Transcript
XPEDITION 425 Model #A00CK42AA Model #A00CK42AB Rev. 02
E 2000 Polaris Sales Inc.
PARTS MANUAL PN 9914930 and MICROFICHE PN 9916574 3/00
TABLE OF CONTENTS XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Parts Manual
A
A-ARM/STRUT MOUNTING . . . . . . . . . . . . . B13 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
C
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS - MASTER CYLINDER/ BRAKE LINE . . . . . . . . . . . . . . . . . . . . CONTROLS - THROTTLE ASM./CABLE . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON . . . . . . . . . . . . . CV JOINT - BTB . . . . . . . . . . . . . . . . . . . . . CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
D
C13-14 D8-11 B9 B8 A11 C8 C11 B3 C9-10
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
E
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . B14 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A13-14 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A12
F
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . FRONT HOUSING . . . . . . . . . . . . . . . . . . . . FRONT RACK and BUMPER MOUNTING . . . FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
B7 A7 C4 A9 B5 B6 D7 B1
H
HANDLEBAR and HEADLIGHT POD . . . . . . B11-12
I
INTAKE and EXHAUST . . . . . . . . . . . . . . . . C12
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D5
O
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D4 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D3
P
PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . B4
R
REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . REAR CAB and SEAT . . . . . . . . . . . . . . . . . REAR HOUSING . . . . . . . . . . . . . . . . . . . . . REAR RACK MOUNTING . . . . . . . . . . . . . . . REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . RECOIL STARTER . . . . . . . . . . . . . . . . . . . .
C1-2 A5-6 C5 A8 C3 D1
SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . STARTING MOTOR . . . . . . . . . . . . . . . . . . . STEERING POST . . . . . . . . . . . . . . . . . . . . . SWING ARM/REAR GEARCASE MOUNTING
C7 D6 B10 C6
S
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . D12
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D2
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
2000 XPEDITION 425 SPECIFICATIONS BRAKES Type - Front Type - Rear Type - Auxiliary Type - Parking
ENGINE Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic Lock, All Wheel
CAPACITIES Coolant Capacity (quarts) Fuel Tank (gallon) Engine Oil (liters) 0W40 Engine Counter Balance Oil (quarts) Injector Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight
2.25 3.75 5.0 N/A N/A 90 180 30 Standard 850
DRIVE TRAIN Type
Shaft Ride System
CLUTCH Drive 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)
65 588 N/A 7.25 47 81 34 647 49.75 46
GEARCASE Trans. Number and Type Shift Type Gear 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Reverse Gear Primary Gear Secondary (At Chain) Gear Secondary (At Bevel Drive) Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type
5 Speed Manual Foot Lever 4.182 2.562 1.522 1.036 0.758 4.484 2.406 1.333 1.313 3.7/1 3.1/1 N/A N/A N/A
TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center
Dunlop 25x8-12 25x11-10 N/A 4 3 N/A
Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc’s) Compression Ratio Cooling Alternator Output (watts) Elec. Start w/Recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Air Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust
EH42PLE03 4 Cycle, Single Cylinder Wet Sump 87.9x70 425 9:2 Full Stroke Liquid 200 Standard 1/BST34 (CV Type) 150 42.5 P-8 N/A 2-5/8 4HB41-3 CDI 30@3500 .028 NGKBKR5E USFS Appr. Pending
GRAPHICS Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color
N/A N/A Desert Dune Desert Dune Black Black Desert Dune Black Desert Dune/Black Black Black Black Black Desert Dune Black Black N/A N/A
ELECTRICAL Headlight - Handlebar(watts) Headlight - Front Hood (watts) Headlight - Grill (watts) Taillight (watts) Brake Light (watts) Indicator Bulb Battery
N/A N/A 2 Single Beam/30 W 12 V/8.26 W 12 V/26.9 W 12 V/1.0 W 12 V/14 AH
SUSPENSION Front Type Front Travel (inches) Rear Type Rear Travel (inches) Shock Adjustment
MacPherson Strut 6.7 Progressive Rate Swing Arm 6.5 2² Gas Charged Monotube Cam
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’S MANUAL
OWNER’S MANUAL SUPPLEMENT
PARTS MANUAL
PARTS MICROFICHE
ASSEMBLY INSTRUCTIONS
XPEDITION 425
A00CK42AA
9915299
9914929
9914930
9916574
9914932
XPEDITION 425
A00CK42AB
9915299
9914929
9914930
9916574
9914932
REAR CAB and SEAT XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
E 2000 Polaris Sales Inc. 16 7
15
8 9
6
10 1
4
18 20
11
19
13 12
5
3 2 41
17
14
38
37
39
21 36
7
22
3
35 28 40
34 33
32
23
31
30
24 25
28 29 26 27 28
A5
REAR CAB and SEAT XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
19 20
7661645 7511930 7555792 5811107 5411042 5432117-282 5432117-136 7541925 5224592 5811308 7512242 7555859 7512085 5431786 7621403 5211033 1040387 7041370 2682441-070 2681747-070 5811104 5811105 5410414 7517599
Qty.
10 2 6 1 1 1 1 4 1 1 4 4 2 1 2 2 1 1 1 1 1 1 8 2
Description
Rivet Bolt Washer Foil, Rear Cab, Rear Grommet Cab, Rear, Desert Dune (A00CK42AA) Cab, Rear, Porsche Red (A00CK42AB) Nut, Nylok Retainer, Seat Latch Foil, Tape, Rear Cab Screw Washer Screw Box, Tool Rivet Bracket, Lever Retainer Latch, Seat Spring, Latch Seat Covering, Seat Foil, Seat Base, Large Foil, Seat Base, Small Bumper, Rubber Screw
Ref. Part No.
Qty.
21 5431787 22 5410896 23 - - - - - - -
1 Cover, Tool Box 1 Cap, Drain 1 Asm., Front Gearcase (See Front Housing Pg. C4 for Details) 4 Washer 4 Bolt 1 Guard, Rock 7 Washer 19 Screw 2 Washer 8 Nut 8 Mount, Rubber 8 Screw 1 Frame, Main 1 Footwell, LH, Black 1 Footwell, RH, Black 1 Foil, Foam, Rear Fender 2 Foil, Rear Cab, Front 1 Decal - Carb Information 1 Decal - Filter Element 1 Foil, Foam 12 Nut, U-Type Speed 1 Guard, Mud, Rear, LH 1 Guard, Mud, Rear, RH
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
7552603 7512492 5811661 7556065 7512232 7558301 7542122 5411548 7517264 1013119-067 5433391-070 5433392-070 5811111 5811106 7073761 7077446 5811087 7670057 5431796 5431797
Description
9/01
A6
FRONT CAB XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
5
1
6
2 3
4
7 8
15 4
14
9
11 10
12 13
4
9
4
17 16
18 Ref. Part No.
1 5811491 2 5810996 3 2632084-282 2632084-136 2632068-282 2632068-136 4 7512232 5 5811801 6 5432088-282 5432088-136 7 7670085
Qty.
19
Description
1 Foil, Side Panel, Gen. IV, RH 1 Foil, Foam, Side Panel 1 Asm., Panel w/Foam, LH, Desert Dune (A00CK42AA) 1 Asm., Panel w/Foam, LH Porsche Red (A00CK42AB) 1 Asm.,Panel w/Foil, RH, Desert Dune (A00CK42AA) 1 Asm.,Panel w/Foil, RH, Porsche Red (A00CK42AB) 12 Screw 1 Foam, Cab, Front 1 Cover, Front, Desert Dune (A00CK42AA) 1 Cover, Front, Porsche Red (A00CK42AB) 2 Clip, Spring
Ref. Part No.
8 2632133-282 2632133-136 9 10 11 12 13 14 15 16 17 18 19
7670057 7670009 7661645 5431798 5431799 7541925 7555792 7512085 7555931 7542122 7670088 5811489
Qty.
Description
1 Cab, Front w/Warning Decals, Desert Dune (A00CK42AA) 1 Cab, Front w/Warning Decals, Porsche Red (A00CK42AB) 10 Nut, U-Type Speed 2 Nut, Push-on 4 Rivet 1 Guard, Mud, Front, LH 1 Guard, Mud, Front, RH 2 Nut, Nylok 2 Washer 2 Screw 2 Washer 2 Nut, Nylok 4 Clip, Dart 2 Shield, Deflector 2/99
A7
REAR RACK MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1 2
3
5
2
4 6 7
8 10 11
6 9
Ref. Part No.
1 7515193 2 7515194 3 2670174 4 2670070 5 1040490-067 6 7542343
Qty.
Description
2 Screw 4 Screw 1 Asm., Rack, Rear (Incl. Ref. 4 and Warning Decal) 2 Reflector, Red 1 Support, Rear Rack 8 Nut, Nylok
10
Ref. Part No.
7 7670096 8 7512329 9 1040524-067 1040525-067 10 7558402 11 5333332-067 12 7515385
12
Qty.
2 4 1 1 2 4 4
Description
Nut, Chimney Bolt Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH Washer, Wrought Spacer Screw 10/98
A8
FRONT RACK and BUMPER MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1 2 5 3
4
7
6
14
8
13
15
12
11
16 17
10
9
18
6
4 26 27
19 20
25
21
24 23 Ref. Part No.
1 7515194 2 2670180 3 4 5 6 7 8 9 10 11 12
2670071 7515399 2200775 7542324 7558403 5432155-070 7515391 7515390 7555954 1013210-067 1013211-067 13 7517386 14 2431011 2431012 4030061
Qty.
22
Description
4 Screw 1 Asm., Front Rack (Incl. Ref. 3 and Warning Decal) 2 Reflector, Amber 6 Screw 1 Kit - Front Rack Mount 4 Nut, Nylok 2 Washer 1 Bumper 2 Screw 2 Screw 4 Washer 1 Support, Front Rack, LH 1 Support, Front Rack, RH 4 Screw 1 Headlight, LH 1 Headlight, RH 2 Bulb, Replacement
Ref. Part No.
15 16 17 18 19 20 21 22 23 24 25 26 27
7515384 7558402 5810467 5241398-067 5241399-067 5241583-067 5240591-067 7621330 5241224-067 7670094 7512097 5433315 5433316 7515547 5211633-067
Qty.
2 4 1 1 1 1 1 7 1 6 6 1 1 2 1
Description
Bolt Washer Plug, Frame Extension, Frame, LH Extension, Frame, RH Guard, Brush Grill, Brush Guard Rivet Hitch, U-Bolt Nut, U-Type Screw Shield, Side, Radiator, LH Shield, Side, Radiator, RH Screw Plate, Back Mount
12/00
A9
DECALS XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
5 1
2
1
4
3
RH
8
11
10
6
7
20
19 18
9
17
4
16
13
14
15
LH
12
Ref. Part No.
1 2 3 4 5 6 7 8 9 10
7074954 7074110 7078022 7078452 7078031 7074935 7078354 7075741 7078315 7078032
Qty.
2 1 1 2 1 1 1 1 1 1
Description
Ref. Part No.
Decal - Rack/Warning Decal - Load Distribution, 4W Decal - “4x4” Shaft Ride System, RH Decal - ‘‘POLARIS” Side Panel Decal - Tank Side, RH Decal - Warning, AWD Switch Decal - Discretionary Warning Decal - Drain Recoil Logo - 45th Anniversary Decal - “425” Four Stroke, Front Cover
11 12 13 14 15 16 17 18 19 20
7076202 7078045 7077919 7078551 7078018 7078038 7077920 7078253 7078030 7078336
Qty.
1 1 1 1 1 1 1 1 1 1
Description
Decal - CE Regulation Decal - “Liquid Cooled” Decal - Warning, General, CPSC Decal - 5 Speed Decal - “4x4” Shaft Ride System, LH Decal - Tire Pressure Decal - Passenger Warning Decal - Age Warning, ATV Decal - Tank Side, LH Decal - Reverse Switch 3/00
A10
COOLING SYSTEM XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1
6
2 4
3
14 15
7
8 9
7
16
17
10 12
5
18
13
20 19
11
38
23
13 1 31 32
10
30
25 26
29
24
27
33
28
34
37
21 22
35 36 Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
7080614 1240044 5433364 5243505-067 7661638 5411534 7080827 7512232 5411632 7080826 7517659 2410123 7670111 7542122 7558301 3110032 5020572 5433059 4010161 1240045
Qty.
2 1 1 1 3 1 2 2 1 2 4 1 4 2 2 2 2 1 1 1
Description
Ref. Part No.
Clamp Cap, Pressure Filler, Coolant Bracket, Filler, Coolant Rivet Hose, Engine, Upper Clamp, 1” Screw Hose, Neck, Filler Clamp Screw Asm., Fan and Motor Nut, U-Type Nut, Nylok Washer Mount, Rubber Spacer Shroud, Fan Sensor, Thermal Radiator
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
7552605 7512113 5433317 5410607 7052244 5411633 5410584 5243503-067 7517386 5411533 5521511 5430743 5810279 5433774 5433318 8450003-1525 7052065 7512084 4010369
Qty.
2 2 1 4 1 1 2 1 2 1 1 1 1 1 1 1 1 2 1
Description
Washer Screw Cover, Radiator O-Ring Valve, Drain O-Ring Bushing, Mount Bracket, Radiator, Lower Screw Hose, Engine, Lower Guard, Hose Cap, Overflow, Drilled Gasket, Overflow Cap Plug, Cap Tank, Surge Line, Fuel Fitting, Barbed, 90 Deg. Screw Breaker, Circuit 3/00
A11
EXHAUST SYSTEM XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1 2 3 4
5 6 8
7 12 16 9
14 10
12
11
15
13
12 12
11
Ref. Part No.
1 2 3 4 5 6 7 8
7542324 7555716 5410436 7555863 5010192 5410241 7515306 1260894-029
Qty.
1 1 1 1 1 1 1 1
Description
Ref. Part No.
Nut, Nylok Washer Washer, Rubber Bushing Bushing Dampener, Vibration Bolt, Carriage Silencer, Exhaust
9 10 11 12 13 14 15 16
7512666 3110064 7542301 7041804 7042029 1260976-029 1260955-029 5243517
10
Qty.
1 2 2 4 2 1 1 2
16
Description
Bolt Mount, Torque Stop Nut Spring, Exhaust Spring, Exhaust Headpipe Manifold Seal, Exhaust 10/98
A12
ENGINE MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
6
7 3 1
6 10
4
8
2 5
9
8
43
11
8
24 25
16
13 14
15 18
11
28
42
17
16
12
19
20
41
21 28
11
11
22
40
25
39
11 28
38
38 25 36
24
37
26 26
27
36 29
30 35
11
34
33
32
31
30
A13
29
23
ENGINE MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
7547069 3110079 3084205 5240609-067 7515106 8450003-1525 7052075 7080003 8450040-60 2530009 7547108 5242964-067 7512315 7552901 3021045 7555823 5132007 7517386 4010132 3085824
Qty.
2 2 2 1 2 AR 1 4 AR 1 6 1 2 2 1 1 1 1 1 1
Description
Ref. Part No.
Nutsert Mount, Rubber Screw Bracket, Mount, Carburetor Screw Line, Vent Fitting, Tee Clamp, Red Line, Fuel Filter, Fuel Nut, Lock, Flange Mount, Engine, Top Screw Washer Mount, Motor, Rubber Washer Spacer, Motor Mount, Top Screw Cable, Ground, Engine Engine, EH42PLE03 NOTE: The Short Block assembly contains a crankcase asm., cylinder & cylinder head assembly and a piston & crankshaft assembly. Prior authorization is required for warranty consideration.
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
7512225 5630960-067 5411364 7515406 7552603 7517289 5242905-067 5411575 7510504 7555746 4010241 7517652 5132141 7517653 5243586-067 7542403 7515458 3110044 5242984-067 7555806 5242965-067 7515398 7542321
Qty.
1 1 1 2 2 3 1 4 3 3 1 3 1 1 1 4 2 2 1 2 1 2 2
Description
Screw Lever Pad Screw Washer Screw Mount, Engine, Lower Mount, Rubber Screw Washer Actuator, Reverse Screw Mount, Actuator, Reverse Screw Lever, Reverse Nut, FLEXLOC Screw Mount, Engine, Rubber Mount, Lower, Rear Washer Mount, Engine, Top, Rear Screw Nut 10/98
A14
FUEL TANK XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1 2
3
4 6 5
7 8
9
10
22 11 20
21 12 16 19
18 17
13
16 15
Ref. Part No.
1 2 3 4 5 6 7 8 9
5430725 5810144 5811052 8360009-600 5431053 7517451 7552801 7558301 5222154-067 5222155-067 10 5811796 11 5332457
Qty.
1 1 1 AR 1 2 2 2 1 1 1 2
14
Description
Ref. Part No.
Cap, Gas Tank Gasket, Fuel Cap Seal, Foam Line, Fuel Vent, Tank Bolt Washer Washer Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH Foam, Intake, Splash Spacer
12 13 14 15 16 17 18 19 20 21 22
7547069 5810317 7517505 5432559 7080003 5432733 7052161 8450040-600 7052148 7052147 2520143
Qty.
4 2 1 1 4 1 1 AR 1 1 1
Description
Nutsert Pad, Fuel Tank Bracket Screw Knob, Fuel Valve Clamp, Hose, Red Nut, Fuel Valve Valve, Fuel, 3-Way Line, Fuel Fitting, Fuel Outlet, Reserve Fitting, Fuel Outlet, Main Asm., Fuel Tank (Incl. 5,20,21) 10/98
B1
AIR BOX XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1 29 2
3
4 5 6 7 28 8
11
27
26 9 10
25
11
21
24
12 20
23
22
13 14
17
14 16
18
14 15
14
19 Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
7517541 5432859 5411422 5432868 5811482 7515179 7558301 5243694 5830128 5432473 7080413 5411539 7080511 7080699 5411723
Qty.
4 1 1 1 1 2 2 2 1 1 2 1 1 2 1
Description
Ref. Part No.
Screw Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover Screw Washer Clip, Low Profile Gasket, Duct Duct, Carburetor, Inlet Clamp Boot, Carburetor Clamp Clamp Hose, Breather, Formed
16 17 18 19 20 21 22 23 24 25 26 27 28 29
2530029 5411724 7670114 7080653 5433678 5431863 5811650 5432377 8450059-150 7080650 5242044 5432601 7080595 5811633
Qty.
1 1 1 1 1 2 1 1 AR 1 4 1 1 1
Description
Filter, Breather Hose, Breather, Formed Rivet, Press In Clamp Box, Air Insulator Foil, Box, Air Plug Line, Fuel Clamp, Hose Clip Collar, Inlet, Carburetor Filter, Air Filter, Sleeve, Precleaner 3/00
B2
CV JOINT - BTB XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
BTB 7 2
1
3
4
6
5
8
9
10
11 12
13
Ref. Part No.
1 2 3 4 5 6 7
1380119 5222299 3260115 7670091 5411106 1380094 1380092
Qty.
2 1 1 1 1 1 1
Description
Ref. Part No.
Asm., CV Housing w/Sleeve Sleeve, Drive Shaft Seal Clamp, CV Joint, Large Circlip Boot, CV Shaft Replacement (Incl. 4) Cardan Replacement (Incl. 4,6,8,9)
8 9 10 11 12
2200771 3260130 7661913 7080627 2200773
13 2200961
Qty.
Description
1 1 1 1 1
Kit - Cross and Bearing Yoke, Splined Pin, Spring Clamp, Band, Small Kit - Boot Replacement, CV Joint (Incl. 3,5,11) 1 Kit - Drive Shaft w/Sleeve BTB 10/98
B3
PROP SHAFT XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1
2
4 3
5
6
Ref. Part No.
Qty.
1380141 1 3260133 2 3260104 3 1350040
1 1 2 1
Description
Ref. Part No.
Asm., Prop Shaft (Incl. 1-4) Yoke, Front Gear Case Kit - Cross and Bearing Shaft, Prop
4 3260131 5 5411092 6 7661913
Qty.
Description
1 Yoke, Prop Shaft, Transmission 1 O-Ring 1 Pin, Spring 10/98
B4
FRONT STRUT XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
26
1
25 24
2
23
6
3
21
4
22 10 11
20
4 19
7
5
8
18
9
13
17 12 14
16
11 10 15
Ref. Part No.
Qty.
1 2 3 4 5 6 7 8 9
5411608 7041761 5211115 7558402 7080573 7542303 7517445 5810439 --------
2 2 2 6 2 4 4 2 1
10 11 12 13 14
3554509 3554507 5222193 7080306 2410133
4 4 2 2 2
Description
Ref. Part No.
Bumper, Strut Strut, Front Washer, Spring Retainer Washer Clamp, Rubber Coated Nut, FLEXLOC Bolt Retainer, Strut Casting Wire Asm., Front Brake Caliper, RH (See Front Brake Pg. B7 for Details) Bearing, Tapered Roller Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal Fitting, Lubrication Coil, Magnetic
15 2201311 2201312 16 17 18 19 20 21
7041375-067 5243364 5432871 7515339 5132062 -------
22 23 24 25 26
3610028 5432872 5810291 7555749 7547104
Qty.
Description
1 Asm., Hubstrut, LH (32mm) (Incl. 8,11-14,22) 1 Asm., Hubstrut, RH (32mm) (Incl. 8,11-14,22) 2 Spring, Coil 2 Retainer, Spring, Top 2 Ball, Pivot, Bottom 4 Bolt 2 Spacer, Threaded 1 Kit - Drive Shaft w/Sleeve BTB (See CV Joint Pg. B3, Ref. 13) 2 Seal, Hubstrut 2 Ball, Pivot, Top 2 Spacer, Rubber 2 Washer 2 Nut, FLEXLOC 3/00
B5
FRONT WHEEL XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1
2 3
4
12
11
10
13
14
5 6
7
9
8
15
16 25 24
7
19 6
17
18
20
21
23 22
Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13
7512325 5242935 3610019 5211148 1520281 3554506 3554507 7515523 1520243 3250028 3250010 3250032 1321814
Qty.
8 2 2 2 2 4 4 8 2 2 12 2 2
Description
Ref. Part No.
Bolt Disc, Brake Seal, Front Hub Plate, Armature Clutch, Front Hub, Elec./Mech. Bearing, Tapered Roller Cone Bearing, Tapered Roller Cup Stud Asm., Hub w/Bearing Race (Incl.3,7,8) Cage, Roll Roll Spring, Garter Spacer
14 15 16 17 18 19 20 21 22 23 24
3250030 7052045 5410568 7556004 7542810 7661401 5410470 5432611 7512027 7542459 1520269-067 1520269-117 25 1525017
Qty.
2 2 2 2 2 2 2 2 6 8 2 2 2
Description
Cam Plug, Magnetic Drain Tire (25x8-12) Washer Nut, Slotted Pin, Cotter O-Ring Cap, Hub Screw Nut, Lock Rim, Front, Black (A00CK42AA) Rim, Front, Silver(A00CK42AB) Valve, Rim 12/98
B6
FRONT BRAKE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
2
3 4
1
5
6
7
12 11
10
8
9
Ref. Part No.
1910309 1910310 1 7080352 2 7515489 3 5131115 5131116 1930642 4 1930665 5 5410779
Qty.
Description
1 Asm., Front Brake Caliper, LH (Incl. 1-7,9,10) 1 Asm., Front Brake Caliper, RH (Incl. 1-7,9,10) 1 Screw, Bleeder 1 Screw, Socket Set 1 Caliper, Brake, LH 1 Caliper, Brake, RH 1 Kit - Front Brake Boot 1 Kit - Piston and Insulator Seal (Incl. 5-7) 1 Square Ring, Molded (.094)
Ref. Part No.
Qty.
6 5410780 7 5132294 8 2200465 2200901 2201149 9 1910299 10 5410495 11 5410494 12 - - - - - - -
1 1 1 1 1 1 1 1 4
Description
Square Ring, Molded (.103 x .134) Piston, Brake, Long Kit - Front Brake Pad, General Duty Kit - Front Brake Pad, Severe Duty Kit - Front Brake Pad, Soft Duty Mount, Caliper Boot, Bushing Boot, Pin Seal Bolt (See Front Strut Pg. B5, Ref. 7) 10/00
B7
CONTROLS - THROTTLE ASM./CABLE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1 2
3
4
5
6
Ref. Part No.
1 5433806 2 5410193 3 5411439
Qty.
Description
Ref. Part No.
1 Cover, Throttle Control 1 O-Ring 1 O-Ring
4 7080709 5 2010188 6 2010191
Qty.
Description
1 Cable, Throttle Control 1 Asm., Throttle Control (Incl.1,3,6) 1 Asm., Throttle Clamp 3/00
B8
CONTROLS - MASTER CYLINDER/BRAKE LINE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1 2
3 4 14
13
15
5
12
28 27
6
11 16
25
26 17
22 20
24
7
18 8
19 9
21 23 Ref. Part No.
2050078 2200809 1 2 3 4 5 6 7
1930797 1930796 1930795 2200808 1930799 1930804 2201034
8 9 10 11 12
------2201090 1930806 1930792 1930805
Qty.
10
22 Description
1 Asm., Master Cylinder (Incl. 1-13) 1 Kit - Master Cylinder Reservoir (Incl. 1-3,13) 2 Bolt, Cap 1 Cap, Reservoir 1 Diaphragm 1 Kit - Master Cylinder Clamp 1 Asm., Piston Master Cylinder 1 Rivet 1 Kit - Brake Lever w/Parking Latch (Incl. 6-9) 1 Spring, Flat 1 Kit - Park Brake Lever (Incl. 6,8) 1 Nut 2 Bolt, Reservoir 1 Bolt, Lever
Ref. Part No.
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
------5411297 5410988 4110164 1910286 7621462 7080539 8360031-30 1930752 7080138 7512084 1930753 8360011-38 7052237 1930816 1930674
Qty.
1 1 2 1 1 1 1 1 1 8 2 1 1 1 1 1
Description
Ring, Square, Reservoir Boot, Brake Line, Rubber Seal Switch, Brake Line Line, Brake, Front Hand Rivet Clamp, Nylon Conduit Line, Brake, Left Front w/Fittings Cable Tie Screw Line, Brake, Right Front w/Fittings Conduit Fitting, Cross Line, Brake Bolt, Banjo 10/98
B9
STEERING POST XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1
16
2 15 14 3
4
13 12
5
11
6 10
6 5 7 5 8 9 Ref. Part No.
1 2 3 4 5 6 7 8
1843067 5433415 7080424 7515321 7555878 5410772 5431571 7543203
Qty.
1 1 1 2 3 2 1 1
Description
Ref. Part No.
Asm., Steering Post (Incl. 12,13) Bushing, Steering, Console Fitting, Lubrication Bolt Bushing O-Ring Spacer, Steering Post Nut
9 10 11 12 13 14 15 16
7661633 5431570 7661632 5431574 7080433 5433416 5222999-067 7542324
Qty.
1 1 2 1 1 1 1 2
Description
Pin, Cotter Bushing, Steering, Lower Rivet Plug, Grease, Steering Fitting, Lubrication Bushing, Steering, Upper Bracket, Upper Steering Bushing Nut, Nylok 3/00
B10
HANDLEBAR and HEADLIGHT POD XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1 2 30 3
29
4 5 6 7
8
13 12
28
9 27
11
10
15
26
26
16 18
25
17 18 23
19
22
24
20 21
B11
14
HANDLEBAR and HEADLIGHT POD XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
Qty.
1 2 3 4 5 6 7 8 9 10 11 12
3280298 7512024 5433183-070 7558212 7555868 7541933 7080229 7517224 5241698-067 7080726 5432926 4010262
1 2 1 2 2 2 1 4 1 1 1 1
13 14 15 16
5431030 5432952 7517625 -------
2 1 1 1
Description
Ref. Part No.
Qty.
Asm., Speedometer Screw Panel, Instrument Washer Washer Nut Nut, Choke Screw Bracket, Panel, Instrument Cable, Choke Spacer, Switch, LH Switch, Handlebar, HI/LO/Rev. Override Grip, Handlebar Plug Screw, Set Asm., Master Cylinder (See Controls - Master Cylinder/Brake Line Pg. B9 for Details) Handlebar
21 7080631 22 4040081 4010298 23 5132382 24 7517658 25 - - - - - - -
1 1 1 1 1 1
26 4110264 5433733 4010278
1 1 1
4010321
1
27 5433534 28 4040054 4040053 5430467 29 2460728 30 5432420
1 1 1 1 1 1
17 5224715-067
1
18 5630629 19 5630633 20 7542122
4 Block, Handlebar 1 Block, Riser 4 Nut, Nylok
Description
Clip Sensor (If built before 8/09/99) Sensor (Incl. 23)(If built after 8/09/99) Cap (Used with 4010298 only) Screw Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B8, Ref. 5) Switch, Ignition (Incl. Key) Nut, Ignition Blank, Key, Series 2000, 6700, 6800 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Blank, Key, Series 2200, 2300, 2700, 2800. NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Cover, Key Indicator - Neutral/Reverse Indicator - “HOT TEMP” Plug Harness, Pod, Headlight Cover, Screw, Hinged 7/00
B12
A-ARM/STRUT MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 4
1
5
6
2
7 8
9
3
30
31
10
11 9 12
29 28
13 14 28
29
23
22
27 15
26 22
23
16
24 25 19
20
1 7542403 2 5333367 3 1820567 1820805 4 5 6 7 8 9 10 11 12 13 14 15
5411291 7061034 7542711 5020926 7547028 7061033 7061054 5411920 7517674 7555806 7556099 7546904 7661203 7080927
Qty. Description
2 Nut, FLEXLOC 1 Bushing 2 Asm., Tie Rod (Incl. 4-9)(If Built before 8/16/99) 2 Asm., Tie Rod (Incl. 4-9)(If Built after 8/16/99) 2 Boot, Seal, Rod End 2 Rod End 2 Nut 2 Tie Rod 2 Nut, LH 2 Rod End, LH (If Built before 8/16/99) 2 Rod End, LH (If Built after 8/16/99) 1 Boot, Seal, Rod End 2 Bolt (If Built after 8/16/99) 4 Washer, Flat (If Built before 8/16/99) 4 Washer, Flat (If Built after 8/16/99) 2 Nut 4 Pin, Cotter 2 Joint, Ball
17
14
21
Ref. Part No.
18
Ref. Part No.
16 17 18 19 20
Qty. Description
26 27
5211121 7512284 5410548 7542438 5431150 5431149 7512084 5433066 5020677 5020681 2200627 2200628 7080433 --------
2 4 2 2 1 1 6 4 4 2 1 1 2 1
28 29 30 31
7512492 7552603 7517527 7515415
4 4 1 1
21 22 23 24 25
Bracket, Ball Joint Screw Boot, Rubber Nut, Castle Shield, CV Joint, LH Shield, CV Joint, RH Screw Bushing, A-Arm, Long Bushing Shaft, A-Arm Kit - A-Frame, LH Kit - A-Frame, RH Fitting, Lubrication Asm., Heavy Hubstrut (See Front Strut Pg. B5, Ref. 15) Screw Washer, Spring Lock Bolt Screw 10/00
B13
ELECTRICAL/TAILLIGHT XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 5
4
1 3
6
2
7 9
33 11
15 16 17
13 12
10
34
14
8
18
11 12 24
22
19
23
21
20
32 30
25
31 30 29
26 27
28
Ref. Part No.
Qty.
1 2 3 4
2460696 2200593 2201795 2432034
1 1 1 1
5 6 7 8 9 10 11 12 13 14 15 16 17
4032046 4032029 4030043 4032045 4032064 7670054 7541925 7571602 7512027 5810290 2200361 4010095 7010032
1 2 1 1 1 2 4 4 2 3 1 1 2
Description
Ref. Part No.
Harness, Wire, Main Kit - Circuit Breaker, 20 AMP Kit - Circuit Breaker, 10 AMP Asm., Taillight w/Brake Light (Incl. 5-10) Lens, Taillight Screw, Taillight Bulb, Taillight Gasket, Taillight Backing, Taillight/Brake Light Nut, Speed Nut, Nylok Washer Screw Pad, Battery Kit - Battery Bolt, Short Cable, Battery/Engine Hook, Strap, Battery
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
5410424 5432077 4140006 5431769 4010094 4010093 7512007 5810455 7080138 7080492 2460442 5241416 7512018 5131818 4060191 4020149 7670109
Qty.
1 AR 1 1 1 1 2 2 8 1 1 1 3 1 1 6 3
Description
Strap, Holddown, Battery Tube, Vent, Battery Battery Cover, Battery Cable, Battery/Solenoid Cable, Solenoid/Starter Bolt Pad, Mount, Rack Cable Tie Cable Tie Pigtail, Power Bracket, CDI Screw Sink, Heat Rectifier, Regulator, LR 35 Clip, Rosebud Clip, Routing 3/00
B14
REAR BRAKE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
3 4
9
6
5
10
11
8 7
2
12
1 13 5 14
15 16 19
17 18
7 19
13
18 17
22
5
21
30
29
26
28
20
25 27
22
24
25
19
26 23
C1
9
21
REAR BRAKE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
Qty.
1 2201189 1910339 1930860 2 1910270 2201428 2201467 2201385 3 7515406 4 7555806 5 5410988 6 1910286 7 1910288 8 7080573 9 7517386 10 7080762 11 7661048 12 7080816 13 1930674
1 1 1 1 1 1 1 2 2 6 1 1 1 2 3 2 1 3
Description
Ref. Part No.
Kit - Brake Pad (Incl. Spacer and Pin) Spacer Pin Asm., Rear Brake Caliper Kit, Bleeder Replacement Piston, Caliper, DH2P, Rear Kit, Caliper Seal Screw Washer Seal Line, Front Hand Brake Line, Rear Foot Brake Clamp Screw Clip, Brake Line Rivet T-Clip, Dual Bolt, Banjo
14 7542403
2 Nut
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
1 1 2 1 3 1 2 2 1 1 2 2 1 1 2 1
7542153 1930854 7080003 1910331 7512240 1012753-067 7542122 7558301 1012991-067 7041750 7555919 5433189 7661401 7556090 7515158 1910311
Qty.
Description
Nut, Nylok, Flange Reservoir, Brake, Rear Clamp Hose, Reservoir Bolt Pivot, Mount, Brake, Rear Nut, Nylok Washer Rod, Brake Spring Washer Bushing, Pedal Pivot Pin, Cotter Washer Bolt Master Cylinder, Foot 9/02
C2
REAR WHEEL DRIVE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
3
2
4 5 1
9 10 11 12
Ref. Part No.
1 2 3 4 5 6 7
7661404 7542714 5131777 7512673 7670081 5411408 1525017
Qty.
2 8 2 8 8 2 2
8
6
7
Description
Ref. Part No.
Pin, Cotter Nut Hub, Wheel, Rear Stud Pushnut Tire, 25x11-10 Valve, Rim
8 1520183-067 1520183-117 9 7555745 10 7555796 11 7543005 12 5411164
Qty.
2 2 2 2 2 2
Description
Rim, Rear, Black (A00CK42AA) Rim, Rear, Silver(A00CK42AB) Washer Washer, Cone Nut, Castle Cover, Dust, Hub 12/98
C3
FRONT HOUSING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
9 10 11
12
15 13 14
16
20
17 18
22
21
2
19 23
1
8 7
12 11
25 24
6 5 4 3 2 1
Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12
1341253 3233319 3233252 3233573 3233588 3233574 3233589 3233590 3233591 7080756 8450003-1525 3233253 3233254
Qty.
1 2 11 1 1 1 1 1 1 1 AR 2 2
Description
Ref. Part No.
Asm., Front Gearcase (Incl. 1-8,11-25) Seal, Oil Screw Cover, Input, Front Housing O-Ring Nut, Lock Bearing, Ball Shaft, Input, Front Housing Bushing Clip Line, Vent Plug, Drain Washer
13 14 15 16 17 18 19 20 21 22 23 24 25
3233578 3233524 3233592 3233593 3233594 3233595 3233020 3233554 3233596 3233597 3233248 3233583 3233582
Qty.
1 1 1 1 1 1 1 1 1 1 1 1 1
Description
Plug, Cap Vent Tube, Vent Hose Gearcase, Front Housing Bushing Gear, 37T, Bevel Shaft, Output, Front Housing Bearing, Ball Shim O-Ring Cover, Output, Front Housing Seal Shim Button, Thrust 10/98
C4
REAR HOUSING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1
2 3 4 5 6 7
26
8
25
9
10 11 12 13 16 17
15
8 14
3 17 16
Ref. Part No.
1341309 1341321 1 2 3 4
3233585 3233252 3233256 3233584 3233741
5 3233529 6 7 8 9 10
3233587 3233581 3233268 3233580 3233579 3233740
11 7670102 12 8450003-1525
Qty. Description
1 Asm., Gearcase, Rear (Incl. 1-10, 14-26) (If built before 7-01-99) 1 Asm., Gearcase, Rear (Incl. 1-10, 14-26) (If built after 7-01-99) 2 Screw 10 Screw 2 Seal 1 Cover, Gearcase, Output (For Gearcase 1341309) 1 Cover, Gearcase, Output (For Gearcase 1341321) 1 Pipe, Knock (For Gearcase and 1341309) 1 O-Ring 1 Shim 2 Bearing, Ball 1 Shaft, Rear Axle 1 Gear, Bevel, 31T, Rear (For Gearcase 1341309) 1 Gear, Bevel, 31T, Rear (For Gearcase 1341321) 3 Clip AR Line, Vent
24
18
19
20
Ref. Part No.
13 7080307 14 3233524 15 3233586 3233739 16 17 18 19
3233711 3233324 3233577 3233707 3233738
20 3233575 3233714 21 22 23 24 25 26
3233588 3233319 3233573 3233574 3233582 3233583
23
21
2 22 Qty. Description
1 Clamp,Hose 1 Tube, Vent 1 Gearcase, Rear Housing (For Gearcase 1341309) 1 Gearcase, Rear Housing (For Gearcase 1341321) 2 Plug 2 Washer 1 Bushing 1 Shaft, Pinion, 10T, Bevel, Rear (For Gearcase 1341309) 1 Shaft, Pinion, 10T, Bevel, Rear (For Gearcase 1341321) 1 Bearing, Ball (For Gearcase 1341309) 1 Bearing, Ball (For Gearcase 1341321) 1 O-Ring 1 Seal, Oil 1 Gearcase, Cover, Input 1 Nut, Lock 1 Button, Thrust 1 Shim 3/00
C5
SWING ARM/REAR GEARCASE MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
9 10 11
1 2 3
4 5
6
12 13
19
14 15
16 18 17
7
15 14 13 12
8
38 37
36
35 34
11
10 9
21 20
33 5 32 21 31 30
27
26
25
24
23
22
28 29
Ref. Part No.
1 5132152 2 ------3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
3513523 5411653 7517604 7512084 7555721 7542703 5411532 5131863 5131864 3610072 3554506 3554507 1541323 5411602 1012839-067 5411092 5132201 7080433 1380137
Qty.
Description
1 Hub, Brake Disc, Rear Axle 1 Asm., Rear Brake Caliper (See Rear Brake Pg C2, Ref. 2) 2 Bearing, Ball 1 Shield, Brake Line 3 Bolt 2 Screw 3 Washer 3 Nut, FLEXLOC 2 Cap, Pivot, Swing Arm 2 Nut 2 Pivot, Shaft 2 Seal, Pivot, Swing Arm 2 Bearing, Roller Cone 2 Bearing, Roller Cup 1 Asm., Swing Arm (Incl. 14,15) 2 Seal, Pivot, Swing Arm 1 Arm, Swing, Rear 1 O-Ring 1 Coupling, Prop Shaft, Rear, Greased 1 Fitting, Lubricating 1 Asm., Rear Prop Shaft
Ref. Part No.
20 21 22 23 24 25
Qty.
7517585 7553201 5131862 7710482 7517612 1012881 5242851-067 5811716 26 5131930 27 5411707 28 - - - - - - -
8 8 1 1 3 1 1 1 1 1 1
29 30 31 32 33 34 35 36 37 38
1 1 1 1 3 1 1 1 1 1
5411531 7661913 7072533 1012740-067 7515481 7710471 5132075 3610071 5211849 5411529
Description
Bolt Washer Axle, Rear Ring, Hog Screw Asm., Skid Plate Plate, Skid, Rear Housing Pad, Rubber Collar, Rear Axle O-Ring Asm., Rear Gearcase (See Rear Housing Pg. C5 for Details) O-Ring Pin Decal - Hitch Tube, Axle, LH Bolt Ring, Retaining Spacer, Bearing Seal, Outer Axle Disc, Brake, Rear O-Ring 7/99
C6
SHOCK MOUNTING XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1
2 3 4
5
6
7
11
8 1
10
Ref. Part No.
1 2 3 4 5 6
7542439 5433213 7515415 5132022 5241147 7041777-067
Qty.
2 2 1 1 1 1
9
Description
Ref. Part No.
Nut, Nylok Bushing Screw Tube Retainer, Spring Spring
7 8 9 10 11
7041774 5630921 5132021 5433212 7515438
Qty.
1 1 1 2 1
Description
Shock Cam, Adjuster Tube Bushing Screw 10/98
C7
CRANKCASE XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
6
7
8 9
3
2
1
11
10
4
23
5 13
22
13 15
13
14
12
21 20
19
2 18
17 16
Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12
3086190 3080103 3086193 3084838 3080676 3086196 3081890 3086195 3086197 3084837 3084836 3083452
Qty.
1 2 1 2 2 1 2 1 1 1 1 2
Description
Ref. Part No.
Asm., Crankcase (Incl. 2,3,5-18,22,23) Pin, Dowel Bush Pin, Straight Bearing, Ball Valve, One Way Screw Pin, Stopper Bush Seal, Mechanical Seal, Oil Pipe, Water
13 14 15 16 17 18 19 20 21 22 23
3084840 3086194 3084834 3086192 3086191 3085295 3082956 3083453 3084847 3083669 3084841
Qty.
6 1 2 1 1 2 1 1 1 1 12
Description
Pin, Dowel Ball, Steel Bearing, Ball Seal, Oil Bearing, Needle Bolt, Flange Gasket Plug O-Ring Bush, Starter Bolt, Flange 10/98
C8
CYLINDER XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 8
2
9
1 3 4
7
6
10
5
12
38
11
36
36
37
13 5 17 36
35
16
14 15
18
19
24
20 34 21
23 22
9
27
26
28 29 18 33
30 31 32 13
C9
25
CYLINDER XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
3083166 3081497 3081330 3084857 3084994 3084858 3084867 3085072 3084877 3084866 3085074 3085073 3084874 3084859 3084875 3084860 3084861 3084862 19 3084215 20 3085075
Qty.
1 1 2 2 4 2 1 1 10 1 1 1 10 2 4 1 1 1 2 1
Description
Ref. Part No.
Asm., Adapter Band (Incl. 2) Screw Bolt Pin, Straight Guide, Valve Seal, Intake Valve O-Ring Adapter, Water Out Bolt, Flange Adapter, Camshaft Gasket, Rocker Cover Cover, Rocker Bolt, Flange Seal, Exhaust Valve Bolt, Cylinder Head Plug Gasket Plug, Blind Bolt, Flange Gasket, Exhaust
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
3085326 3080285 3080530 3085854 3084876 3084864 3084863 3084838 3084849 3084873 3086198 3084130 3085370 3086199 3086200 3085527
37 3085337 38 3086201
Qty.
Description
2 2 2 1 4 1 1 2 1 4 1 1 1 1 1 1
Stud Nut Washer Bolt, Rocker Shaft Bolt Support, Valve Rocker Shaft (PTO) Support, Valve Rocker Shaft (MAG) Pin, Straight Union, Oil Pump Bolt, Flange Cylinder (Incl. 32) Pipe 1, Elbow Gasket, Cylinder Cover, Camshaft Gasket, Cover, Cam Cylinder Head (Incl. 4-6,14,16-18,21) 1 Gasket, Head 1 Adapter 10/98
C10
CRANKSHAFT and PISTON XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1
3 2
2
4 5
8
13
7
6
9 10
7
8
11 21
12
20 19 18 17 14 Ref. Part No.
Qty.
1 3086488 3086489 3086490 2 3085534 3 3085345 4 3086207 3086208 3086209 5 3085346 6 3086204 7 3085024 8 3085344 9 3086205 10 3086206 11 3085400
1 1 1 2 1 1 1 1 1 1 2 2 1 1 1
15
16
Description
Ref. Part No.
Qty.
Piston Ring Set (Std) Piston Ring Set (0.25 O/S) Piston Ring Set (0.50 O/S) Clip Gear 1, Balancer Piston Set (Std) (Incl. 2,4) Piston Set (0.25 O/S) (Incl. 2,4) Piston Set (0.50 O/S) (Incl. 2,4) Pin, Dowel Crankshaft 2 Ball, Steel Spacer, Crank Pin Pin, Crank Rod, Connecting Bearing, Large End
12 3086202 3086203 13 3240168 14 3083905 15 3083904 16 3085980 17 3085979 18 3240088 3084892 3084893 3084894 19 3086211 20 3084895 3084896 3084897 21 3086210
1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1
Description
Asm., Crankshaft (Incl. 3,5,6-12) Crankshaft 1 Key, Woodruff Nut, Lock Washer Nut, Slit Sprocket 1 Spacer (0.6) Spacer (0.8) Spacer (1.0) Spacer (1.2) Spacer, Crankshaft Spacer (0.8) Spacer (1.0) Spacer (1.2) Shaft, Balancer 12/98
C11
INTAKE and EXHAUST XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
8 8
9
10 6
9
1 11 12
2 3 4
6
27
14
13 7
8
15
9
16
5
17
26 18 13 12
11
25
24 23 20
21
22
Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3084845 3084920 3086025 3086024 3084922 3084910 3084913 3084912 3084911 3084909 3084908 3084907 3084906 3086212
Qty.
1 1 1 1 1 2 1 4 4 1 8 4 4 1
19
Description
Ref. Part No.
Plug Gasket, Plug Spring, Tensioner Asm., Tensioner (Incl. 1-3) Gasket, Tensioner Asm., Intake Rocker Arm (Incl. 8,9) Asm., Exhaust Rocker Arm (Incl. 8,9) Nut Screw, Adjusting Shaft, Rocker Collet, Valve Retainer, Spring Spring, Valve Camshaft (Incl. 15-18)
15 16 17 18 19 20 21 22 23 24 25 26 27
3080103 3085348 3085076 3084899 3084914 3081657 3084916 3084915 3084924 3084917 3085349 3085412 3084874
Qty.
1 1 1 1 1 3 1 1 1 1 2 2 2
Description
Pin, Dowel Lever, Release Spring, Return Pin, Dowel Sprocket 2 Bolt and Washer Guide, Chain Chain, Timing Bolt, Pivot, Lever Lever Valve, Intake Valve, Exhaust Bolt, Flange 10/98
C12
CARBURETOR XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1
2 54
3 4
53
5 52 7 8
6
46 49
9
51
47
48
44
45
50
15 43
10 11 14 15
13
42
12
18 16 17
19
19
29
20
28
38
30 31 32 33
37 36 35
34
21
27
26
22
25 24 23
C13
39
40
41
CARBURETOR XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
3130507 3130508 3130963 3130752 3130732 3130510 3130541 3130540 3130504 3130014 3130569 3131115 3131116 3131117 3130535 3130519 3130518 3130517 3130515 3130361 3130594 3130532 3130520 3130590 3130521 3130529 3130591
Qty.
1 1 1 1 1 1 2 2 1 1 1 1 1 1 6 1 1 1 2 1 1 1 4 1 1 1 2
Description
Ref. Part No.
Qty.
Ring E-Ring Needle, Jet Ring Asm., Diaphragm Jet, Needle (P-8) Screw Washer, Spring Asm., Jet Block Washer Jet, Main (#150) Diaphragm Spring Cover Screw Cap E-Ring Packing Seal Pin, Float Plate O-Ring Screw Asm., Float Body Screw Asm., Float Screw
28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
3130668 3130533 3130526 3130522 3130523 3130525 3130524 3130546 3130545 3130544 3130502 3130589 3130514 3130501 3130513 3130543 3130511 3130512 3130199 3130538 3130593 3130625 3131114
1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1
51 52 53 54
3084205 3131351 3130503 3130592
2 1 1 4
Description
Valve, Needle (1.5) O-Ring Jet, Pilot (#42.5) O-Ring Washer Spring Adjuster Screw, Adjust Ring Spring Valve, Throttle (100) Spring Ring Screw Asm., Throttle Shaft Guide, Cable Cover O-Ring Holder, Guide Spring Asm., Plunger Jet, Air (#160) Asm., Carburetor (Incl. 1-14,16-42,46-54) Screw and Washer Spring Asm., Cover Screw 2/01
C14
RECOIL STARTER XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
3
2
1
5
4
6
7 8 9 15
11
10
12
14
8
13
7 Ref. Part No.
1 2 3 4 5 6 7 8
3084822 3083463 3083378 3083379 3084744 3085266 3083453 3082956
Qty.
1 1 1 1 1 1 2 2
Description
Ref. Part No.
Reel Spring, Return Ratchet Spring, Friction Plate, Friction Bolt and Washer Plug Gasket
9 10 11 12 13 14
3083669 3083185 3084750 3084933 3084877 3085856 3087060 15 3085083
Qty.
1 1 1 1 9 1 1 1
Description
Bush, Starter Spring, Spiral Bush Gasket, Recoil Bolt, Flange Asm., Recoil (Incl. 1-6,9-11,14,15) Starter Case (Incl. 11) Asm., Rope 1/01
D1
WATER PUMP XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1
2
3
4 11
5
Ref. Part No.
1 2 3 4 5 6
3084940 3085352 3086217 3084191 3084942 3086214
Qty.
1 1 1 2 1 1
6
Description
Ref. Part No.
Thermostat Switch, Thermostat Hose, Main Clamp, Hose Washer, Seal Impeller
7 8 9 10 11
7
3083138 3085077 3086216 3086215 3086498
8
10 9
Qty.
1 1 1 1 6
Description
Gasket, Aluminum Nut, Self Lock Gasket, Water Pump Cover, Water Pump Bolt, Flange 2/99
D2
OIL PUMP XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1 2 3 4
8
10
Ref. Part No.
1 2 3 4 5
3086218 3086220 3086499 3086900 3083453
Qty.
1 1 1 6 1
7
6
5
9
Description
Ref. Part No.
Cover, Oil Pump Rotor, Outer Feed Pump, Inner Oil Screw, Counter Sunk Plug
6 7 8 9 10
3082956 3086223 3086222 3086221 3083568
Qty.
1 1 1 1 1
Description
Gasket Spring, Relief Valve Valve, Oil Relief Strainer, Oil Bolt, Flange 1/01
D3
OIL FILTER XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
1
2 3 6
7
4 2
5
6
8
7
5
5 9 5
7 10
5
Ref. Part No.
1 2 3 4 5 6
3084963 3086228 3086227 3084566 3084846 3083482
Qty.
1 2 1 1 9 4
Description
Ref. Part No.
Filter, Oil Bolt, Banjo Pipe 6, Oil Delivery Bolt, Flange Gasket, Aluminum Gasket, Aluminum
7 8 9 10 11
3086815 3086224 3086226 3086225 3086229
Qty.
3 1 1 1 1
11
Description
Bolt, Banjo Pipe 3, Oil Delivery Pipe 5, Oil Delivery Pipe 4, Oil Delivery Bolt, Banjo 1/01
D4
MAGNETO XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
2
1 3
16 17 18 19 20
15
4 14
13 12
5
11 21
6
10 7 9
Ref. Part No.
Qty.
1 3084690 3084979 2 3084980 3 3070175 4 3084978 5 3086234 6 3086232 3087140 7 3081657 8 3084973 9 3086239 10 3081342
1 1 1 1 1 1 1 1 5 1 1 3
Description
Ref. Part No.
Asm., Ignition Coil (Incl. 1,2) Ignition Coil Cap, Plug, Spark Plug, Spark O-Ring Metal, Bearing Asm., Plate (Incl. 5,6,8-12,14,15) Plate Bolt and Washer Seal, Oil Stator (Incl. 13) Screw and Washer
11 12 13 14 15 16 17 18 19 20 21
D5
3085554 3084976 3087141 3084977 3081256 3083447 3086235 3083073 3080077 3086236 3086238 3086231
8
Qty.
1 2 1 1 3 1 1 2 2 1 1 1
Description
Band, Pulse Screw and Washer Coil, Pulser Clamp Screw and Washer Band, Wire CDI System Nut Washer, Spring Switch, Magnetic Asm., Magneto (Incl.5,6,8-15,21 Flywheel w/Ring Gear 2/01
STARTING MOTOR XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 5 6 4
1 3
7
3
2
11 3 8
1
7 12 3 13 9
1 14
10 15
16 18
17
Ref. Part No.
Qty.
1 3086240 3084405 2 3240111 3 3086242 4 3086245 5 3083730 6 3086241 7 3084982 8 3086244 9 3240114
1 2 4 1 1 2 2 1 1 1
Description
Ref. Part No.
Motor, Starting (Incl. 1-4,6-12) Ring, Rubber Spring, Brush Carbon Brush Set (Incl. 2,11,12) Asm., Rear Bracket Bolt and Washer Asm., Set Bolt Washer Set Asm., Armature O-Ring
10 11 12 13 14 15 16 17 18
D6
3086243 3084408 3083649 3083737 3084412 3084411 3084410 3084409 3085394
Qty.
1 1 2 1 1 1 1 1 1
Description
Asm., Front Bracket (Incl. 9) O-Ring Nut, Flange Washer, Gear Shaft Clip Spring, Weight Spring, Return Clip Asm., Gear Shaft (Incl. 13-17) 10/98
FUEL PUMP XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
4
3
3
5
2 1
5
Ref. Part No.
1 3085275 2 3084999 3 3085000
Qty.
Description
Ref. Part No.
1 Asm., Fuel Pump (Incl. 2-5) 1 Screw and Washer 2 Screw and Washer
4 3084591 5 3084998
Qty.
Description
4 Screw 1 Diaphragm Gasket Set 10/98
D7
CLUTCH XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 31
4 7
3
6
5
1
29
28
32 33 35 34
1
2
30
8
26 24
25 27
22
11 14
10
13 12
9
20 22 18
15
17
23
21
19
16 Ref. Part No.
Qty.
1 3086274 3086275 2 3086278 3 3086276 4 3086281 5 3086282 6 3086280 7 3086279 8 3086277 9 3086263 3086264 3086265 3086266 3086267 3086268 3086269 3086270 10 3086261 11 3086256
1 1 1 6 4 1 1 4 5 1 1 1 1 1 1 1 1 1 1
3086257 12 3086258 13 3086288 14 3086259
1 1 8 1
Description
Ref. Part No.
Asm., Clutch (Incl. 1-8) Outer Washer, Thrust Disk, Clutch Bolt, Socket Bearing, Ball Plate, Lifter Spring Plate, Clutch 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) Bearing, Ball Asm., Reduction Cover (Incl. 10-12,14,15,18) Cover, Reduction Seal, Oil Bolt, Flange Plug
15 16 17 18 19 20 21 22 23 24 25 26 27
3086260 3084179 3086283 3086262 3086287 3086284 3086272 3086271 3086273 3086381 3086378 3086254 3086246
1 2 1 1 4 1 1 1 1 1 1 1 1
28 29 30 31 32 33 34 35
3086247 3086255 3086253 3086249 3084874 3086248 3086251 3086252 3086250
1 1 1 1 16 1 1 1 1
D8
Qty.
Description
O-Ring Bolt, Flange Gasket, Reduction Cover Bearing, Ball Bolt, Flange Gasket, Clutch Cover Drum, Outer Asm., Clutch (Incl. 21-23) Asm., Plate Washer, Lock Nut, Lock Bearing, Ball Asm., Clutch Cover (Incl. 26,27,29,30,32-35) Cover, Clutch Plug, Blind Nut, Flange Seal, Oil Bolt, Flange Bush, Flange Pin, Clutch Cover O-Ring Lever, Release 3/00
CLUTCH XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB 1
12
2 33
11 10 9
13
32
34
3
35
8 7 6
31 34
5
30
29
28
25
27
26
4 23 24
16
15
14
22 18
17
21 19
Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16
3086330 3086324 3086327 3086306 3086300 3086322 3086323 3086328 3086329 3086326 3086331 3086289 3086290 3086291 3086292 3086293 3086294 3086295 3086296 3086325 3086332 3086297 3086305 3084566
Qty.
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 2
20
Description
Ref. Part No.
Key Shaft, Output Seal, Oil Spring, Reverse Arm Asm., Reverse Arm Asm., Output Shaft (Incl. 2,3,6,7,9,12) Gear, Bevel Ring, Snap Bearing, Ball Nut, Lock O-Ring Shim (.15) Shim (.2) Shim (.25) Shim (.3) Shim (.5) Shim (.175) Shim (.225) Shim (.275) Holder, Bearing Bolt, Flange Asm., Reverse Cam Switch, Position Bolt, Flange
17 18 19 20 21 22
3086314 3086310 3086304 3086303 3086321 3086318
1 1 1 1 1 1
23 24 25 26 27 28 29 30 31 32 33 34 35
3086319 3086320 3086380 3086299 3086302 3086311 3086301 3086317 3086316 3086307 3086308 3086312 3086298 3086309 3086315
1 1 1 1 1 1 1 1 1 1 1 1 1 2 1
D9
Qty.
Description
Washer, Lock Nut, Lock Chain Sprocket, Driven Bearing, Ball Asm., Pinion and Shaft (Incl. 1-3,6-10,12,21,22) Asm., Drive Pinion (Incl. 28,29) Pinion, Drive Washer Gear, Primary Arm, Stopper Bolt Arm, Release Spacer Spacer Spring, Return Spring, Stopper Arm Key, Woodruff Asm., Shift Shaft Spring, Shift Spacer 3/00
CLUTCH XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
2 5
6 1
3
4
7 22 9
24
23
25
26
21
8
27 28
10
20
1 18 15
13 11
31
19
16
17
16
33
17
30
29
32
29
42
34
14
33 29
12
41 43
35 38
37
40
36
44
30 39
47 46 45
D10
CLUTCH XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB Ref. Part No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
3086375 3086377 3086370 3086369 3086368 3086373 3086371 3086366 3086367 3086379 3086376 3086348 3086350 3086341 3086345 3086344 3086346 3086349 3086343 3086342 3086339 3086340 3086372 3086347 3086382 3086313
Qty.
2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 6 1 1 1
Description
Ref. Part No.
Qty.
Shaft, Shift Fork Fork, Shift, Driven Bolt, Lock Washer Cam, Shift Bearing, Ball Pin Asm., Shift Drum (Incl. 3-8,21) Drum, Shift Pin, Dowel Fork, Shift, Drive Bearing, Ball Washer Gear, 2nd Drive Collar Gear, 5th Drive Washer Ring, Snap Gear, 4th Drive Gear, 3rd Drive Asm., Main Shaft (Incl. 11-20,22) Shaft, Main Pin Bearing, Ball Bush, Flange Washer
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
3086286 3086285 3086358 3086354 3086363 3086359 3086355 3086356 3086353 3086357 3086364 3086360 3086383 3086374 3086361 3086351
1 1 1 1 3 3 1 1 2 1 1 1 1 1 1 1
41 42 43 44 45 46 47
3086352 3086362 3086365 3086337 3086338 3086335 3086336 3086333 3086334
1 1 1 1 1 1 1 1 1
Description
Washer, Lock Nut, Lock Gear Gear, 3rd Driven Ring, Snap Washer Gear, 4th Driven Gear, 5th Driven Gear, 2nd Driven Clutch Washer Bearing, Ball Spacer Sprocket, Drive Washer Asm., Counter Shaft (Incl. 27-36,39-42) Shaft, Counter Bearing, Ball Plug Pin Pin Gear Collar Asm., Reverse Shaft (Incl. 43-47) Shaft, Reverse 3/00
D11
TOOL KIT XPEDITION 425 A00CK42AA and XPEDITION 425 A00CK42AB
9 2
3 10 4
5 1 6 11 7 12
8
Ref. Part No.
1 2 3 4 5 6 7
3085544 2870725 3082657 3085001 3085002 3085567 3085569
Qty.
1 1 1 1 1 1 1
Description
Ref. Part No.
Qty.
Asm., Tool Kit (Incl. 3-8) Gauge, Tire Pressure Screwdriver Wrench, Open 8-10mm Wrench, Open 12-14mm Wrench, Box, 100mm Puller, Spark Plug (Wrench Handle)
8 2682572 9 2871515 10 9915299 9914929
1 1 1 1
11 2871095-067 12 2460442
Description
Pouch, Tool Kit Lube, U-Joint, 3 oz., Case Owner’s Manual, ‘00 ATV Supplement, Owner’s Manual, ’00 Xpedition 425 1 Wrench, Spanner, Cam 1 Pigtail, Power 3/00
D12
PRINTED IN THE USA
PARTS MANUAL PN 9914930 and MICROFICHE PN 9916574 3/00
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Changed pages in 9914930
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