Man when it rains it pours! After troubleshooting my ingition problem and realizing the stator was bad, I went to push the quad back into the garage. I knew it was in gear so I kicked the shifter down and it snapped off.
I have the service manual for my quad but was wondering if anyone else has had this problem and how difficult it is to fix.

Do you have to remove the clutches to get the shaft out/in? Also, what should I use to ensure I get a good gasket seal when I put the cover back on?

 

dressel1 had the same thing happen a while back, he may be able to help. I hate hearing all your bad luck with the Xped, good luck.

 

Hey Ronnie,

I do recall Dressel1 having that happen. I kind of made a joke out of it. (sorry Dressel1).
I was reading a Dirt wheels the other day, and another guy had it happen. The replacement he got was machined differently. He said it was tapered to the splines instead of a square cut. It sounds like Polaris reengineered the shaft. I now this doesn't help you now, but I think I will take this guys advice and carry a set of Vice grips in my tool box.

Brian

 

Fyi, the article described above is in the March Dirt Wheels on page 28.

 

 

Pfelect,

Don't feel to bad. The stator burnt up on my bike and developed a few other problems this weekend. From what the book shows you are gonna have to pull both clutches off to get the shaft out. The good news is that it does not run all the way through the motor like most shafts do. You could seal the cover with gray permatex but I would just get the gasket from Polaris. It does not look like it is a difficult job to do. The hardest part will be getting the nuts off of the clutches. Good luck. When I get my bike back I am going to look and see which shaft is in it.

 

I think I will be more carefull when I shift those
gears. It must not be that hard to break them. I have jerked down on the shifter a time or 2. I may
order 27 inch mudbugs today. I looked around on the internet and could not find any, other then from highlifter. I bought polaris's new style gas cap. Mine was leaking. Got tired of monkeying with
the gasket in there all the time. It was only about 4 dollars and 50 cents. Hope it works better. My atv has had dificulty starting this winter. I store it in my dads garage in northern minnesota. The method I found that will get it started is to take a light bulb on an extension cord. I can't remember what you call it. I place it under the plastic near the carb. for about 20 minutes. then it always starts. It then always starts the rest of the day. Even if I leave it off
and it gets very cold again. But by next morning, I have to use the light bulb. I put isophropol in the gas to. I was at polaris dealer 3 days ago. and I did see on a xpedition they had installed. that the emergency break on the right side is not the same style as whats on mine. I think its the same one they put on there sportsmens. I hope you get your shifter fixed all right.

rangerchet, 2000 polaris xpedition 425 cc 5-speed.
actually it was made in 99 but they call it a 2000
model.

2000lb. warn. winch. polaris's new brush guard. short extender bar on the front storage rack. 2 gun, gun rack mounted on that. 4 inch extender bar mounted on back storage rack. Tamarack utility box
fits nicely inside that. K&N air filter. 26 inch mudbugs with itp magnum billet aluminum rims. Crome lugnuts that completely cover the lug bolts.
Polaris's extended mudskirts. Progressive lift springs/cams in the front. two bar bumper mounted on the back. Polaris Coffee cup/beer/pop can holder mounted on the handle bar. planning to buy
27 inch mudbugs. rangerchet

 

Ronnie,
Sorry to hear about your bad luck on the Xpedition.. I pulled a guy out of Mocassin Slough last time I rode, and his shift shaft was broken off also.. I've heard of SEVERAL occurances of this happening on the earlier Xpeditions... Is it still under warranty? Maybe your dealership will spring for the part if you fund the labor???... On the gasket, buy a new one as others have said... It's cheaper in the long run than taking it apart twice... Dang ATV oil is EXPENSIVE!!.. Tracy now owns the USS_Polaris... I'm currently without a ride... guess that will motivate me to get the Super Possum goin... Nah'-Prolly not..
Good Luck with the Xpedition...

 

I appreciate the input guys. I ordered the shifter shaft from Chopperbill when I was ordering the stator, both should be here this week.

Hey Robert,
This is an ATV forum, if you dont own one, what are you doing here?....LOL
You need to get that Possum up and runing, either that or just go get you a new one. Youve got a job now, no excuses right?

 

Ronnie,
Couldnt have put it in better words myself. The man thinks he can just work all day and never play, whats up with that. Robert, you need to quit working on that yamaha and get busy building up the Super Possum. If ya ever get MudSick, you can always ride in the bed of the 6x6 and guard the cooler. Hope to ride with one of yall in the near future, later. Ryan