Hi, new to the forum and just got a 2000 425 xpedition that has been sitting for 4yrs and in the process of doing a complete tuneup. Changed front hub oil with demand drive fluid, greased it, changed fuel and air filter, checked front and rear diff. On the diffs what is proper fluid level, do you top them off at check bolt, when I checked them they were both about 1 inch below that. Is that normal? I'm going to change spark plug and engine oil. I do have repair manual ordered, but take week to get. Can't find any info on quad about spark plug gap or oil. I need to know gap, know it takes 0w-40 oil and holds around 5.5 qts. I'm looking for good oil that is a little cheaper than polaris. Also does it take synthetic? It needs outer tie-rods and needle and seat for carb, can't seem to find complete rebuild kit. Any sites to get parts for this? Overall quad looks new, only has 74hrs 527 miles on it. I know tranny recall was completed, checked with polaris. Sorry for long post and any info would be appreciated.

 

It holds 5.5 qts of oil? So my 350 ci engine in my truck only needs .5qts more than your 425 cc quad? That seems like a lot...my grizzly only gets 2.1!

 

I read that it actually takes 5 quarts and when the manual said 5.5 it was a misprint.

 

Synthetic only! You can us Mobil 1 0w40,don't use car oil on this engine since it has a wet clutch.(NO energy conserving oil as it has friction modifiers that cause clutch slippage) I does just take a bit over 5 quarts(at least the last one I changed) As far as filters the Polaris # 3084963 will cross over to several filters(Fram 6017, K&N 303,Wix 51358,etc) This filter is used on many different atvs and motorcycles. There are carb kits sometimes on Ebay,but the needle and seat are mainly what you need as you can just clean and reuse the jets. Try Cycle Parts Warehouse # 3131360 needle valve assembly is $27, cheaper than the dealers(there are other parts suppliers out there as cheap or cheaper) Plug gap straight out of the box is close to range usually (.032) Also check the valves, .006 intake and exhaust and also change the oil between 40-50 hrs as this was the last year model on the soft cams! Some would hold up some would flatten the exhaust cam lobe! Overall they were good machines and the only problem I encountered on several was after a time the reverse actuator would go out(but you can shift the lever by hand if you don't want to replace the actuator! Good luck! PLUS welcome to the forum! OPT

 

0w-40 grade only comes in synthetic. The ATV takes 2 quarts tops. Its the exact same Fuji built motor as there 500s and 455s just a different bore and stroke.

600 miles and you need to fool with the carb? I have 4000 miles on my 2001 and 8000 miles on our 97 and never even took the carb off once.

 

TLC the Expedition 425 is NOT the same engine! It has two wet clutches and has a five speed auto clutch transmission and holds a little over 5 quarts of oil! Similar in design to the old Honda atv autos that have been out for years! When I first had to do an oil change on one years ago when they first came out,I had to pull the manual too! The engine cases are somewhat similar as is the top end,but that's where the similarity ends! My 5.3 Chevy engine hold six quarts, and first time Expedition 425 owners couldn't believe they held that much oil either when they read the owners manual! Mobil 1 ow40 is API certified synthetic but doesn't have as many of the friction modifiers as the other weight Mobil 1 oils have that can cause a motorcycle or atv wet clutch to slip UNLESS they have changed the formula recently? Another oil that others have used is Rotella 5w40 synthetic which is really for diesels but doesn't have friction modifiers in it and is Jaso ma and md certified which most motorcycles require! I've used it in my Honda 750 and my son uses it in his Suzuki SV1000. We didn't sell but about 5 or 6 Expedition 425s so I don't know how this oil worked out in this atv,but I know a couple people that have used it. Bad thing is now it costs almost as much as Mobil 1. OPT

 

TLC yes I know 527 miles and 75hrs isn't much time, but I bought the quad off friend for $1200 and had been sitting for 4yrs. It would start and run with choke on and wouldn't respond well to any throttle. Took carb apart today and float body was all tarnished and needle was stuck in seat, I'm impressed that it would run. I have 2 other quads 660 grizzly with 3,500 miles and 400 big bear 10,000 miles and never done anything to either carb, but neither sat idle for 4yrs.

 

Ok I thought it had the same 425 as the 05 400 Sportsman. I never seen a foot shift Polaris ATV before, sounds cool though.

Here is a PM I received from a person who swapped a 425 for a 500 H.O motor. He also used the 425's smaller 34mm carb vs the 500's larger 40mm.

 

Sorry to hijack this thread but couldn't see where to start a new one. We just got a 2001 Polaris Xpedition 425 Manual. Went to start it today and the electric start will not work. What is the override button for? Any help will be appreciated.

We did press the override button several times while it was running not reading it correctly and thinking is was an "Over DRIVE" button. When hubby brought it back all was fine. Kid went to use and turned key and put start button to run and correctly tried to start and would not. Started with pull cord just fine.

We are newbies to the atv world and would appreciate anyones suggestions or ideas. Thanks

 

Welcome!Has to be in neutral to crank,plus could be as simple as a dead battery? Check the voltage,should be a little over 12.5 volts if the battery is good and charging system is operating properly. Especially If you just bought it and don't know how old the battery is. If battery voltage is ok,then check that it has voltage on the sealed circuit breaker wires on each side of the black pouch in front of the battery. Could be this is the problem,allowing only pull starting? Pressing the "over ride" button shouldn't have any negative results while riding. This button just allows full power while in reverse. OPT