Howdy Folks
I just picked up a 2000 425 Expedition, the bike is in overall very good condition. Got it cheap because it has no fire.
Upon 1st inspection, I realized it was not fully automatic, I did not know Polaris made such a bike.
Fooled with it enough to get it into nuetral and rolled it up on the trailer.
I was wondering what are the gears on this this 5 down?, then 5 up?, where is nuetral? and how to find revearse?
The seller told me that the recoil housing had water in it, that leads me to believe that the stator sat in water as well. Maybe part of the reason there is no fire. He had also replace the battery, starter and CDI. I ordered a repair manual and will get to the no fire issue soon.
Going through the brakes right now.

I need all the help I can get, thanks
Paul

 

The manual will help you a lot. Yes if the recoil sat with water in it,could be some problem. 1st gear is down one position from neutral,then up for 3,4,5. Reverse is mechanical/electrically operated from the module on the right side of the atv. A lot of the time it messes up and you have to manually pull the lever,then press down on the shift lever past first to hit reverse.Item 31.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I change out the stator with an after marker one, same issue as before, I get one spark as soon as I start cranking, then no more sparks. Each time I crank, just one spark.
What should I check next?

 

Don't throw any more parts at it until you have the manual to check out all the electrical tests!

 

I got the manual today and have a good multi meter, Ill go thru it and check back in a couple of days.

Thank you

 

I disconnected the black wire from the ignition system, the first step in the trouble shooting guide and got fire. I went thru all the harnesses and found a couple of broke wires but no shorts. So I get it to start, put all the connections back together and never loose fire again. I've got thru the carb and got it very clean. The motor starts right up, idles good but bogs and dies on a little throttle. the main jet is 2.5 turns out from seat. Thinking I should go thru the fuel lines and fuel valve what do you think old Polaris tech? Thanks

 

This morning I took the fuel valve out of the circuit and connected a fuel line directly to the pump, no change.

 

Pulling the black wire(kill wire) from the cdi either means you have short in the left control cut off switch or wiring or the ignition switch itself or it's wiring,OR it doesn't happen often,but the cdi kill wire could have shorted out internally and it's a cdi problem. 2.5 turns out is about right of the fuel/air screw. Plus just have the fuel lines hooked up correctly and pull the fuel line at the carb. Crank the engine over and see if you have a good flow of fuel from the pump. If you do,I'd recheck the carb. If it still bogs and dies,could be the limiter built into the speedo.
On this it would help to have a good wiring schematic to help you trace things down. Here's a cheap 5 buck 2002 pdf service manual, which is essentially the same as your 2000 model. 2002 Polaris Xpedition 425 Service Manual PDF Download

 

I check fuel flow from the pump, made sure all fuel lines are hooked up correctly, made sure there were no restrictions in the filter and the fuel valve.
I went back thru the carberator, made sure it was very clean, noticed I was missing a small washer and O ring on a jet, Main jet I think, only one with a spring, washer and O ring. Replaced those missing parts, reassembled, smae problem still exsists.

Doesn't act it's a limiter issue, it runs really crappy when you throttle up.
That main jet screw is really hard to adjust when the carb is installed on the bike, any tricks you can share for finding the right screw driver for that?

Can the limiter just be disconnected, that device isn't jumping out at me on the drawing, I don't get it.
Look forward to your response, thanks OPT

 

If you have small hands and a small screw driver you can adjust the fuel/air(pilot) screw to get the best idle while it's running. If you're like me and you have large hands,it's hard to do. This is the tool I have,but you can find cheaper carb tools on Ebay,etc that that can make this job a lot easier. I'm not sure what color wire you have from the speedo harness on the Expedition, either gray/orange or gray/red but try jumping this wire to a brown(ground wire) or jump the gray/orange or gray/red from the left over ride switch to a brown wire and see if any change.If this doesn't work,then save up for possibly for a new speedometer which isn't cheap. http://www.ebay.com/itm/MOTORCYCLE-CARB-ADJUSTING-TOOL-90-DEGREE-/370664534563?pt=Motors_Automotive_Tools&hash=item564d53f223&vxp=mtr