Xplorer 325 stuck in high gear.
Shfter feels ok, but will not shift down.
I will remove outer cover to inspect.
Anything I need to watch for?

 

Guess you mean the Expedion 325. Before you tear the cover off rock the machine back and forth and see if you can get it to shift down. Also pull the reverse actuator lever and see if that might help to free it from high gear. Had problems with those things.

 

Yes Xpedition 325.
The reverse is the yellow button on the left handlebar.
Is there another way to to actuate?

 

Yes the lever on the lower right side of the engine. It's the reverse actuator assembly that always screws up. The over ride button can fail and you manually pull the lever.This may or may not help but worth a shot. #21 in the parts break down or the small lever on the actuator module itself.

 

Thank you sir.
I will give it a shot.

 

i have tried shaking and jerking, still stuck.
Cover is removed. Looks like I need to remove clutches to remove shift fork
Are the threads right hand? Or left? Will I need a puller?

 

Normal right hand threads and the clutches can usually slide right off. If in doubt get the manual. 2002 same as the 2001 basically no changes in these two years.http://polaris-atv.brssm.com/2002-Po...ce-Manual.html

 

Thank you,

I have the clutches off. Found the shift fork on the end distorted. I will order and reassemble. Any tips or tricks?

Slow Ride

 

Pretty self explaining on replacing the shift fork.Taking pictures helps along with the manual in case you get into trouble.