s.
Xpedition Line:
The Xpedition line was introduced by Polaris as a versatile, powerful utility ATV designed for both work and aggressive trail riding, often featuring IRS (Independent Rear Suspension) in larger displacements, though the 325 might differ.
Production Era:
Early 2000s, a period of significant growth and competition in the ATV market.
