The 2002 Xpedition, available in 325cc and 425cc variants, represents a robust all-terrain vehicle designed for utility and recreational purposes. A leading American manufacturer is known for its durable powersports vehicles. The Xpedition series distinguished itself with features often including independent rear suspension and a focus on rider comfort for extended use, setting it apart from more sport-oriented ATVs. These vehicles typically offer a liquid-cooled, SOHC, single-cylinder engine and an automatic Continuously Variable Transmission (CVT) with selectable gear ranges, powered by a shaft drive system, making them capable and versatile for various terrains.
This comprehensive service and repair manual provides essential information for maintaining and repairing your 2002 Xpedition 325 or 425. It covers a wide array of topics including detailed engine system procedures such as removal, installation, fuel, lubrication, and cooling, as well as drivetrain components like the transmission and drive chain. The manual also details chassis systems, electrical systems, routine maintenance, and component repair and replacement. With its focus on repair, maintenance, and troubleshooting, this English-language, searchable manual is an invaluable resource for owners and technicians alike, offering critical specifications, diagnostic steps, and rebuild information for ensuring the longevity and optimal performance of your vehicle.
Sub Model Variants:
325, 425
Vin Code Digit 4:
N/A (ATV specific)
Product Category:
All-Terrain Vehicle (ATV) Service Manual
Value Proposition:
Provides comprehensive, essential repair and maintenance data in an easily accessible digital format, offering cost-effectiveness and immediate utility compared to traditional paper manuals.
Digital Advantage:
Printable pages, smartphone accessibility for trailside repairs, lifetime protection policy.
User Profile:
ATV owners, DIY mechanics, service technicians seeking to maintain or repair 2002 Polaris Xpedition 325 and 425 models.
Manual Content Scope:
Repair, maintenance, troubleshooting, parts lookup
Estimated Page Count:
Varies by specific manual (typically 300-600 pages for comprehensive manuals)
Manual Classification:
Service/Repair Manual
Primary Language:
English
File Format:
PDF (Electronic Download)
Engine Systems:
Engine removal/installation, fuel system, lubrication, cooling, intake, exhaust, engine specifications
Drivetrain Systems:
Transmission, drive chain, sprockets
Chassis Systems:
Steering system, shocks, body work
Electrical Systems:
Electrical system, advanced troubleshooting
Maintenance Procedures:
Routine maintenance, scheduled service
Repair Procedures:
Component repair and replacement for all covered systems
Troubleshooting Procedures:
Diagnostic steps for common and advanced issues
Diagnostic Capabilities:
Comprehensive diagnostics for mechanical and electrical issues
Rebuild Information:
Detailed procedures for engine and transmission rebuilds
Specification Detail:
Includes critical torque values, clearances, fluid capacities, and electrical schematics
Scalability:
High resolution, scalable for clear printing
Binding Method:
Digital Download (No Physical Binding)
Physical Paper Type:
N/A (Digital File)
Text Searchability:
Searchable text content for quick information retrieval
Delivery Method:
Instant download after payment
Engine Type 325:
4-stroke, Liquid-Cooled, SOHC, Single Cylinder
Engine Type 425:
4-stroke, Liquid-Cooled, SOHC, Single Cylinder
Cooling System:
Liquid Cooling
Fuel Delivery:
Carburetor (Specific model may vary, manual will detail exact type)
Oil Type:
Refer to manual for specific API rating and viscosity grade (e.g., SAE 10W-40 or 20W-50 for 4-stroke ATV engines)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Drive System:
Shaft Drive (Likely AWD/4WD with selectable options)
Cvt Fluid Type:
Refer to manual for specific CVT fluid specification (often a proprietary blend or specific viscosity)
Overall Length:
Varies by model; typical for this class around 80-85 inches. Manual will provide exact dimensions.
Overall Width:
Varies by model; typical for this class around 45-50 inches. Manual will provide exact dimensions.
Overall Height:
Varies by model; typical for this class around 45-50 inches. Manual will provide exact dimensions.
Dry Weight:
Varies by model; typically in the 500-600 lb range. Manual will provide exact dry weight.
Towing Capacity:
Likely around 1000-1500 lbs. Manual will specify exact towing capacity.
Cargo Capacity:
Front and rear racks with specified weight limits. Manual will detail capacity.
Rollover Protection:
N/A (ATV design inherently lacks enclosed rollover protection)
Braking System:
Hydraulic Disc Brakes (Front and Rear). Manual will detail brake system service.
Lighting System:
Headlights, Taillight, Brake Light. Manual covers electrical system and bulb replacement.
Display Features:
Basic digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and indicator lights. Manual will detail gauge functions.
4Wd System:
Likely a selectable 2WD/4WD system with potential for automatic engagement based on wheel slip. Manual will detail operation and maintenance.
Diagnostic Ports:
The manual will detail any diagnostic connectors for electronic troubleshooting.
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first. Manual will provide precise intervals.
Air Filter Maintenance:
Check and clean/replace every 25-50 hours or as needed based on operating conditions. Manual will detail specific procedure.
Spark Plug Replacement:
Recommended replacement at specified mileage or hours. Manual will provide interval and spark plug part number.
Coolant Type:
Ethylene glycol-based antifreeze for liquid-cooled engines. Manual will specify the exact type and mixture ratio.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify the exact type and bleeding procedure.
Typical Wear Items:
CVT belt wear, suspension component wear, electrical connections, fuel system cleaning (carburetors).
Common Repairs:
Refer to manual for specific common issues related to the 325cc and 425cc engines and drivetrains. Common areas include starter solenoid, fuel petcock, and drive clutch maintenance.
Manufacturer:
Polaris Industries Inc. is a well-established American manufacturer known for powersports vehicles including ATVs, snowmobiles, and UTVs.
Xpedition Series:
The Xpedition line was Polaris's foray into larger, more utility-focused ATVs, often featuring independent rear suspension (IRS) and more comfortable seating for longer rides, distinguishing it from sport-oriented models.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States, primarily in Minnesota and Iowa. Specific location for 2002 models would be detailed in factory documents.
Market Reception:
Polaris ATVs from this era were generally well-regarded for their performance and utility. Specific awards for the Xpedition model would be detailed in industry reviews from the period.
