xpedition 425 model #a00ck42aa model …pi54.com/corp/manuals/parts/9914930r02.pdfpolaris industries...

PARTS MANUAL PN 9914930 and MICROFICHE PN 9916574 3/00

XPEDITION 425Model #A00CK42AAModel #A00CK42AB

Rev. 02

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

Parts ManualA

A-ARM/STRUT MOUNTING B13. . . . . . . . . . . . .AIR BOX B2. . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR C13-14. . . . . . . . . . . . . . . . . . . . . .CLUTCH D8-11. . . . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/

BRAKE LINE B9. . . . . . . . . . . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B8. . .COOLING SYSTEM A11. . . . . . . . . . . . . . . . . . .CRANKCASE C8. . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON C11. . . . . . . . . . . . .CV JOINT - BTB B3. . . . . . . . . . . . . . . . . . . . .CYLINDER C9-10. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A10. . . . . . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT B14. . . . . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A12. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B7. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C4. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A9. . .FRONT STRUT B5. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B6. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D7. . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . .

HHANDLEBAR and HEADLIGHT POD B11-12. . . . . .

IINTAKE and EXHAUST C12. . . . . . . . . . . . . . . .

MMAGNETO D5. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL FILTER D4. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D3. . . . . . . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B4. . . . . . . . . . . . . . . . . . . . . . .

RREAR BRAKE C1-2. . . . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A5-6. . . . . . . . . . . . . . . . .REAR HOUSING C5. . . . . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . . . . . . .REAR WHEEL DRIVE C3. . . . . . . . . . . . . . . . .RECOIL STARTER D1. . . . . . . . . . . . . . . . . . . .

SSHOCK MOUNTING C7. . . . . . . . . . . . . . . . . . .STARTING MOTOR D6. . . . . . . . . . . . . . . . . . .STEERING POST B10. . . . . . . . . . . . . . . . . . . . .SWING ARM/REAR GEARCASE MOUNTING C6

TTOOL KIT D12. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D2. . . . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for as-sembly.

2000 XPEDITION 425 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallon)Engine Oil (liters) 0W40Engine Counter BalanceOil (quarts) InjectorRack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

2.253.755.0N/AN/A9018030

Standard850

DRIVE TRAINType Shaft Ride System

CLUTCHDrive System Type 5 Speed

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)Box, Tool Volume (Cu. Inches)Box Dimensions (inches)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

65588N/A7.25478134647

49.7546

GEARCASETrans. Number and TypeShift TypeGear 1stGear 2ndGear 3rdGear 4thGear 5thGear ReverseGear PrimaryGear Secondary (At Chain)Gear Secondary (At Bevel Drive)Front Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

5 Speed ManualFoot Lever

4.1822.5621.5221.0360.7584.4842.4061.3331.3133.7/13.1/1N/AN/AN/A

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Dunlop25x8-1225x11-10

N/A43

N/A

ENGINEEngine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator Output (watts)Elec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

EH42PLE034 Cycle, Single Cylinder

Wet Sump87.9x70

4259:2 Full Stroke

Liquid200

Standard1/BST34 (CV Type)

15042.5P-8N/A2-5/8

4HB41-3CDI

[email protected]

NGKBKR5EUSFS Appr. Pending

GRAPHICSBumper Caps/Polyprop.Cargo Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverHandlebar CoverHeadlight/Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

N/AN/A

Desert DuneDesert Dune

BlackBlack

Desert DuneBlack

Desert Dune/BlackBlackBlackBlackBlack

Desert DuneBlackBlackN/AN/A

ELECTRICALHeadlight - Handlebar(watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillight (watts)Brake Light (watts)Indicator BulbBattery

N/AN/A

2 Single Beam/30 W12 V/8.26 W12 V/26.9 W12 V/1.0 W12 V/14 AH

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)ShockAdjustment

MacPherson Strut6.7

Progressive Rate Swing Arm6.5

2� Gas Charged MonotubeCam

Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

2000 XPEDITION PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUALSUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

XPEDITION 425 A00CK42AA 9915299 9914929 9914930 9916574 9914932

XPEDITION 425 A00CK42AB 9915299 9914929 9914930 9916574 9914932

A5

REAR CAB and SEATXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

2524

2

8

3

7

5

1011

15

14

16

17

18

3837

13

20

21

22

32

6

28

40

41

1

39

35

124

36

19

3

31

33

30

9

27

23

34

26

7

28

28 29

E 2000 Polaris Sales Inc.

A6

REAR CAB and SEATXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 6 Washer4 5811107 1 Foil, Rear Cab, Rear5 5411042 1 Grommet6 5432117-282

5432117-13611

Cab, Rear, Desert Dune (A00CK42AA)Cab, Rear, Porsche Red (A00CK42AB)

7 7541925 4 Nut, Nylok8 5224592 1 Retainer, Seat Latch9 5811308 1 Foil, Tape, Rear Cab10 7512242 4 Screw11 7555859 4 Washer12 7512085 2 Screw13 5431786 1 Box, Tool14 7621403 2 Rivet15 5211033 2 Bracket, Lever Retainer16 1040387 1 Latch, Seat17 7041370 1 Spring, Latch18 2682441-070

2681747-07058111045811105

1111

SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small

19 5410414 8 Bumper, Rubber20 7517599 2 Screw

21 5431787 1 Cover, Tool Box22 5410896 1 Cap, Drain23 ------ -- -- -- -- 1 Asm., Front Gearcase

(See Front Housing Pg. C4 for Details)24 7552603 4 Washer25 7512492 4 Bolt26 5811661 1 Guard, Rock27 7556065 7 Washer28 7512232 19 Screw29 7558301 2 Washer30 7542122 8 Nut31 5411548 8 Mount, Rubber32 7517264 8 Screw33 1013119-067 1 Frame, Main34 5433391-070

5433392-07011

Footwell, LH, BlackFootwell, RH, Black

35 5811111 1 Foil, Foam, Rear Fender36 5811106 2 Foil, Rear Cab, Front37 7073761 1 Decal - Carb Information38 7077446 1 Decal - Filter Element39 5811087 1 Foil, Foam40 7670057 12 Nut, U-Type Speed41 5431796

543179711

Guard, Mud, Rear, LHGuard, Mud, Rear, RH

9/01

A7

FRONT CABXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

6

78

9

1011

12

32

1819

4

1617

1413

159

1

4

4

4

5


1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5810996 1 Foil, Foam, Side Panel3 2632084-282

2632084-136

2632068-282

2632068-136

1

1

1

1

Asm., Panel w/Foam, LH, Desert Dune(A00CK42AA)Asm., Panel w/Foam, LH Porsche Red(A00CK42AB)Asm.,Panel w/Foil, RH, Desert Dune(A00CK42AA)Asm.,Panel w/Foil, RH, Porsche Red(A00CK42AB)

4 7512232 12 Screw5 5811801 1 Foam, Cab, Front6 5432088-282

5432088-136

1

1

Cover, Front, Desert Dune(A00CK42AA)Cover, Front, Porsche Red(A00CK42AB)

7 7670085 2 Clip, Spring

8 2632133-282

2632133-136

1

1

Cab, Front w/Warning Decals, DesertDune (A00CK42AA)Cab, Front w/Warning Decals, PorscheRed (A00CK42AB)

9 7670057 10 Nut, U-Type Speed10 7670009 2 Nut, Push-on11 7661645 4 Rivet12 5431798

543179911

Guard, Mud, Front, LHGuard, Mud, Front, RH

13 7541925 2 Nut, Nylok14 7555792 2 Washer15 7512085 2 Screw16 7555931 2 Washer17 7542122 2 Nut, Nylok18 7670088 4 Clip, Dart19 5811489 2 Shield, Deflector

2/99

A8

REAR RACK MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

4

3

1

2

8

6

9

11

1210

10

6

5

7

2


1 7515193 2 Screw2 7515194 4 Screw3 2670174 1 Asm., Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 2670070 2 Reflector, Red5 1040490-067 1 Support, Rear Rack6 7542343 8 Nut, Nylok

7 7670096 2 Nut, Chimney8 7512329 4 Bolt9 1040524-067

1040525-06711

Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH

10 7558402 2 Washer, Wrought11 5333332-067 4 Spacer12 7515385 4 Screw

10/98

A9

FRONT RACK and BUMPER MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

13

14

15

1617

18

12

6

5

8

910

19

20

21

2324

25

2

3

4

11

4

7

1

27

6

26

22


1 7515194 4 Screw2 2670180 1 Asm., Front Rack

(Incl. Ref. 3 and Warning Decal)3 2670071 2 Reflector, Amber4 7515399 6 Screw5 2200775 1 Kit - Front Rack Mount6 7542324 4 Nut, Nylok7 7558403 2 Washer8 5432155-070 1 Bumper9 7515391 2 Screw10 7515390 2 Screw11 7555954 4 Washer12 1013210-067

1013211-06711

Support, Front Rack, LHSupport, Front Rack, RH

13 7517386 4 Screw14 2431011

24310124030061

112

Headlight, LHHeadlight, RHBulb, Replacement

15 7515384 2 Bolt16 7558402 4 Washer17 5810467 1 Plug, Frame18 5241398-067

5241399-06711

Extension, Frame, LHExtension, Frame, RH

19 5241583-067 1 Guard, Brush20 5240591-067 1 Grill, Brush Guard21 7621330 7 Rivet22 5241224-067 1 Hitch, U-Bolt23 7670094 6 Nut, U-Type24 7512097 6 Screw25 5433315

543331611

Shield, Side, Radiator, LHShield, Side, Radiator, RH

26 7515547 2 Screw27 5211633-067 1 Plate, Back Mount

12/00

A10

DECALSXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1 2 3

5

46

78

4

20 1918

15

17

16

1312 LH

RH

109

1 11

14


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution, 4W3 7078022 1 Decal - “4x4” Shaft Ride System, RH4 7078452 2 Decal - ‘‘POLARIS” Side Panel5 7078031 1 Decal - Tank Side, RH6 7074935 1 Decal - Warning, AWD Switch7 7078354 1 Decal - Discretionary Warning8 7075741 1 Decal - Drain Recoil9 7078315 1 Logo - 45th Anniversary10 7078032 1 Decal - “425” Four Stroke, Front Cover

11 7076202 1 Decal - CE Regulation12 7078045 1 Decal - “Liquid Cooled”13 7077919 1 Decal - Warning, General, CPSC14 7078551 1 Decal - 5 Speed15 7078018 1 Decal - “4x4” Shaft Ride System, LH16 7078038 1 Decal - Tire Pressure17 7077920 1 Decal - Passenger Warning18 7078253 1 Decal - Age Warning, ATV19 7078030 1 Decal - Tank Side, LH20 7078336 1 Decal - Reverse Switch

3/00

A11

COOLING SYSTEMXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

31

2

12

11

30 29

18

34

23

10

32

35

36

37

15

33

3

19

14

2120

26

9

25

17

22

28

27

24

13

167

13

10

6

7

4

5

8

1

1

38


1 7080614 2 Clamp2 1240044 1 Cap, Pressure3 5433364 1 Filler, Coolant4 5243505-067 1 Bracket, Filler, Coolant5 7661638 3 Rivet6 5411534 1 Hose, Engine, Upper7 7080827 2 Clamp, 1”8 7512232 2 Screw9 5411632 1 Hose, Neck, Filler10 7080826 2 Clamp11 7517659 4 Screw12 2410123 1 Asm., Fan and Motor13 7670111 4 Nut, U-Type14 7542122 2 Nut, Nylok15 7558301 2 Washer16 3110032 2 Mount, Rubber17 5020572 2 Spacer18 5433059 1 Shroud, Fan19 4010161 1 Sensor, Thermal20 1240045 1 Radiator

21 7552605 2 Washer22 7512113 2 Screw23 5433317 1 Cover, Radiator24 5410607 4 O-Ring25 7052244

541163311

Valve, DrainO-Ring

26 5410584 2 Bushing, Mount27 5243503-067 1 Bracket, Radiator, Lower28 7517386 2 Screw29 5411533 1 Hose, Engine, Lower30 5521511 1 Guard, Hose31 5430743 1 Cap, Overflow, Drilled32 5810279 1 Gasket, Overflow Cap33 5433774 1 Plug, Cap34 5433318 1 Tank, Surge35 8450003-1525 1 Line, Fuel36 7052065 1 Fitting, Barbed, 90 Deg.37 7512084 2 Screw38 4010369 1 Breaker, Circuit

3/00

A12

EXHAUST SYSTEMXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

8

14

3

1

10

9

2

11

6

4

16

5

7

12

12

12

13

1110

15

16

12


1 7542324 1 Nut, Nylok2 7555716 1 Washer3 5410436 1 Washer, Rubber4 7555863 1 Bushing5 5010192 1 Bushing6 5410241 1 Dampener, Vibration7 7515306 1 Bolt, Carriage8 1260894-029 1 Silencer, Exhaust

9 7512666 1 Bolt10 3110064 2 Mount, Torque Stop11 7542301 2 Nut12 7041804 4 Spring, Exhaust13 7042029 2 Spring, Exhaust14 1260976-029 1 Headpipe15 1260955-029 1 Manifold16 5243517 2 Seal, Exhaust

10/98

A13

ENGINE MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

19

14

7

6

2

37

25

15

28

3

1

27

95

28

1213

8

4

1816 17

11

6

8

8

16

2811

11

26

2511

26

11

20

10

41

11

39

36

25

36

21

2223

2930

3029

31323334

35

42

43

24

24

3838

40

A14

ENGINE MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB


1 7547069 2 Nutsert2 3110079 2 Mount, Rubber3 3084205 2 Screw4 5240609-067 1 Bracket, Mount, Carburetor5 7515106 2 Screw6 8450003-1525 AR Line, Vent7 7052075 1 Fitting, Tee8 7080003 4 Clamp, Red9 8450040-60 AR Line, Fuel10 2530009 1 Filter, Fuel11 7547108 6 Nut, Lock, Flange12 5242964-067 1 Mount, Engine, Top13 7512315 2 Screw14 7552901 2 Washer15 3021045 1 Mount, Motor, Rubber16 7555823 1 Washer17 5132007 1 Spacer, Motor Mount, Top18 7517386 1 Screw19 4010132 1 Cable, Ground, Engine20 3085824 1 Engine, EH42PLE03 NOTE: The

Short Block assembly contains acrankcase asm., cylinder & cylinderhead assembly and a piston & crank-shaft assembly. Prior authorization isrequired for warranty consideration.

21 7512225 1 Screw22 5630960-067 1 Lever23 5411364 1 Pad24 7515406 2 Screw25 7552603 2 Washer26 7517289 3 Screw27 5242905-067 1 Mount, Engine, Lower28 5411575 4 Mount, Rubber29 7510504 3 Screw30 7555746 3 Washer31 4010241 1 Actuator, Reverse32 7517652 3 Screw33 5132141 1 Mount, Actuator, Reverse34 7517653 1 Screw35 5243586-067 1 Lever, Reverse36 7542403 4 Nut, FLEXLOC37 7515458 2 Screw38 3110044 2 Mount, Engine, Rubber39 5242984-067 1 Mount, Lower, Rear40 7555806 2 Washer41 5242965-067 1 Mount, Engine, Top, Rear42 7515398 2 Screw43 7542321 2 Nut

10/98

B1

FUEL TANKXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

22

5

20 21

9

17

15

1

11

2

13

3

18

16

14

7

4

19

8

6

16

12

10


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Fuel Cap3 5811052 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517451 2 Bolt7 7552801 2 Washer8 7558301 2 Washer9 5222154-067

5222155-06711

Bracket, Mounting, Rear, LHBracket, Mounting, Rear, RH

10 5811796 1 Foam, Intake, Splash11 5332457 2 Spacer

12 7547069 4 Nutsert13 5810317 2 Pad, Fuel Tank Bracket14 7517505 1 Screw15 5432559 1 Knob, Fuel Valve16 7080003 4 Clamp, Hose, Red17 5432733 1 Nut, Fuel Valve18 7052161 1 Valve, Fuel, 3-Way19 8450040-600 AR Line, Fuel20 7052148 1 Fitting, Fuel Outlet, Reserve21 7052147 1 Fitting, Fuel Outlet, Main22 2520143 1 Asm., Fuel Tank (Incl. 5,20,21)

10/98

B2

AIR BOXXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

23

26

10

27

9

12

14

6

2

20

5

28

16

25

24

4

11

13

7

14

11

17

29

22

3

1

21

8

14

14 1518

19


1 7517541 4 Screw2 5432859 1 Duct, Inlet3 5411422 1 Gasket, Intake4 5432868 1 Cover, Air Box5 5811482 1 Seal, Cover6 7515179 2 Screw7 7558301 2 Washer8 5243694 2 Clip, Low Profile9 5830128 1 Gasket, Duct10 5432473 1 Duct, Carburetor, Inlet11 7080413 2 Clamp12 5411539 1 Boot, Carburetor13 7080511 1 Clamp14 7080699 2 Clamp15 5411723 1 Hose, Breather, Formed

16 2530029 1 Filter, Breather17 5411724 1 Hose, Breather, Formed18 7670114 1 Rivet, Press In19 7080653 1 Clamp20 5433678 1 Box, Air21 5431863 2 Insulator22 5811650 1 Foil, Box, Air23 5432377 1 Plug24 8450059-150 AR Line, Fuel25 7080650 1 Clamp, Hose26 5242044 4 Clip27 5432601 1 Collar, Inlet, Carburetor28 7080595 1 Filter, Air29 5811633 1 Filter, Sleeve, Precleaner

3/00

B3

CV JOINT - BTBXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

BTB

1012 3 4 5

6

7

8 9

12

11

13


1 1380119 2 Asm., CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, CV Joint, Large4 7670091 1 Circlip5 5411106 1 Boot, CV6 1380094 1 Shaft Replacement (Incl. 4)7 1380092 1 Cardan Replacement (Incl. 4,6,8,9)

8 2200771 1 Kit - Cross and Bearing9 3260130 1 Yoke, Splined10 7661913 1 Pin, Spring11 7080627 1 Clamp, Band, Small12 2200773 1 Kit - Boot Replacement, CV Joint

(Incl. 3,5,11)13 2200961 1 Kit - Drive Shaft w/Sleeve BTB

10/98

B4

PROP SHAFTXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

12 3

45

6


1380141 1 Asm., Prop Shaft (Incl. 1-4)1 3260133 1 Yoke, Front Gear Case2 3260104 2 Kit - Cross and Bearing3 1350040 1 Shaft, Prop

4 3260131 1 Yoke, Prop Shaft, Transmission5 5411092 1 O-Ring6 7661913 1 Pin, Spring

10/98

B5

FRONT STRUTXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

2

35

67

8

9

1011

12

14

15

13

16

17

18

20

4

19

2122

23

2425

26

1011

4


1 5411608 2 Bumper, Strut2 7041761 2 Strut, Front3 5211115 2 Washer, Spring Retainer4 7558402 6 Washer5 7080573 2 Clamp, Rubber Coated6 7542303 4 Nut, FLEXLOC7 7517445 4 Bolt8 5810439 2 Retainer, Strut Casting Wire9 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH (See

Front Brake Pg. B7 for Details)10 3554509 4 Bearing, Tapered Roller11 3554507 4 Bearing, Tapered Roller Cup12 5222193 2 Sleeve, Hubstrut Seal13 7080306 2 Fitting, Lubrication14 2410133 2 Coil, Magnetic

15 2201311

2201312

1

1

Asm., Hubstrut, LH (32mm)(Incl. 8,11-14,22)Asm., Hubstrut, RH (32mm)(Incl. 8,11-14,22)

16 7041375-067 2 Spring, Coil17 5243364 2 Retainer, Spring, Top18 5432871 2 Ball, Pivot, Bottom19 7515339 4 Bolt20 5132062 2 Spacer, Threaded21 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve BTB

(See CV Joint Pg. B3, Ref. 13)22 3610028 2 Seal, Hubstrut23 5432872 2 Ball, Pivot, Top24 5810291 2 Spacer, Rubber25 7555749 2 Washer26 7547104 2 Nut, FLEXLOC

3/00

B6

FRONT WHEELXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

10 11 12 14

1 2

34

5

79

8

15

1625

24 7

17 18 2021

23

13

6

6

22

19


1 7512325 8 Bolt2 5242935 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm., Hub w/Bearing Race (Incl.3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5410568 2 Tire (25x8-12)17 7556004 2 Washer18 7542810 2 Nut, Slotted19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut, Lock24 1520269-067

1520269-11722

Rim, Front, Black (A00CK42AA)Rim, Front, Silver(A00CK42AB)

25 1525017 2 Valve, Rim

12/98

B7

FRONT BRAKEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

2 3

89

11

10

12

4

5 6 7


1910309 1 Asm., Front Brake Caliper, LH(Incl. 1-7,9,10)

1910310 1 Asm., Front Brake Caliper, RH(Incl. 1-7,9,10)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5131115

51311161930642

111

Caliper, Brake, LHCaliper, Brake, RHKit - Front Brake Boot

4 1930665 1 Kit - Piston and Insulator Seal(Incl. 5-7)

5 5410779 1 Square Ring, Molded (.094)

6 5410780 1 Square Ring, Molded (.103 x .134)7 5132294 1 Piston, Brake, Long8 2200465

22009012201149

111

Kit - Front Brake Pad, General DutyKit - Front Brake Pad, Severe DutyKit - Front Brake Pad, Soft Duty

9 1910299 1 Mount, Caliper10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 ------ -- -- -- -- 4 Bolt

(See Front Strut Pg. B5, Ref. 7)

10/00

B8

CONTROLS - THROTTLE ASM./CABLEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

3

1

6

5

4

2


1 5433806 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle Control5 2010188 1 Asm., Throttle Control (Incl.1,3,6)6 2010191 1 Asm., Throttle Clamp

3/00

B9

CONTROLS - MASTER CYLINDER/BRAKE LINEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

2

3

5

10

6

4

12

1

11

13

23

27

17

20

21

22

22

25

24

2616

1819

28

15

14

9

8

7


20500782200809

11

Asm., Master Cylinder (Incl. 1-13)Kit - Master Cylinder Reservoir(Incl. 1-3,13)

1 1930797 2 Bolt, Cap2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm4 2200808 1 Kit - Master Cylinder Clamp5 1930799 1 Asm., Piston Master Cylinder6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever w/Parking Latch

(Incl. 6-9)8 ------ -- -- -- -- 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8)10 1930806 1 Nut11 1930792 2 Bolt, Reservoir12 1930805 1 Bolt, Lever

13 ------ -- -- -- -- 1 Ring, Square, Reservoir14 5411297 1 Boot, Brake Line, Rubber15 5410988 2 Seal16 4110164 1 Switch, Brake Line17 1910286 1 Line, Brake, Front Hand18 7621462 1 Rivet19 7080539 1 Clamp, Nylon20 8360031-30 1 Conduit21 1930752 1 Line, Brake, Left Front w/Fittings22 7080138 8 Cable Tie23 7512084 2 Screw24 1930753 1 Line, Brake, Right Front w/Fittings25 8360011-38 1 Conduit26 7052237 1 Fitting, Cross27 1930816 1 Line, Brake28 1930674 1 Bolt, Banjo

10/98

B10

STEERING POSTXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

16

1514

2

3

4

13

9

125

6

10

5

5

8

11

6

7


1 1843067 1 Asm., Steering Post (Incl. 12,13)2 5433415 1 Bushing, Steering, Console3 7080424 1 Fitting, Lubrication4 7515321 2 Bolt5 7555878 3 Bushing6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post8 7543203 1 Nut

9 7661633 1 Pin, Cotter10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5433416 1 Bushing, Steering, Upper15 5222999-067 1 Bracket, Upper Steering Bushing16 7542324 2 Nut, Nylok

3/00

B11

HANDLEBAR and HEADLIGHT PODXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

28109

8

18

1

2

3

14

67

11

12

13

17

20

21

26

27

24

29

45

25

22

15

16

18

26

19

30

23

B12

HANDLEBAR and HEADLIGHT PODXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB


1 3280298 1 Asm., Speedometer2 7512024 2 Screw3 5433183-070 1 Panel, Instrument4 7558212 2 Washer5 7555868 2 Washer6 7541933 2 Nut7 7080229 1 Nut, Choke8 7517224 4 Screw9 5241698-067 1 Bracket, Panel, Instrument10 7080726 1 Cable, Choke11 5432926 1 Spacer, Switch, LH12 4010262 1 Switch, Handlebar, HI/LO/Rev. Over-

ride13 5431030 2 Grip, Handlebar14 5432952 1 Plug15 7517625 1 Screw, Set16 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Controls - Master Cylinder/BrakeLine Pg. B9 for Details)

17 5224715-067 1 Handlebar

18 5630629 4 Block, Handlebar19 5630633 1 Block, Riser20 7542122 4 Nut, Nylok

21 7080631 1 Clip22 4040081

401029811

Sensor (If built before 8/09/99)Sensor (Incl. 23)(If built after 8/09/99)

23 5132382 1 Cap (Used with 4010298 only)24 7517658 1 Screw25 ------ -- -- -- -- 1 Asm., Throttle Control

(See Controls - Throttle Asm./CablePg. B8, Ref. 5)

26 411026454337334010278

4010321

111

1

Switch, Ignition (Incl. Key)Nut, IgnitionBlank, Key, Series 2000, 6700, 6800NOTE: Your key can be duplicated onlyby obtaining a key blank from Polarisand having it cut by mating it with yourexisting key.Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blank fromPolaris and having it cut by mating itwith your existing key.

27 5433534 1 Cover, Key28 4040054

40400535430467

111

Indicator - Neutral/ReverseIndicator - “HOT TEMP”Plug

29 2460728 1 Harness, Pod, Headlight30 5432420 1 Cover, Screw, Hinged

7/00

B13

A-ARM/STRUT MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1 45

6

7

89

3

12

1314

27

15

16

181719

21

25

26

2423

22

2829

29 28

2322

20

31 30

2

14

9

11

10


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567

1820805

2

2

Asm., Tie Rod(Incl. 4-9)(If Built before 8/16/99)Asm., Tie Rod(Incl. 4-9)(If Built after 8/16/99)

4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7061033

706105422

Rod End, LH (If Built before 8/16/99)Rod End, LH (If Built after 8/16/99)

10 5411920 1 Boot, Seal, Rod End11 7517674 2 Bolt (If Built after 8/16/99)12 7555806

755609944

Washer, Flat (If Built before 8/16/99)Washer, Flat (If Built after 8/16/99)

13 7546904 2 Nut14 7661203 4 Pin, Cotter15 7080927 2 Joint, Ball

16 5211121 2 Bracket, Ball Joint17 7512284 4 Screw18 5410548 2 Boot, Rubber19 7542438 2 Nut, Castle20 5431150

543114911

Shield, CV Joint, LHShield, CV Joint, RH

21 7512084 6 Screw22 5433066 4 Bushing, A-Arm, Long23 5020677 4 Bushing24 5020681 2 Shaft, A-Arm25 2200627

220062811

Kit - A-Frame, LHKit - A-Frame, RH

26 7080433 2 Fitting, Lubrication27 ------ -- -- -- -- -- 1 Asm., Heavy Hubstrut

(See Front Strut Pg. B5, Ref. 15)28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Bolt31 7515415 1 Screw

10/00

B14

ELECTRICAL/TAILLIGHTXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

2

4 5

6

78

910 13

12

11

23

22

14

21

15 1617

18

19

2024

1211

34

33

29

25

32

31

30

28

30

26

27

3


1 2460696 1 Harness, Wire, Main2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2201795 1 Kit - Circuit Breaker, 10 AMP4 2432034 1 Asm., Taillight w/Brake Light (Incl.

5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw, Taillight7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight/Brake Light10 7670054 2 Nut, Speed11 7541925 4 Nut, Nylok12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 2200361 1 Kit - Battery Bolt, Short16 4010095 1 Cable, Battery/Engine17 7010032 2 Hook, Strap, Battery

18 5410424 1 Strap, Holddown, Battery19 5432077 AR Tube, Vent, Battery20 4140006 1 Battery21 5431769 1 Cover, Battery22 4010094 1 Cable, Battery/Solenoid23 4010093 1 Cable, Solenoid/Starter24 7512007 2 Bolt25 5810455 2 Pad, Mount, Rack26 7080138 8 Cable Tie27 7080492 1 Cable Tie28 2460442 1 Pigtail, Power29 5241416 1 Bracket, CDI30 7512018 3 Screw31 5131818 1 Sink, Heat32 4060191 1 Rectifier, Regulator, LR 3533 4020149 6 Clip, Rosebud34 7670109 3 Clip, Routing

3/00

C1

REAR BRAKEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

30

4

27

11

25

9

29

8

7

10

12

26

18

1

65

17

13

20

23

21

3

2

24

16

19

5

7

13

5

1817

252622

22

15

19

19

21

928

14

C2

REAR BRAKEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB


1 220118919103391930860

111

Kit - Brake Pad (Incl. Spacer and Pin)SpacerPin

2 1910270220142822014672201385

1111

Asm., Rear Brake CaliperKit, Bleeder ReplacementPiston, Caliper, DH2P, RearKit, Caliper Seal

3 7515406 2 Screw4 7555806 2 Washer5 5410988 6 Seal6 1910286 1 Line, Front Hand Brake7 1910288 1 Line, Rear Foot Brake8 7080573 1 Clamp9 7517386 2 Screw10 7080762 3 Clip, Brake Line11 7661048 2 Rivet12 7080816 1 T-Clip, Dual13 1930674 3 Bolt, Banjo

14 7542403 2 Nut

15 7542153 1 Nut, Nylok, Flange16 1930854 1 Reservoir, Brake, Rear17 7080003 2 Clamp18 1910331 1 Hose, Reservoir19 7512240 3 Bolt20 1012753-067 1 Pivot, Mount, Brake, Rear21 7542122 2 Nut, Nylok22 7558301 2 Washer23 1012991-067 1 Rod, Brake24 7041750 1 Spring25 7555919 2 Washer26 5433189 2 Bushing, Pedal Pivot27 7661401 1 Pin, Cotter28 7556090 1 Washer29 7515158 2 Bolt30 1910311 1 Master Cylinder, Foot

9/02

C3

REAR WHEEL DRIVEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

67

1011

1

12

4

8

2

3

5

9


1 7661404 2 Pin, Cotter2 7542714 8 Nut3 5131777 2 Hub, Wheel, Rear4 7512673 8 Stud5 7670081 8 Pushnut6 5411408 2 Tire, 25x11-107 1525017 2 Valve, Rim

8 1520183-0671520183-117

22

Rim, Rear, Black (A00CK42AA)Rim, Rear, Silver(A00CK42AB)

9 7555745 2 Washer10 7555796 2 Washer, Cone11 7543005 2 Nut, Castle12 5411164 2 Cover, Dust, Hub

12/98

C4

FRONT HOUSINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

2

1

3

4

5

6

7

8 12

2314

192017

21 22

25 24

2

11

16 18

10

15

1

1112

9

13


1341253 1 Asm., Front Gearcase (Incl. 1-8,11-25)1 3233319 2 Seal, Oil2 3233252 11 Screw3 3233573 1 Cover, Input, Front Housing4 3233588 1 O-Ring5 3233574 1 Nut, Lock6 3233589 1 Bearing, Ball7 3233590 1 Shaft, Input, Front Housing8 3233591 1 Bushing9 7080756 1 Clip10 8450003-1525 AR Line, Vent11 3233253 2 Plug, Drain12 3233254 2 Washer

13 3233578 1 Plug, Cap Vent14 3233524 1 Tube, Vent Hose15 3233592 1 Gearcase, Front Housing16 3233593 1 Bushing17 3233594 1 Gear, 37T, Bevel18 3233595 1 Shaft, Output, Front Housing19 3233020 1 Bearing, Ball20 3233554 1 Shim21 3233596 1 O-Ring22 3233597 1 Cover, Output, Front Housing23 3233248 1 Seal24 3233583 1 Shim25 3233582 1 Button, Thrust

10/98

C5

REAR HOUSINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

9

16

7

4

1

15

21

6

5

23

2

2019

14

3

12

18 22

2417

825

10

8

317

2

26

11

16

13


1341309

1341321

1

1

Asm., Gearcase, Rear (Incl. 1-10,14-26) (If built before 7-01-99)Asm., Gearcase, Rear (Incl. 1-10,14-26) (If built after 7-01-99)

1 3233585 2 Screw2 3233252 10 Screw3 3233256 2 Seal4 3233584

3233741

1

1

Cover, Gearcase, Output(For Gearcase 1341309)Cover, Gearcase, Output(For Gearcase 1341321)

5 3233529 1 Pipe, Knock(For Gearcase and 1341309)

6 3233587 1 O-Ring7 3233581 1 Shim8 3233268 2 Bearing, Ball9 3233580 1 Shaft, Rear Axle10 3233579

3233740

1

1

Gear, Bevel, 31T, Rear(For Gearcase 1341309)Gear, Bevel, 31T, Rear(For Gearcase 1341321)

11 7670102 3 Clip12 8450003-1525 AR Line, Vent

13 7080307 1 Clamp,Hose14 3233524 1 Tube, Vent15 3233586

3233739

1

1

Gearcase, Rear Housing(For Gearcase 1341309)Gearcase, Rear Housing(For Gearcase 1341321)

16 3233711 2 Plug17 3233324 2 Washer18 3233577 1 Bushing19 3233707

3233738

1

1

Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341309)Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341321)

20 3233575

3233714

1

1

Bearing, Ball(For Gearcase 1341309)Bearing, Ball(For Gearcase 1341321)

21 3233588 1 O-Ring22 3233319 1 Seal, Oil23 3233573 1 Gearcase, Cover, Input24 3233574 1 Nut, Lock25 3233582 1 Button, Thrust26 3233583 1 Shim

3/00

C6

SWING ARM/REAR GEARCASE MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

12

26

33

11

20

18

22

27

38

2523

34

15

9

29

11

37

910

10

15

21

75

5

30

35

8

32

1

16

28

192

3

13

14

361213

14

31

24

64

21

17


1 5132152 1 Hub, Brake Disc, Rear Axle2 ------ -- -- -- -- 1 Asm., Rear Brake Caliper

(See Rear Brake Pg C2, Ref. 2)3 3513523 2 Bearing, Ball4 5411653 1 Shield, Brake Line5 7517604 3 Bolt6 7512084 2 Screw7 7555721 3 Washer8 7542703 3 Nut, FLEXLOC9 5411532 2 Cap, Pivot, Swing Arm10 5131863 2 Nut11 5131864 2 Pivot, Shaft12 3610072 2 Seal, Pivot, Swing Arm13 3554506 2 Bearing, Roller Cone14 3554507 2 Bearing, Roller Cup15 1541323

541160212

Asm., Swing Arm (Incl. 14,15)Seal, Pivot, Swing Arm

16 1012839-067 1 Arm, Swing, Rear17 5411092 1 O-Ring18 5132201

708043311

Coupling, Prop Shaft, Rear, GreasedFitting, Lubricating

19 1380137 1 Asm., Rear Prop Shaft

20 7517585 8 Bolt21 7553201 8 Washer22 5131862 1 Axle, Rear23 7710482 1 Ring, Hog24 7517612 3 Screw25 1012881

5242851-0675811716

111

Asm., Skid PlatePlate, Skid, Rear HousingPad, Rubber

26 5131930 1 Collar, Rear Axle27 5411707 1 O-Ring28 ------ -- -- -- -- 1 Asm., Rear Gearcase (See Rear

Housing Pg. C5 for Details)29 5411531 1 O-Ring30 7661913 1 Pin31 7072533 1 Decal - Hitch32 1012740-067 1 Tube, Axle, LH33 7515481 3 Bolt34 7710471 1 Ring, Retaining35 5132075 1 Spacer, Bearing36 3610071 1 Seal, Outer Axle37 5211849 1 Disc, Brake, Rear38 5411529 1 O-Ring

7/99

C7

SHOCK MOUNTINGXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

3

8

4

711

5

6

1

9

2

10

1


1 7542439 2 Nut, Nylok2 5433213 2 Bushing3 7515415 1 Screw4 5132022 1 Tube5 5241147 1 Retainer, Spring6 7041777-067 1 Spring

7 7041774 1 Shock8 5630921 1 Cam, Adjuster9 5132021 1 Tube10 5433212 2 Bushing11 7515438 1 Screw

10/98

C8

CRANKCASEXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

5

15

17

1

1011

22

2

16

13

23 4

2019

76

8

18

3

21

1214

13

2

13

9


1 3086190 1 Asm., Crankcase (Incl. 2,3,5-18,22,23)2 3080103 2 Pin, Dowel3 3086193 1 Bush4 3084838 2 Pin, Straight5 3080676 2 Bearing, Ball6 3086196 1 Valve, One Way7 3081890 2 Screw8 3086195 1 Pin, Stopper9 3086197 1 Bush10 3084837 1 Seal, Mechanical11 3084836 1 Seal, Oil12 3083452 2 Pipe, Water

13 3084840 6 Pin, Dowel14 3086194 1 Ball, Steel15 3084834 2 Bearing, Ball16 3086192 1 Seal, Oil17 3086191 1 Bearing, Needle18 3085295 2 Bolt, Flange19 3082956 1 Gasket20 3083453 1 Plug21 3084847 1 O-Ring22 3083669 1 Bush, Starter23 3084841 12 Bolt, Flange

10/98

C9

CYLINDERXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

2

20

38

2223

21

12

5

4

37

107

34

9

25

29

1617

3

6

18

27

1

26

13

35

28

33

31

32

8

11

30

36

14

24

15

19

5

36

36

13

9

18

C10

CYLINDERXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB


1 3083166 1 Asm., Adapter Band (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 3084857 2 Pin, Straight5 3084994 4 Guide, Valve6 3084858 2 Seal, Intake Valve7 3084867 1 O-Ring8 3085072 1 Adapter, Water Out9 3084877 10 Bolt, Flange10 3084866 1 Adapter, Camshaft11 3085074 1 Gasket, Rocker Cover12 3085073 1 Cover, Rocker13 3084874 10 Bolt, Flange14 3084859 2 Seal, Exhaust Valve15 3084875 4 Bolt, Cylinder Head16 3084860 1 Plug17 3084861 1 Gasket18 3084862 1 Plug, Blind19 3084215 2 Bolt, Flange20 3085075 1 Gasket, Exhaust

21 3085326 2 Stud22 3080285 2 Nut23 3080530 2 Washer24 3085854 1 Bolt, Rocker Shaft25 3084876 4 Bolt26 3084864 1 Support, Valve Rocker Shaft (PTO)27 3084863 1 Support, Valve Rocker Shaft (MAG)28 3084838 2 Pin, Straight29 3084849 1 Union, Oil Pump30 3084873 4 Bolt, Flange31 3086198 1 Cylinder (Incl. 32)32 3084130 1 Pipe 1, Elbow33 3085370 1 Gasket, Cylinder34 3086199 1 Cover, Camshaft35 3086200 1 Gasket, Cover, Cam36 3085527 1 Cylinder Head

(Incl. 4-6,14,16-18,21)37 3085337 1 Gasket, Head38 3086201 1 Adapter

10/98

C11

CRANKSHAFT and PISTONXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

5

19

9

12

18

21

6

11

14

20

7

15

10

8

3

2

1716

4

12

8

137


1 308648830864893086490

111

Piston Ring Set (Std)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

2 3085534 2 Clip3 3085345 1 Gear 1, Balancer4 3086207

30862083086209

111

Piston Set (Std) (Incl. 2,4)Piston Set (0.25 O/S) (Incl. 2,4)Piston Set (0.50 O/S) (Incl. 2,4)

5 3085346 1 Pin, Dowel6 3086204 1 Crankshaft 27 3085024 2 Ball, Steel8 3085344 2 Spacer, Crank Pin9 3086205 1 Pin, Crank10 3086206 1 Rod, Connecting11 3085400 1 Bearing, Large End

12 30862023086203

11

Asm., Crankshaft (Incl. 3,5,6-12)Crankshaft 1

13 3240168 2 Key, Woodruff14 3083905 1 Nut, Lock15 3083904 1 Washer16 3085980 1 Nut, Slit17 3085979 1 Sprocket 118 3240088

308489230848933084894

1111

Spacer (0.6)Spacer (0.8)Spacer (1.0)Spacer (1.2)

19 3086211 1 Spacer, Crankshaft20 3084895

30848963084897

111

Spacer (0.8)Spacer (1.0)Spacer (1.2)

21 3086210 1 Shaft, Balancer

12/98

C12

INTAKE and EXHAUSTXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

14

18

15

1617

25

26

13 1211

10

6

98

22

7

19

8

21

24

4

3

21

5

20

27

23

89 6

9

1211

13


1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086025 1 Spring, Tensioner4 3086024 1 Asm., Tensioner (Incl. 1-3)5 3084922 1 Gasket, Tensioner6 3084910 2 Asm., Intake Rocker Arm (Incl. 8,9)7 3084913 1 Asm., Exhaust Rocker Arm (Incl. 8,9)8 3084912 4 Nut9 3084911 4 Screw, Adjusting10 3084909 1 Shaft, Rocker11 3084908 8 Collet, Valve12 3084907 4 Retainer, Spring13 3084906 4 Spring, Valve14 3086212 1 Camshaft (Incl. 15-18)

15 3080103 1 Pin, Dowel16 3085348 1 Lever, Release17 3085076 1 Spring, Return18 3084899 1 Pin, Dowel19 3084914 1 Sprocket 220 3081657 3 Bolt and Washer21 3084916 1 Guide, Chain22 3084915 1 Chain, Timing23 3084924 1 Bolt, Pivot, Lever24 3084917 1 Lever25 3085349 2 Valve, Intake26 3085412 2 Valve, Exhaust27 3084874 2 Bolt, Flange

10/98

C13

CARBURETORXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

50

41

38

9

53

5

52

12

4

6

4445

42

40

1939

1819

1716

25

23

31

34

33

30

1110

3

26

24

20

28

22

29

15

27

54

4748

87

49

43

3736

35

32

21

51

46

15

1213

14

C14

CARBURETORXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB


1 3130507 1 Ring2 3130508 1 E-Ring3 3130963 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Asm., Diaphragm6 3130510 1 Jet, Needle (P-8)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130569 1 Jet, Main (#150)12 3131115 1 Diaphragm13 3131116 1 Spring14 3131117 1 Cover15 3130535 6 Screw16 3130519 1 Cap17 3130518 1 E-Ring18 3130517 1 Packing19 3130515 2 Seal20 3130361 1 Pin, Float21 3130594 1 Plate22 3130532 1 O-Ring23 3130520 4 Screw24 3130590 1 Asm., Float Body25 3130521 1 Screw26 3130529 1 Asm., Float27 3130591 2 Screw

28 3130668 1 Valve, Needle (1.5)29 3130533 1 O-Ring30 3130526 1 Jet, Pilot (#42.5)31 3130522 1 O-Ring32 3130523 1 Washer33 3130525 1 Spring34 3130524 1 Adjuster35 3130546 1 Screw, Adjust36 3130545 1 Ring37 3130544 1 Spring38 3130502 1 Valve, Throttle (100)39 3130589 1 Spring40 3130514 1 Ring41 3130501 2 Screw42 3130513 1 Asm., Throttle Shaft43 3130543 1 Guide, Cable44 3130511 1 Cover45 3130512 1 O-Ring46 3130199 1 Holder, Guide47 3130538 1 Spring48 3130593 1 Asm., Plunger49 3130625 1 Jet, Air (#160)50 3131114 1 Asm., Carburetor

(Incl. 1-14,16-42,46-54)51 3084205 2 Screw and Washer52 3131351 1 Spring53 3130503 1 Asm., Cover54 3130592 4 Screw

2/01

D1

RECOIL STARTERXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7


1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bush, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bush12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3085856

308706011

Asm., Recoil (Incl. 1-6,9-11,14,15)Starter Case (Incl. 11)

15 3085083 1 Asm., Rope

1/01

D2

WATER PUMPXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

6

10

9

4

2

1

8

5

11

3

7


1 3084940 1 Thermostat2 3085352 1 Switch, Thermostat3 3086217 1 Hose, Main4 3084191 2 Clamp, Hose5 3084942 1 Washer, Seal6 3086214 1 Impeller

7 3083138 1 Gasket, Aluminum8 3085077 1 Nut, Self Lock9 3086216 1 Gasket, Water Pump10 3086215 1 Cover, Water Pump11 3086498 6 Bolt, Flange

2/99

D3

OIL PUMPXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

8

1

3

2

6 57

9

4

10


1 3086218 1 Cover, Oil Pump2 3086220 1 Rotor, Outer Feed3 3086499 1 Pump, Inner Oil4 3086900 6 Screw, Counter Sunk5 3083453 1 Plug

6 3082956 1 Gasket7 3086223 1 Spring, Relief Valve8 3086222 1 Valve, Oil Relief9 3086221 1 Strainer, Oil10 3083568 1 Bolt, Flange

1/01

D4

OIL FILTERXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

9

10

7

7

7

5

5

5

5

5

8

3

4

6

6

2

2

11


1 3084963 1 Filter, Oil2 3086228 2 Bolt, Banjo3 3086227 1 Pipe 6, Oil Delivery4 3084566 1 Bolt, Flange5 3084846 9 Gasket, Aluminum6 3083482 4 Gasket, Aluminum

7 3086815 3 Bolt, Banjo8 3086224 1 Pipe 3, Oil Delivery9 3086226 1 Pipe 5, Oil Delivery10 3086225 1 Pipe 4, Oil Delivery11 3086229 1 Bolt, Banjo

1/01

D5

MAGNETOXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

216

5

89

10

11

12

13 14

4

7

1

2

17

20

3

1518

19

16


1 30846903084979

11

Asm., Ignition Coil (Incl. 1,2)Ignition Coil

2 3084980 1 Cap, Plug, Spark3 3070175 1 Plug, Spark4 3084978 1 O-Ring5 3086234 1 Metal, Bearing6 3086232

308714011

Asm., Plate (Incl. 5,6,8-12,14,15)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086239 1 Stator (Incl. 13)10 3081342 3 Screw and Washer

11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3087141 1 Coil, Pulser14 3084977 1 Clamp15 3081256 3 Screw and Washer16 3083447 1 Band, Wire17 3086235 1 CDI System18 3083073 2 Nut19 3080077 2 Washer, Spring20 3086236 1 Switch, Magnetic21 3086238

308623111

Asm., Magneto (Incl.5,6,8-15,21Flywheel w/Ring Gear

2/01

D6

STARTING MOTORXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

9

7

11

6

12

3

18

13

17

16

15

14

5

4

10

8

7

1

3

3

3

1

2


1 30862403084405

12

Motor, Starting (Incl. 1-4,6-12)Ring, Rubber

2 3240111 4 Spring, Brush3 3086242 1 Carbon Brush Set (Incl. 2,11,12)4 3086245 1 Asm., Rear Bracket5 3083730 2 Bolt and Washer6 3086241 2 Asm., Set Bolt7 3084982 1 Washer Set8 3086244 1 Asm., Armature9 3240114 1 O-Ring

10 3086243 1 Asm., Front Bracket (Incl. 9)11 3084408 1 O-Ring12 3083649 2 Nut, Flange13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip18 3085394 1 Asm., Gear Shaft (Incl. 13-17)

10/98

D7

FUEL PUMPXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

5

2

4 3

3

5

1


1 3085275 1 Asm., Fuel Pump (Incl. 2-5)2 3084999 1 Screw and Washer3 3085000 2 Screw and Washer

4 3084591 4 Screw5 3084998 1 Diaphragm Gasket Set

10/98

D8

CLUTCHXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

2

15

6

8

7

119

1413 12

35

4

10

1

1

1617

1819

20

21

2223

24

22

2526

27

2829

3031

32333435


1 30862743086275

11

Asm., Clutch (Incl. 1-8)Outer

2 3086278 1 Washer, Thrust3 3086276 6 Disk, Clutch4 3086281 4 Bolt, Socket5 3086282 1 Bearing, Ball6 3086280 1 Plate, Lifter7 3086279 4 Spring8 3086277 5 Plate, Clutch9 3086263

3086264308626530862663086267308626830862693086270

11111111

Shim, Drive Pinion (.15)Shim, Drive Pinion (.2)Shim, Drive Pinion (.25)Shim, Drive Pinion (.3)Shim, Drive Pinion (.5)Shim, Drive Pinion (.175)Shim, Drive Pinion (.225)Shim, Drive Pinion (.275)

10 3086261 1 Bearing, Ball11 3086256

3086257

1

1

Asm., Reduction Cover(Incl. 10-12,14,15,18)Cover, Reduction

12 3086258 1 Seal, Oil13 3086288 8 Bolt, Flange14 3086259 1 Plug

15 3086260 1 O-Ring16 3084179 2 Bolt, Flange17 3086283 1 Gasket, Reduction Cover18 3086262 1 Bearing, Ball19 3086287 4 Bolt, Flange20 3086284 1 Gasket, Clutch Cover21 3086272 1 Drum, Outer22 3086271 1 Asm., Clutch (Incl. 21-23)23 3086273 1 Asm., Plate24 3086381 1 Washer, Lock25 3086378 1 Nut, Lock26 3086254 1 Bearing, Ball27 3086246

3086247

1

1

Asm., Clutch Cover(Incl. 26,27,29,30,32-35)Cover, Clutch

28 3086255 1 Plug, Blind29 3086253 1 Nut, Flange30 3086249 1 Seal, Oil31 3084874 16 Bolt, Flange32 3086248 1 Bush, Flange33 3086251 1 Pin, Clutch Cover34 3086252 1 O-Ring35 3086250 1 Lever, Release

3/00

D9


9

7

3

4

1112

14

2928

2

18

19

1

56

10

16 15

8

17

13

22

23 24

2526

27

21

20

3031

3233

34

35

34


1 3086330 1 Key2 3086324 1 Shaft, Output3 3086327 1 Seal, Oil4 3086306 1 Spring, Reverse Arm5 3086300 1 Asm., Reverse Arm6 3086322

308632311

Asm., Output Shaft (Incl. 2,3,6,7,9,12)Gear, Bevel

7 3086328 1 Ring, Snap8 3086329 1 Bearing, Ball9 3086326 1 Nut, Lock10 3086331 1 O-Ring11 3086289

3086290308629130862923086293308629430862953086296

11111111

Shim (.15)Shim (.2)Shim (.25)Shim (.3)Shim (.5)Shim (.175)Shim (.225)Shim (.275)

12 3086325 1 Holder, Bearing13 3086332 4 Bolt, Flange14 3086297 1 Asm., Reverse Cam15 3086305 1 Switch, Position16 3084566 2 Bolt, Flange

17 3086314 1 Washer, Lock18 3086310 1 Nut, Lock19 3086304 1 Chain20 3086303 1 Sprocket, Driven21 3086321 1 Bearing, Ball22 3086318

30863193086320

1

11

Asm., Pinion and Shaft(Incl. 1-3,6-10,12,21,22)Asm., Drive Pinion (Incl. 28,29)Pinion, Drive

23 3086380 1 Washer24 3086299 1 Gear, Primary25 3086302 1 Arm, Stopper26 3086311 1 Bolt27 3086301 1 Arm, Release28 3086317 1 Spacer29 3086316 1 Spacer30 3086307 1 Spring, Return31 3086308 1 Spring, Stopper Arm32 3086312 1 Key, Woodruff33 3086298 1 Asm., Shift Shaft34 3086309 2 Spring, Shift35 3086315 1 Spacer

3/00

D10


7

8

20

17

21

2223

2426

34

36 40

39

38

43

45

19

6

42

5

13

2

44

25

10

37

46

4

32

14

1235

33

1

31

3

41

11

9

16

33

15

3029

28

27

1

1716

29

29

30

47

18

D11



1 3086375 2 Shaft, Shift Fork2 3086377 2 Fork, Shift, Driven3 3086370 1 Bolt, Lock4 3086369 1 Washer5 3086368 1 Cam, Shift6 3086373 1 Bearing, Ball7 3086371 1 Pin8 3086366

308636711

Asm., Shift Drum (Incl. 3-8,21)Drum, Shift

9 3086379 1 Pin, Dowel10 3086376 1 Fork, Shift, Drive11 3086348 1 Bearing, Ball12 3086350 1 Washer13 3086341 1 Gear, 2nd Drive14 3086345 1 Collar15 3086344 1 Gear, 5th Drive16 3086346 2 Washer17 3086349 2 Ring, Snap18 3086343 1 Gear, 4th Drive19 3086342 1 Gear, 3rd Drive20 3086339

308634011

Asm., Main Shaft (Incl. 11-20,22)Shaft, Main

21 3086372 6 Pin22 3086347 1 Bearing, Ball23 3086382 1 Bush, Flange24 3086313 1 Washer

25 3086286 1 Washer, Lock26 3086285 1 Nut, Lock27 3086358 1 Gear28 3086354 1 Gear, 3rd Driven29 3086363 3 Ring, Snap30 3086359 3 Washer31 3086355 1 Gear, 4th Driven32 3086356 1 Gear, 5th Driven33 3086353 2 Gear, 2nd Driven34 3086357 1 Clutch35 3086364 1 Washer36 3086360 1 Bearing, Ball37 3086383 1 Spacer38 3086374 1 Sprocket, Drive39 3086361 1 Washer40 3086351

3086352

1

1

Asm., Counter Shaft(Incl. 27-36,39-42)Shaft, Counter

41 3086362 1 Bearing, Ball42 3086365 1 Plug43 3086337 1 Pin44 3086338 1 Pin45 3086335 1 Gear46 3086336 1 Collar47 3086333

308633411

Asm., Reverse Shaft (Incl. 43-47)Shaft, Reverse

3/00

D12

TOOL KITXPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB

1

3

8

2

10

4

5

12

9

11

6

7


1 3085544 1 Asm., Tool Kit (Incl. 3-8)2 2870725 1 Gauge, Tire Pressure3 3082657 1 Screwdriver4 3085001 1 Wrench, Open 8-10mm5 3085002 1 Wrench, Open 12-14mm6 3085567 1 Wrench, Box, 100mm7 3085569 1 Puller, Spark Plug (Wrench Handle)

8 2682572 1 Pouch, Tool Kit9 2871515 1 Lube, U-Joint, 3 oz., Case10 9915299

991492911

Owner’s Manual, ‘00 ATVSupplement, Owner’s Manual, ’00Xpedition 425

11 2871095-067 1 Wrench, Spanner, Cam12 2460442 1 Pigtail, Power

3/00

PRINTED IN THE USA PARTS MANUAL PN 9914930 and MICROFICHE PN 9916574 3/00

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