Xpedition 425, used atv a lot last year, ran good, just had some issues in the trans. Hard to get from 1st to neutral, also when going from reverse to neutral; it would go to first gear. Also in 4th gear, while driving, I could hear what sounds like the sycronizers rubbing, at times. I can deal with this issue for now. I can’t seem to get it running right. Started to be really hard to get started. Took carb off, cleaned out some gunk but wasn’t a lot. Found the diaphragm on the side of the card had a small hole in it, took me forever to find a replacement. Mikuni carbs website, part was for a Yamaha 300 I believe, but fit just right. After this, still wouldn’t start right, so I tried a aftermarket carb off eBay, it leaked and wouldn’t come off idle without dieing, adjusting made no difference. So used a few parts from new carb( needle and float for original carb), reinstalled. Found a video on YouTube about adjusting choke and throttle cables, did this and was able to get engine to start easier. Now when running, it will idle and I can rev it. However, idle is not consistant. I’d will sometime hiccup and shut off. When this happens I see a spurt of fuel into the fuel filter going to carb. I have checked valves, they were good, and i didn’t notice any abnormal wear on the cam lobes. I have checked the intake tube, and no splits or leaks. Fuel valve has been replaced, tank cleaned out, new fuel lines, fuel pump is new. Also noticed the fuel filter is not filling with fuel when running. When it does the hiccup and shuts off, it will restart fairly well. I’m at a lose and will soon take to a Polaris dealer, which I hate to do.

 

Hello, I was following up to see if you had a resolution to this?

I recently picked up a clean Xpedition that had been sitting in a barn for a few years. It had bad gas and the carb was completely clogged but now I have it running pretty good. It does however have the similar idle issue where it sputters and sometimes will shutdown, I have the idle set a little high to prevent this from happening. I also have similar issues surrounding neutral/reverse where finding neutral from first gear can sometimes be hard and shifting out of reverse can be difficult... I think I have traced those issues to the reverse actuator. When the actuator works, I am able to shift normally through reverse - neutral - 1st - neutral. When the actuator does not work as it should, shifting between those gears is sometimes impossible without shutting off the engine.

Thank you and I look forward to your feedback.