I have a 2000 Xpedition 425, Last week the shift lever broke, I opened up the clutch cover and replaced it, But I noticed on the drive clutch (the one on the right) there was a lot of side to side play, and the inner basket is cracked. But it worked before, So i put it back together and tried it, Well It feels like the clutch is slipping. The first few gears are fine, but when I get into 3,4,5 the RPMs get high then eventually it will grab and keep going. So im thinking the play in the clutch is my problem, Does this sound right? I also put new oil in it when I put it back together, I used mobil 1 0w40 full synthetic, I thought this was wet clutch safe, is it? Thanks.

 

If the drum or is cracked then it could be the problem as well as worn clutch shoes. Mobil 1 car oil isn't the best oil for wet clutches also. Designated cycle or atv oil for wet clutches with a jaso ma or md rating doesn't have friction modifiers that can cause slipping. Most Polaris oils will work as well as oil such as what Amsoil has or even Shell RotellaT6 5w40 that a lot of atv and street bike owners use that is jaso rated. Best to have a manual to help on this as it does have a good section on both on the pressure plate clutch system along with the centrifugal shoe and drum clutch.There is virtually no difference between the 2000-2002 Expeditons and this 5 buck manual can help. 2002 Polaris Xpedition 425 Service Manual PDF Download

 

OK, thanks for the help. It is the pressure plate clutch that is cracked and the disc in it have a lot of play now, I can take the whole inner basket with disc and wiggle side to side quite a bit. Parts are almost impossible to find for this clutch system. But I did find a used whole clutch assembly on ebay. So I'll probably go ahead and get that, swap it out and fill with the shell Rotella oil.

 

Check the fiber plates out carefully as they can be worse than what you may have. You can usually reuse the steel plates but the fiber plates I wouldn't trust. You might check Vesrah or Barnett to see if they supply new ones. The centrifugal clutch is also important as it's the main power transfer to the transmission gears. Check it out carefully. Some grooving is normal on the drum. This is one expensive system if needed. Hopefully not. New OEM Polaris Xpedition 425 Clutch Assembly 2000 2001 2002 3086504 | eBay Does show to be $407 at Partzilla..

 

Ok, I can't find the fiber pads anywhere. But I need a whole new one since it is cracked, I found it on ebay for $100. As far as the other clutch, I believe that one is fine. Because it worked great before i replaced the shifter shaft. And the only thing that has changed is there is a lot more play because it got cracked more when I took it apart. As well as different oil. So I will replace that clutch and inspect the other one. As well as fill with the correct oil. And hope it works.

 

I will get that manual as well, thanks for that link. And check the fiber pads on the clutch I get. Thanks again for your help. I will update this when I get the parts in

 

I forgot to update this. I got the new clutch in and everything works perfect again. Thanks for the help.

 

Makes you feel good when you can repair one yourself,plus the money you save versus having a shop repair it.

 

Does any one have the paqrt numbers for the lock nuts that hold the clutches in place. one of the part numbers is 3086378, but I can not find the part number for the other one.

 

Try partzilla atv website they have good parts diagrams.