I just picked up a 2000 Xpedition 425 that has been sitting for a couple of years. I cleaned the fuel system and got it fired up! So where to go from here?

Needs:
Seat foam and cover (does the Sportsman seat fit on the Xpedition? Would like to have camo)
Battery (Which brand is the best?)
Oil change (What oil and filter are the best without breaking the bank?)
Coolant (What coolant to use or not to use and how to make sure there is no air in the system?)
4 wheel drive does not work (Found a broken grey wire that goes to the right front hub)

Wants:
Supertrapp exhaust (anyone have one or know where I can find one?)
Will a 500 exhaust fit or work on the 425 engine?
K&N (the good, bad, and ugly?)
500 H.O. cam, intake, and carb (worth it?)

If anyone has any upgrade or performance input or ideas I am all ears.

-Thank you

 

does it shift....polaris had a recall on those for bolt coming loose in the tranny and it locking up.

 

The headpipe and the muffler are different on the 425 and 500 models, but it looks like the seat is the same.

http://partsfinder.onlinemicrofiche..../showmodel.asp

With the 425cc 4-stoke engine it's difficult to make big power without spending big money. I have a Sportsman with the same engine as you have and I would recommend going with simple bolt-on parts like an exhaust, filter, clutching and airbox mods for the best bang for your buck and less headaches.

If you want a Supertrapp exhaust you'll probably have to order it directly from Supertrapp unless you just want a slip on muffler. Hot Seat makes a really nice exhaust for Polaris but it's not adjustable like the Supertrapp and may be too loud for some people.

For a battery and oil I go to places like Rocky Mountain ATV or Dennis Kirk.

Some people like K&N and some people don't. I happen to be one of the people that like them and run them on all three of the ATV's that I own with an Outerwear. The best advice I could give anyone on airfilters is to try a paper, foam and cloth filter and see which one they like best. If you're looking to make more power then focus on the airbox and air intake tube and see where you can improve on the air intake velocity in those areas.

Here's what my Sportsman sounds like with the Hot Seat exhaust.

 

Halffwolf - As far as I know it does shift. I have not driven the wheeler around the yard yet, but I have had to shift it in and out of gear while moving it from the truck to the garage. Was the recall a safety or service recall? I plan on running the VIN through the dealer to see if the work has been done yet.

WaaHehe- Thank you for the info and video, your machine looks real clean. Does Speedwerx (Hotseat) make a full exhaust or just the slip on muffler? Supertrapp does not list an exhaust for the Xpedition on their website, but I know they made them once upon a time. As for the filter I have had paper, foam and cloth, but I am just wondering if one is more reliable than the other. I am assuming K&N is the best choice.

Thanks

 

Been too long to remember what we had to do on the recall. If the vin site doesn't show warranty/recall work performed,any Polaris dealers site can.CPSC, Polaris Industries Inc. Announce Recall of ATVs | CPSC.gov

 

safety

 

I know that Hot Seat used to sell both a slip on and a full system, but I'm not sure if they still sell both of them. Supertrapp sells a universal muffler that would probably work well with either the factory head pipe or a bigger headpipe from a different brand. The best thing to do would be to call Supertrapp and Hot Seat and talk with one of their tech guys and see what they have and recommend. Supertrapp might even be willing to put a system together for you.

Back in 1990 with the help of a friend and Summit Racing I made a Supertrapp exhaust system for a V6 Fiero that I owned with good results.



With airfilters I like a K&N with an outerwear for the best performance. Someone else might like a foam UNI filter with a pre-filter that probably works well for them. With a cloth filter like a K&N I think that it's best to run a Outerwear for maximum protection because when cloth gets wet it absorbs water and doesn't allow much room to breath. With an Outerwear you can pour water over it and it beads up and runs off, plus mud doesn't stick to it as easily or clog it up.

 

Welcome to the Polaris Foot Shifter Club!

I bought a used '02 Xpedition 325 few years ago for a couple hundred bucks, put a little bit of work into it and love it!

Mine came with a Supertrapp on it, not sold either way, I ended up taking half the discs out to quiet it down a bit.

I have dreamed about finding a good used 425 to put in it. Like you doing the 500 piston/jug, head, cam and carb. Have a look at this guys' project, he has videos posted on youtube.

2000 polaris expedition 425 4x4

If you are simply interested in bolt on stuff:

Aaen Performance - Polaris ATV Four Stroke - ATV Accessories