My dealer finally talked to polaris about my rev box sticking. The dealer said they would replace the box because its a saftey issue. Even though the warrenty has expired. I have to take the whole machine in to the dealer
and he will fix it. I'm kind a curious why I cant take just the box in and switch with the dealer. Anyway it should be fixed at no cost to me, thats always good news. Hope anyone else with the same problem gets results like mine.


2000 expedition 425
warn 2000lb winch

 

Thanks for the info... Maybe it will get my dealer off his ***[img]i/expressions/face-icon-small-mad.gif[/img]

 

i have a Xpedtion 4x4 with a lift and k&n filter i have 1,500 mile and had the atv one year. I have replaced this black box three times and i dont ride in much water or mud. I am very pissed off at my atv. everything keeps breaking its in the shop now getting a hole new engine put in. It just decided to lock up on me. Yea i would expect this from a four wheeler that was not taken care of. But I dont ride hard at all and i grease and change all of the fluids every 200-500 miles even thow the dealer say 800 miles. and the peace of crap just keeps breaking. I would tell you every thing that broke on it but that would take all day to list. My friends have Hondas and ride the hell out of them and dont break at all. I am getting a real mans four wheller HONDA!!!!!!!!

 

Is the Xpedition the only quad with this 'BLACK BOX'?

I have only heard of this problem with Xpeditions. My friend has a Sportsman and I do not think he has a black box on his machine.

Do the Xplorer 400s have a box?

 

Yes the only quads that have these are the Xpedition 425's and 325's, because they are the only manual shift Polaris's. The reverse operates differently through the PVT on the automatic models!!!!

Peace Out Dudes!!!!

 

The Xpedition is the only Polaris with the "Black Box" it is an actuator for the reverse lever on the MANUAL gear box. I attached an old lawnmower carb. spring to the lever and the mounting bolt to pull the lever back down after use. Seems to work for 4 months since my 2nd "box" died.

I too have a POS Xpedition that ALWAYS breaks, But I love to ride.

 

I'm going to try the spring idea... sounds better than puting a new box on that will probably go bad anyway!

 

Maybe the new box is not any better then they old box. I am on my 2nd. box. polaris replaced my original and paid for it. that original black box was considered an un-official recalled part. Its not recorded as a recall but any one bring there atv back with it broke and it was the original one. they were replacing it. even after warranty which they did for me to. My 2nd. one is still working most of the time. When it dont I just reach down and push the lever down. rangerchet 2000 polaris xpedition 425 cc 5 speed.

 

I have a 2000 Expedition 425 and it will stick in reverse and I have trouble getting it out. What could be the problem? Is it that little black box doing it.

 

Not that it is my business but it has been found by many riders that the K&N gauze style air filters are not the best use on an ATV. They are not intended for very dusty conditions that arc’s can be exposed too. The foam style or stock paper element with the ore filters are considered to be a much better option.
There are multiple accounts of engines getting “dusted “ by using the gauze style filters. They are just not able to trap enough of the very fine particles and can ruin engines