I've read thru the repair manual for my bike and found that the Exedition does not have a reverse limiter, the limiting is done by the gear ratio. Please tell me if I'm missed somethere here.
So now I'm pulling the carb apart again, going to closely examine the diaphrams, espesially on the slide.
Any thoughts on this direction?

Thanks

 

Your left control switch controls the lights: hi/low/off and also the yellow button serves two purposes: push the button to electrically allow the foot pedal to engage reverse gear and also as the reverse over ride button. When you push the button again while in reverse it over rides the limiter and allows full power while in reverse.If it cuts out in reverse,then has full power when you push the button,the limiter is working.The limiter is is in the speedo and not a separate module as the older models had. Look at the description on Item #12 as to it's functions. As far as going back through the carb,hopefully this is where your problem is. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I have 2002425 xpedition front axles turn but wheels don't help

 

have 02 xpedition 425 front axles turn but wheels don't?

 

First things first. Check that you have both small connectors for the awd hooked up under the front panel.Change hub fluid if it's been awhile. Easiest way to tell if the awd is working is to have all 4 tires off the ground,in gear,and with the awd switched on. If both front tires spin and you can't stop them,the awd is ok.If only one or neither tires turn it could be a simple grounding issue or a mechanical problem in the hubs. Here's one fix that helps on some machines.On a Sportsman 500,but has the same set up on the awd as your Expedition.

 

I started the trouble shooting process as outlined in the repair manual, I think the first step was to disconnect the black wire.
I got fire immediately, reconnected the black wire and still had fire, never lost it again.
Got it running, but wouldn't rev, only idle.
After multiple times thru the carb, finally took it to a shop.
Turned out it had a flat exhaust cam lobe.
Had cam and rocker replaced for $600
The bike has been great.
My new issue is the left front caliper is locking up on the disk, I find that the brake lever is full up hard with no movement when this happens.
I can bleed the front caliper one time and it acts ok for a bit then the lever gets hard and the front caliper grabs the disc again.
Maybe trash in the hydraulic line.
What do you think?

 

First Expedition I heard of on cam replacement,but it shares the same cam with the Magnum 425 which had problems also.Plus we didn't sell that many to begin with.Sounds liking sticking caliper piston. Piston and seal kits are available for rebuild. Also make sure you have good pads or the piston can go out to far and stick.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I have an older Polaris Expedition and I keep losing the right front wheel drive.. The left front work OK. Wher do I start to find the problem?

 

First thing I'd do is check the small wiring connector and wiring leading to the hub for any damage along with changing the Demand Drive fluid. If fluid is low or dry check for any leakage around the inside of the hub and back side of the strut for hub and strut seal leakage. If awd is still intermittent,it could be an internal hub problem such as the awd coil getting weak, wear to the face of the hub coil sleeve or armature plate problem causing problems. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse Plus could just be a simple grounding problem on the thin brown ground wires to the hub that starts at the awd switch. You can try the regrounding method this guy did on the Sportsman 500,plus another one on checking/servicing the awd system.Shows a Scrambler,but has the same system as your Magnum.