XPEDITION 325 Model #A00CK32AA Rev. 01

XPEDITION 325
Model #A00CK32AA
Rev. 01
E 2000 Polaris Sales Inc.
PARTS MANUAL PN 9915489 and MICROFICHE PN 9916574 3/00
TABLE OF CONTENTS
A
XPEDITION 325 A00CK32AA
Parts Manual
A-ARM/STRUT MOUNTING . . . . . . . . . . . . . B13
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
C
CARBURETOR . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - MASTER CYLINDER/BRAKE
LINE . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS - THROTTLE ASM./CABLE . . . .
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . .
CRANKSHAFT and PISTON . . . . . . . . . . . . .
CV JOINT - BTB . . . . . . . . . . . . . . . . . . . . . .
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . .
I
INTAKE and EXHAUST . . . . . . . . . . . . . . . . C11
C12-13
D7-10
B9
B8
C8
C10
B3
C9
D
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
E
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . B14
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . A12-13
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . A11
F
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . .
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . .
FRONT HOUSING . . . . . . . . . . . . . . . . . . . .
FRONT RACK and BUMPER MOUNTING . . .
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . .
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . .
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . .
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . .
H
HANDLEBAR and HEADLIGHT POD . . . . . . B11-12
B7
A7
C4
A9
B5
B6
D6
B1
M
MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . D4
O
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . A14
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . D3
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . D2
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
C14
SHOCK MOUNTING . . . . . . . . . . . . . . . . . . .
STARTING MOTOR . . . . . . . . . . . . . . . . . . .
STEERING POST . . . . . . . . . . . . . . . . . . . . .
SWING ARM/REAR GEARCASE MOUNTING
C7
D5
B10
C6
S
T
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . D11
W
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . D1
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 325 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
NA
3.75
4.5
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
6.25
46
81
33.5
635
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
1.111
0.813
4.128
2.655
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
Titan
24x8-12
24x11.5-10
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
ES32PLE03
4 Cycle, Single Cylinder
Wet Sump
78x68
325
9:2/1 Full Stroke
Air Cooled/Oil Asist
200
Standard
1/BST31 (CV Type)
152.5
47.5
P-0(829)
N/A
TBD
4HB40-3
CDI
30@5000
.036
BKR6E
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
Silver
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 Dual 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
1 5/8² Twintube
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 325
A00CK32AA
9915299
9915474
9915489
9916574
9915510
REAR CAB and SEAT
XPEDITION 325 A00CK32AA
E 2000 Polaris Sales Inc.
18
9
17
10
11
8
12
3
6
20
22
13
21
15
14
7
5
4
2
19
16
42
43
41
23
40
9
24
5
39
38
1
37
36
34
35
25
33
32
30
26
27
31
28
29
30
A5
REAR CAB and SEAT
XPEDITION 325 A00CK32AA
Ref. Part No.
Qty.
1 7670057
2 5431796
5431797
3 7661645
4 7511930
5 7555792
6 5811107
7 5411042
8 5432117-282
9 7541925
10 5224592
11 5811308
12 7512242
13 7555859
14 7512085
15 5431786
16 7621403
17 5211033
18 1040387
19 7041370
20 2682441-070
2681747-070
5811104
5811105
21 5410414
12
1
1
10
2
4
1
1
1
4
1
1
4
4
2
1
2
2
1
1
1
1
1
1
8
Description
Nut, U-Type Speed
Guard, Mud, Rear, LH
Guard, Mud, Rear, RH
Rivet
Bolt
Washer
Foil, Rear Cab, Rear
Grommet
Cab, Rear, Desert Dune
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
Ref. Part No.
22
23
24
25
7517599
5431787
5410896
-------
26
27
28
29
30
31
32
33
34
35
36
37
7552603
7512492
5433435
7556065
7517386
7558301
7542122
5411548
7515111
7512297
1013119-067
5433391-070
5433392-070
7512232
5811111
5811106
5811087
7077446
7073761
38
39
40
41
42
43
Qty.
2
1
1
1
4
4
1
7
9
2
8
8
4
4
1
1
1
12
1
2
1
1
1
Description
Screw
Cover, Tool Box
Cap, Drain
Asm., Front Gearcase
(See Front Housing Pg. C4 for Details)
Washer
Bolt
Guard, Rock
Washer
Screw
Washer
Nut
Mount, Rubber
Screw
Screw
Frame, Main
Footwell, LH, Black
Footwell, RH, Black
Screw
Foil, Foam, Rear Fender
Foil, Rear Cab, Front
Foil, Foam
Decal - Filter Element
Decal - Carb Information
3/00
A6
FRONT CAB
XPEDITION 325 A00CK32AA
1
6
4
2
3
7
5
8
9
17
13
16
10
12
11
14
15
5
10
5
19 18
20
21
Ref. Part No.
1 5811491
2 5811210
3 2632084-282
2632147-282
4 5811798
5 7512232
6 5811801
7 5432088-282
8 7670085
9 2632133-282
10 7670057
Qty.
1
1
1
1
1
12
1
1
2
1
Description
Foil, Side Panel, Gen. IV, RH
Foil, Foam, Side Panel
Asm., Panel w/Foam, LH, Desert Dune
Asm.,Panel w/Foil, RH, Desert Dune
Foam
Screw
Foam, Cab, Front
Cover, Front, Desert Dune
Clip, Spring
Cab, Front w/Warning Decals, Desert
Dune
10 Nut, U-Type Speed
Ref. Part No.
11
12
13
14
15
16
17
18
19
20
21
7670068
7661645
7517312
5431798
5431799
7541925
7555792
7512085
7555931
7542122
7621509
5811917
Qty.
2
4
2
1
1
2
2
2
2
2
4
2
Description
Nut, Push-on
Rivet
Screw
Guard, Mud, Front, LH
Guard, Mud, Front, RH
Nut, Nylok
Washer
Screw
Washer
Nut, Nylok
Rivet, Plastic
Shield, Deflector
3/00
A7
REAR RACK MOUNTING
XPEDITION 325 A00CK32AA
1
2
3
5
2
4
6
7
8
10
11
6
9
Ref. Part No.
1 7517686
2 7517685
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
3/00
A8
FRONT RACK and BUMPER MOUNTING
XPEDITION 325 A00CK32AA
1
2
5
3
4
7
6
14
13
15
12
11
16
17
6
8
10
9
18
4
19
20
24
21
23
22
Ref. Part No.
1 7517685
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
Qty.
Description
4 Screw
1 Asm., Front Rack
(Incl. Ref. 3 and Warning Decal)
2 Reflector, Amber
8 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
4
Ref. Part No.
14 2431011
2431012
4030059
15 7515384
16 7558402
17 5810467
18 5241398-067
5241399-067
19 5241583-067
20 5240591-067
21 7621330
22 7670094
23 7512097
24 5431814
5431815
Qty.
1
1
2
2
4
1
1
1
1
1
7
6
6
1
1
Description
Headlight, LH
Headlight, RH
Bulb, Replacement, 27W
Bolt
Washer
Plug, Frame
Extension, Frame, LH
Extension, Frame, RH
Guard, Brush
Grill, Brush Guard
Rivet
Nut, U-Type
Screw
Shield, Side, Radiator, LH
Shield, Side, Radiator, RH
3/00
A9
DECALS
XPEDITION 325 A00CK32AA
5
1
2
4
3
RH
6
8
7
19
10
18
17
9
16
4
1
15
14
12
13
LH
11
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
7074954
7074110
7078022
7078452
7078451
7074935
7078390
7078577
7078315
7078015
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 - “325” Four Stroke, Front Cover
11
12
13
14
15
16
17
18
19
7074220
7077919
7078551
7078018
7078004
7077920
7078253
7078450
7078336
Qty.
1
1
1
1
1
1
1
1
1
Description
Decal - “Macpherson Strut”
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
7/99
A10
EXHAUST SYSTEM
XPEDITION 325 A00CK32AA
1
2
3
4
5
6
8
7
12
16
9
14
10
12
11
17
13
12
15
11
Ref. Part No.
1
2
3
4
5
6
7
8
9
7542324
7555716
5410436
7555863
5132295
5411790
7515339
1260961-029
7512666
Qty.
1
1
1
1
1
1
1
1
1
Description
Ref. Part No.
Nut, Nylok
Washer
Washer, Rubber
Bushing
Bushing
Dampener, Vibration
Bolt
Silencer, Exhaust
Bolt
10
11
12
13
14
15
16
17
3110064
7542301
7041804
7042029
1260987-029
7041789
5243517
1261011-029
10
Qty.
2
2
4
1
1
1
2
1
16
Description
Mount, Torque Stop
Nut
Spring, Exhaust
Spring, Exhaust
Headpipe
Spring, Exhaust
Seal, Exhaust
Manifold
7/99
A11
ENGINE MOUNTING
XPEDITION 325 A00CK32AA
1
10
9
5
6
2
42
11
8
7
14
15
17 16
40
39
13
4
3
41
12
9
4
18
19
20
38
21 22
37
24 25
26
36
34
35
26
4
28
4
23
32
27
33
31
4
4
29
30
4
A12
29
4 28
27
ENGINE MOUNTING
XPEDITION 325 A00CK32AA
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
7517756
5243829-067
7080003
7547108
7517386
4010132
7552901
7512315
8450003-1525
7052075
7542122
7558301
5244058-067
3084205
3110050
7555823
3021108
Qty.
2
1
4
6
1
1
2
2
AR
1
1
1
1
2
1
1
1
3021180
18 5244075-067
5244517-067
1
1
1
19
20
21
22
1
1
1
3
5243586-067
7517653
5132141
7517652
Description
Ref. Part No.
Qty.
Screw
Strap
Clamp
Nut, Lock, Flange
Screw
Cable, Ground, Engine
Washer
Screw
Line, Vent
Fitting, Tee
Nut, Nylok
Washer
Bracket, Mount, Carburetor
Screw
Mount, Rubber
Washer
Mount, Motor. Rubber
(If built before 8/21/99)
Mount, Engine (If built after 8/21/99)
Mount, Engine, Top(If built before
8/26/99)
Mount, Engine, Top(If built after
8/26/99)
Lever, Reverse
Screw
Mount, Actuator, Reverse
Screw
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
4010265
7555746
7510504
5411927
7515406
7555806
3110045
7512492
7552603
5242984-067
5242905-067
7517388
5631054-067
5411364
7512225
3086945
1
3
3
2
1
1
2
2
2
1
1
3
1
1
1
1
39
40
41
42
8360009-600
7080816
8450040-60
2530009
AR
1
AR
1
Description
Actuator, Reverse
Washer
Screw
Mount, Rubber
Screw
Washer
Mount, Engine, Rubber
Screw
Washer
Mount, Lower, Rear
Mount, Engine. Lower
Screw
Lever
Pad
Screw
Engine (ES32 PLE 03) 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.
Line, Fuel
Clip
Line, Fuel
Filter, Fuel
3/00
A13
OIL COOLER
XPEDITION 325 A00CK32AA
3
2
4
1
5
8
6
7
8
8
13
7
9
8
8
10
12
8
7
6
11
Ref. Part No.
1
2
3
4
5
6
7
5411787
7080474
5411892
7080862
5243783-067
7512276
7542122
Qty. Description
1
2
1
2
1
4
8
Hose, Outlet
Clamp
Hose, Inlet
Clamp
Bracket, Top
Screw
Nut, Nylok
Ref. Part No.
8 7558301
9 3110032
10 1240074
4010282
11 7080869
12 1013302
13 7547133
Qty. Description
12
4
1
1
1
1
2
Washer
Mount, Rubber
Cooler, Oil
Switch Thermal
P-Clamp
Bracket, Lower
Nut
6/01
A14
FUEL TANK
XPEDITION 325 A00CK32AA
1
2
3
4
6
5
7
8
9
10
24
11
22
16
23
21
20
12
18
17
13
19
16
15
Ref. Part No.
1
2
3
4
5
6
7
8
9
5430725
5810144
5811899
8360009-600
5431053
7517451
7552801
7558301
5222154-067
5222155-067
10 5811939
11 5332457
12 7547069
Qty.
1
1
1
AR
1
2
2
2
1
1
1
2
4
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
Nutsert
13
14
15
16
17
18
19
20
21
22
23
24
5810317
7517505
5432559
7080003
5432733
7052161
7661637
5240577-067
8450040-600
7052149
7052146
2520174
Qty.
2
1
1
4
1
1
2
1
AR
1
1
1
Description
Pad, Fuel Tank Bracket
Screw
Knob, Fuel Valve
Clamp, Hose, Red
Nut, Fuel Valve
Valve, Fuel, 3-Way
Rivet
Bracket
Line, Fuel
Fitting, Fuel Outlet, Reserve
Fitting, Fuel Outlet, Main
Asm., Fuel Tank (Incl. 5,22,23)
7/99
B1
AIR BOX
XPEDITION 325 A00CK32AA
1
27
2
3
4
5
6
7
26
8
13
25
9
10
8
11
12
24
23
1
2
3
4
5
6
7
8
9
10
11
12
13
14
7517541
5432859
5411422
5432868
5811482
7515180
7558301
5243694
7080534
5433396
5830128
5433180
7080413
5411810
14
19
22
Ref. Part No.
13
20
21
Qty.
4
1
1
1
1
2
2
6
1
1
1
1
2
1
15
18
17
16
Description
Ref. Part No.
Screw
Duct, Inlet
Gasket, Intake
Cover, Air Box
Seal, Cover
Screw
Washer
Clip, Low Profile
Clamp
Cap
Gasket, Duct
Duct, Carburetor, Inlet
Clamp
Boot, Carburetor
15
16
17
18
19
20
21
22
23
24
25
26
27
7080511
7080694
5411866
7080699
5433678
5431863
5811650
5432377
8450059-150
7080650
5432601
7080595
5811633
Qty.
1
1
1
1
1
2
1
1
AR
1
1
1
1
Description
Clamp
Clamp
Hose, Breather, Formed
Clamp
Box, Air
Insulator
Foil, Box, Air
Plug
Line, Fuel
Clamp, Hose
Collar, Inlet, Carburetor
Filter, Air
Filter, Sleeve, Precleaner
7/99
B2
CV JOINT - BTB
XPEDITION 325 A00CK32AA
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 325 A00CK32AA
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 325 A00CK32AA
27
1
26
25
2
24
6
3
22
20
8
4
4
23
11
12
21
4
7
5
9
19
10
14
18
13
15
17
12
11
16
Ref. Part No.
Qty.
1
2
3
4
5
6
7
8
9
10
5411608
7041761
5211115
7558402
7080573
7542303
7517445
7552901
5810439
--------
2
2
2
10
2
4
4
4
2
1
11
12
13
14
15
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
Screw
Washer, Lock
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
16 2201311
2201312
17
18
19
20
21
22
7041375-067
5243364
5432871
7515339
5132062
-------
23
24
25
26
27
3610028
5432872
5810291
7555749
7547104
Qty.
Description
1 Asm., Hubstrut, LH (32mm)
(Incl. 9,12-15,23)
1 Asm., Hubstrut, RH (32mm)
(Incl. 9,12-15,23)
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 325 A00CK32AA
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
5211869
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
25
3250030
7052045
5411709
7556004
7542810
7661401
5410470
5432611
7512027
7542459
1520269-117
1525017
Qty.
2
2
2
2
2
2
2
2
6
8
2
2
Description
Cam
Plug, Magnetic Drain
Tire (24x8-12)
Washer
Nut, Slotted
Pin, Cotter
O-Ring
Cap, Hub
Screw
Nut, Lock
Rim, Front, Silver
Valve, Rim
3/00
B6
FRONT BRAKE
XPEDITION 325 A00CK32AA
2
3
4
1
5
6
7
12
11
10
8
9
Ref. Part No.
1910271
Qty.
Description
5 5410779
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 Seals
(Incl. 5-7)
1 Square Ring, Molded (.094)
6 5410780
1 Square Ring, Molded (.103 x .134)
1910264
1 7080352
2 7515489
3 5131115
5131116
1930642
4 1930665
Ref. Part No.
Qty.
7 5132294
8 2200465
2200901
2201149
9 1910412
10 5410495
11 5410494
12 - - - - - - -------------
1
1
1
1
1
1
1
4
4
4
Description
Piston, 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
Screw (See Front Strut Pg. B5, Ref. 7)
Washer (See Front Strut Pg. B5, Ref.
4)
Washer, Lock (See Front Strut Pg. B5,
Ref. 8)
7/99
B7
CONTROLS - THROTTLE ASM./CABLE
XPEDITION 325 A00CK32AA
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 7080857
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 325 A00CK32AA
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 325 A00CK32AA
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, Console
Bracket, Upper Steering Bushing
Nut, Nylok
7/99
B10
HANDLEBAR and HEADLIGHT POD
XPEDITION 325 A00CK32AA
1
2
3
22
4
5
10
9
21
6
20
8
7
12
19
19
13
15
18
14
15
16
17
B11
11
HANDLEBAR and HEADLIGHT POD
XPEDITION 325 A00CK32AA
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Qty.
5432247-070
7512024
5432246-070
7080229
7517216
5241397-067
7080726
5432926
4010262
1
2
1
1
4
1
1
1
1
5431030
5432952
7517625
-------
2
1
1
1
14 5224715-067
15 5630629
16 7542122
Description
Ref. Part No.
Cover, Logo
Screw
Panel, Instrument
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)
17 7080631
18 - - - - - - -
1 Handlebar
4 Block, Handlebar
4 Nut, Nylok
19 4110264
4010278
4010321
20 5433534
21 4040054
4040053
5430467
22 2460728
Qty.
Description
1 Clip
1 Asm., Throttle Control
(See Controls - Throttle Asm./Cable
Pg. B8, Ref. 5)
1 Switch, Ignition (Incl. Key)
1 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.
1 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.
1 Cover, Key
1 Indicator - Neutral/Reverse
1 Indicator - “HOT TEMP.”
1 Plug
1 Harness, Pod, Headlight
10/00
B12
A-ARM/STRUT MOUNTING
XPEDITION 325 A00CK32AA
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. 16)
Screw
Washer, Spring Lock
Bolt
Screw
10/00
B13
ELECTRICAL/TAILLIGHT
XPEDITION 325 A00CK32AA
4
3
1
2
5
6
8
14 15
16
12
11
9
29
13
7
28
17
10
23
18
24
22
19
27
20
12
26
12
21
25
Ref. Part No.
1 2460798
2460849
2
3
4
5
6
7
8
9
10
11
12
13
2201795
2432034
4032046
4032029
4030043
4032045
4032064
7670054
7541925
7571602
7512027
5810290
Qty.
Description
1 Harness, Wire, Main
(If built before 1/01/00)
1 Harness, Wire, Main
(If built after 1/01/00)
1 Kit - Circuit Breaker, 10 AMP
1 Asm., Taillight w/Brake Light (Incl. 4-9)
1 Lens, Taillight
2 Screw, Taillight
1 Bulb, Taillight
1 Gasket, Taillight
1 Backing, Taillight/Brake Light
2 Nut, Speed
2 Nut, Nylok
2 Washer
7 Screw
3 Pad, Battery
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
2200361
4010095
7010032
5410424
5432077
4140006
7670102
7080367
5431769
4010094
4010093
5132214
4060191
4010285
4020149
7670109
Qty.
1
1
2
1
AR
1
1
1
1
1
1
1
1
1
6
3
Description
Kit - Battery Bolt, Short
Cable, Battery/Engine
Hook, Strap, Battery
Strap, Holddown, Battery
Tube, Vent, Battery
Battery
Clip
Clamp
Cover, Battery
Cable, Battery/Solenoid
Cable, Solenoid/Starter
Sink, Heat
Rectifier, Regulator, LR 35
Switch, LR-84
Clip, Rosebud
Clip, Routing
3/00
B14
REAR BRAKE
XPEDITION 325 A00CK32AA
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
20
30
29
26
25
19
26
28
27
22
24
9
23
C1
21
REAR BRAKE
XPEDITION 325 A00CK32AA
Ref. Part No.
Qty.
1 2201189
1910339
1930860
2 1910367
2201428
2201467
2201385
3 7515406
4 7555806
5 5410988
6 1910286
7 1910288
8 7080573
9 7517386
10 7080762
11 7512084
12 7670113
13 1930674
1
1
1
1
1
1
1
2
2
6
1
1
1
1
3
1
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
Screw
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
1
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
Screw
Master Cylinder, Foot
9/02
C2
REAR WHEEL DRIVE
XPEDITION 325 A00CK32AA
3
2
4
5
1
9
10
11
12
Ref. Part No.
1
2
3
4
5
6
7661404
7542714
5131777
7512673
7670081
5411710
Qty.
2
8
2
8
8
2
8
6
7
Description
Ref. Part No.
Pin, Cotter
Nut
Hub, Wheel, Rear
Stud
Pushnut
Tire, 24x11.5-10
7
8
9
10
11
12
1525017
1520183-117
7555745
7555796
7543005
5411164
Qty.
2
2
2
2
2
2
Description
Valve, Rim
Rim, Rear, Silver
Washer
Washer, Cone
Nut, Castle
Cover, Dust, Hub
3/00
C3
FRONT HOUSING
XPEDITION 325 A00CK32AA
10
11
12
15
13
14
9
16
20
17
18
22
21
2
19
23
1
8
7
13
12
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
7080307
7080756
8450003-1525
3233253
Qty.
1
2
11
1
1
1
1
1
1
1
1
AR
2
Description
Ref. Part No.
Asm., Front Gearcase (Incl. 1-8,12-25)
Seal, Oil
Screw
Cover, Input, Front Housing
O-Ring
Nut, Lock
Bearing, Ball
Shaft, Input, Front Housing
Bushing
Clamp
Clip
Line, Vent
Plug, Drain
13
14
15
16
17
18
19
20
21
22
23
24
25
3233254
3233524
3233592
3233593
3233594
3233595
3233020
3233554
3233596
3233597
3233248
3233583
3233582
Qty.
2
1
1
1
1
1
1
1
1
1
1
1
1
Description
Washer
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
7/99
C4
REAR HOUSING
XPEDITION 325 A00CK32AA
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 325 A00CK32AA
9
1
10
11
12 13
14
2
3
4
5
6
20
15
16
17 18 19
7
16
15 14 12
13
11
8
19
37
36
35
34
10
9
22 21
33 5
32 22
31
28
27
26
25
24
23
29
30
Ref. Part No.
1 5132152
2 ------3
4
5
6
7
8
9
10
11
12
13
14
15
16
3513523
5411653
7517604
7512084
7555721
7542703
5411532
5131863
5131864
5131848
3610072
3554506
3554507
1541323
5411602
17 1012839-067
18 5132201
7080433
19 5411092
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 Bushing
2 Seal, Pivot, Swing Arm
2 Bearing, Roller Cone
2 Bearing, Roller Cup
1 Asm., Swing Arm (Incl. 15,16)
2 Seal, Pivot, Swing Arm
1 Arm, Swing, Rear
1 Coupling, Prop Shaft, Rear, Greased
1 Fitting, Lubricating
2 O-Ring
Ref. Part No.
20
21
22
23
24
25
26
Qty.
1380154
7517585
7553201
5131862
7710482
7517612
1012881
5242851-067
5811716
27 5131930
28 5411707
29 - - - - - - -
1
8
8
1
1
3
1
1
1
1
1
1
30
31
32
33
34
35
36
37
1
1
1
3
1
1
1
1
5411531
7072533
1012740-067
7515481
7710471
5132075
3610071
5211849
Description
Asm., Rear Prop Shaft
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. NO TAG for Details)
O-Ring
Decal - Hitch
Tube, Axle, LH
Screw
Ring, Retaining
Spacer, Bearing
Seal, Outer Axle
Disc, Brake, Rear
3/00
C6
SHOCK MOUNTING
XPEDITION 325 A00CK32AA
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
7041849-067
Qty.
2
2
1
1
1
1
9
Description
Ref. Part No.
Nut, Nylok
Bushing
Screw
Tube
Retainer, Shock
Spring
7
8
9
10
11
7041890
5630551
5132021
5433212
7515438
Qty.
1
1
1
2
1
Description
Shock
Cam, Adjuster
Tube
Bushing
Screw
7/99
C7
CRANKCASE
XPEDITION 325 A00CK32AA
26
3
25
1
24
2
23
3
22
9
21
8
7
6
10
5
4
20
3
11
17
18
3
19
7
12
13
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
3083568
3086881
3084840
3085815
3084838
3086193
3080103
3086879
3085850
3084841
3083669
3082956
3083453
14
Qty.
1
1
10
2
2
1
2
1
1
12
1
1
1
15
16
Description
Ref. Part No.
Bolt
Plate, Partition
Pin, Dowel
Bearing, Ball
Pin, Straight
Bush
Pin, Dowel
Asm., Crankcase (Incl. 7,6,4-14,11,10)
Pipe Comp.
Bolt, Flange
Bush, Starter
Gasket
Plug
14
15
16
17
18
19
20
21
22
23
24
25
26
3085295
3086191
3086192
3086194
3086880
3086882
3086397
3084862
3084849
3086197
3086195
3081890
3086196
Qty.
2
1
1
1
1
2
1
1
1
1
1
2
1
Description
Bolt, Flange
Bearing, Needle
Seal, Oil
Ball, Steel
O - Ring
Union
Plug
Plug, Blind
Pump, Union Oil
Bush
Pin, Stopper
Screw
Bearing, Plate
3/00
C8
CYLINDER
XPEDITION 325 A00CK32AA
2
1
3
4
5
27
2
1
26
6
25
21
6
7
8
9
11
10
8
9
12
24
23
22
13
14
15
9
14
20
16
15
17
19
4
18
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
3086413
3086414
3086412
3084874
3086417
3086410
3084858
3084994
3084798
3084859
3086418
3086796
13 3086421
Qty. Description
2
2
4
6
1
2
1
2
3
1
4
1
Cover, Valve
O-Ring
Bolt, Flange
Bolt, Flange
Plug, Cylinder Block
Pin, Straight
Seal, Intake Valve
Guide, Valve
Fin Damper A
Seal, Exhaust Valve
Bolt and Washer
Asm., Cylinder Head (Incl. 3,4,6-10,
12,14,26)
1 Gasket, Exhaust
Ref. Part No.
14
15
16
17
18
19
20
21
22
23
24
25
26
27
3085326
3080530
3080285
3084838
3086407
3086883
3086415
3086416
3086885
3083166
3081497
3081330
3086884
3086419
Qty. Description
2
2
2
2
1
1
1
1
1
1
1
2
1
2
Stud
Washer
Nut
Pin, Straight
Gasket, Cylinder
Cylinder
Gasket, Head
Gasket, Cam
Adapter
Asm., Adapter Band (Incl. 24)
Screw
Bolt
Cover, Rocker
Bolt, Flange
8/99
C9
CRANKSHAFT and PISTON
XPEDITION 325 A00CK32AA
1
4
2
3
4
5
5
6
16
14
7
8
8
9
10
11
13
12
14
6
15
Ref. Part No.
1 3085774
3085775
3085776
2 3086800
3086801
3086802
3 3086846
4 3084167
5 3086425
6 3087017
7 3086886
8 3240168
Qty. Description
1
1
1
1
1
1
1
2
2
1
1
2
Piston Ring Set (STD)
Piston Ring Set (0.25 O/S)
Piston Ring Set (0.50 O/S)
Piston Set (STD)(Incl. 3,4))
Piston Set (0.25 O/S)(Incl. 3,4)
Piston Set (0.50 O/S)(Incl. 3,4)
Pin, Piston
Clip
Bolt
Asm., Connecting Rod (Incl. 5,15)
Crankshaft, Complete (Incl. 16)
Key, Woodruff
Ref. Part No.
9 3086888
3086889
3086890
3086891
10 3086492
11 3085528
12 3083904
13 3083905
14 3086427
3086798
3086799
15 3086426
16 3085024
Qty. Description
1
1
1
1
1
1
1
1
2
2
2
2
1
Spacer
Spacer
Spacer
Spacer
Sprocket 1
Nut
Washer
Nut
Bearing (STD)
Bearing (0.05 U/S)
Bearing (0.25 U/S)
Nut
Ball, Steel
4/00
C10
INTAKE and EXHAUST
XPEDITION 325 A00CK32AA
3
1
2
1
2
5
6
7
7
8
4
6
9
10
11
8
12
19
18
17
20
22
21
16
23
14
13
24
15
Ref. Part No.
1
2
3
4
5
6
7
8
9
10
11
12
3084911
3084912
3084910
3086442
3085836
3084908
3086893
3086892
3086439
3086804
3086803
3084899
Qty. Description
2
2
2
1
1
4
2
2
1
1
1
1
Screw, Adjusting
Nut
Asm., Rocker Arm (Incl. 1,2)
Shaft, Rocker
Washer
Collet, Valve
Retainer, Spring
Spring, Valve
Lever, Release
Spring, Return
Camshaft (Incl. 9,10,12)
Pin, Dowel
Ref. Part No.
13
14
15
16
17
18
19
20
21
22
23
24
3085778
3086441
3086445
3086444
3086448
3086493
3083361
3086443
3083663
3086449
3086446
3084924
Qty. Description
1
1
1
1
1
1
2
1
1
1
1
1
Valve, Intake
Valve, Exhaust
Guide, Chain
Chain, Timing
Gasket, Tensioner
Tensioner
Bolt, Flange
Sprocket 2
Washer
Bolt, Flange
Lever
Bolt, Pivot
8/99
C11
CARBURETOR
XPEDITION 325 A00CK32AA
1
2
3
54
4
53
5
52
7
8
6
46
49
9
51
47
48
44
45
50
15
43
10
11
14
13
42
12
15
18
16 17
19
19
29
20
28
38
30
31
32
33
37
36
35
34
21
27
26
22
25
24
23
C12
39
40
41
CARBURETOR
XPEDITION 325 A00CK32AA
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
3130962
3130752
3130732
3131130
3130541
3130540
3130504
3130014
3130570
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 (J8-4HB40)
Ring
Asm., Diaphragm
Jet, Needle
Screw
Washer, Spring
Asm., Jet Block
Washer
Jet, Main (#152.5)
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
3130531
3130533
3131226
3130522
3130523
3130525
3131131
3130546
3130545
3130544
3131126
3130589
3130514
3130501
3130513
3130543
3130511
3130512
3130199
3130538
3131228
3131229
3131225
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
3131129
3131127
3130592
2
1
1
4
Description
Valve, Needle (1.5)
O-Ring
Jet, Pilot (#47.5)
O-Ring
Washer
Spring
Adjuster
Screw, Adjust
Ring
Spring
Valve, Throttle (120)
Spring
Ring
Screw
Asm., Throttle Shaft
Guide, Cable
Cover
O-Ring
Holder, Guide
Spring
Asm., Plunger
Jet, Air (#100)
Asm., Carburetor
(Incl. 1-14,16-42,46-54)
Screw and Washer
Spring
Asm., Cover
Screw
8/99
C13
RECOIL STARTER
XPEDITION 325 A00CK32AA
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
3086896
3086897
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
3086898
3084877
3086894
3086895
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
8/99
C14
WATER PUMP
XPEDITION 325 A00CK32AA
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
D1
OIL PUMP
XPEDITION 325 A00CK32AA
1
2
3
4
8
9
7
10
6
5
Ref. Part No.
1
2
3
4
5
3086899
3086220
3086499
3086900
3083453
Qty.
1
1
1
6
1
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
3086454
3083568
Qty.
1
1
1
1
1
Description
Gasket
Spring, Relief Valve
Valve, Oil Relief
Strainer, Oil
Bolt, Flange
8/99
D2
OIL FILTER
XPEDITION 325 A00CK32AA
3
4
2
5
1
2
5
6
5
2
Ref. Part No.
1 3084963
2 3086228
3 3086903
Qty.
Description
Ref. Part No.
1 Filter, Oil
3 Bolt, Banjo
1 Pipe 6, Oil Delivery
4 3085359
5 3083482
6 3086902
Qty.
Description
1 Bolt, Flange
6 Gasket, Aluminum
1 Pipe 5, Oil Delivery
8/99
D3
MAGNETO
XPEDITION 325 A00CK32AA
2
1
3
10
12 11
4
13
5
14
6
8
7
9
Ref. Part No.
Qty.
1 3086483
3086807
2 3086463
3 3084997
4 3084978
1
1
1
1
1
3086992
5 3086460
6 3086904
Description
Asm., Ignition Coil (Incl. 1,2)
Ignition Coil
Cap, Plug, Spark
Plug, Spark
O-Ring, Black
(Must replace with same color)
1 O-Ring, Red
(Must replace with same color)
1 Dry, Bearing
1 Asm., Plate (Incl. 5,6,8)
Ref. Part No.
7
8
9
10
11
12
13
14
3081657
3084973
3086239
3086905
3083073
3080077
3086236
3086238
3086457
Qty.
5
1
1
1
2
2
1
1
1
Description
Bolt and Washer
Seal, Oil
Stator
CDI System
Nut
Washer, Spring
Switch, Magnetic
Asm., Magneto (Incl. 5,6,8,14)
Flywheel w/Ring Gear
1/00
D4
STARTING MOTOR
XPEDITION 325 A00CK32AA
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
D5
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 325 A00CK32AA
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
D6
CLUTCH
XPEDITION 325 A00CK32AA
7
6
4
30
12
29
28
5
3
31
34
1
2
1
32
33
8
24
25 26
27
22
20
11
14
13
9
10
12
22
23
18
15
17
16
Ref. Part No.
Qty.
1 3086913
3086914
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 3086908
1
1
1
6
4
1
1
4
5
1
1
1
1
1
1
1
1
1
1
3086909
12 3086258
13 3086288
14 3086502
1
2
8
1
22
19
21
Description
Ref. Part No.
Qty.
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
3086915
3086503
3086287
3086916
3086911
3086910
3086912
3086381
3086378
3086254
3086906
1
2
1
1
4
1
1
1
1
1
1
1
1
28
29
30
31
32
33
34
3086907
3086255
3086253
3084874
3086248
3086251
3086252
3086250
1
1
1
16
1
1
1
1
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. 26,27,29,31-34)
Cover, Clutch
Plug, Blind
Nut, Flange
Bolt, Flange
Bush, Flange
Pin, Clutch Cover
O-Ring
Lever, Release
3/00
D7
CLUTCH
XPEDITION 325 A00CK32AA
1
13 12
33
2
11
10
32
28
34
3
30
35
5
8
7
25
6
16
26
4
23
15
29
31
34
9
27
24
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
3086919
3086322
3086507
3086328
3086329
3086326
3086331
3086289
3086290
3086291
3086292
3086293
3086294
3086295
3086296
3086923
3086332
3086917
3086920
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
3086922
1
1
1
1
1
1
23
24
25
26
27
28
29
30
31
32
33
34
35
3086319
3086320
3086380
3086918
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
D8
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 325 A00CK32AA
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
41
34
14
33 29
12
42
35
37
36
40
38
22
39
30
43
46
45
44
D9
CLUTCH
XPEDITION 325 A00CK32AA
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
3086938
3086939
3086379
3086376
3086348
3086350
3086928
3086345
3086931
3086346
3086349
3086930
3086929
3086926
3086927
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
2
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
3086286
3086285
3086937
3086934
3086363
3086359
3086935
3086936
3086933
3086357
3086364
3086941
3086374
3231513
3086932
1
1
1
1
3
3
1
1
2
1
1
1
1
1
1
40
41
42
43
44
45
46
3086352
3086362
3086365
3086337
3086338
3086925
3086336
3086924
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
Spacer
Sprocket, Drive
Washer
Asm., Counter Shaft
(Incl. 22,27-35,38-41)
Shaft, Counter
Bearing, Ball
Plug
Pin
Pin
Gear
Collar
Asm., Reverse Shaft (Incl. 42-46)
Shaft, Reverse
3/00
D10
TOOL KIT
XPEDITION 325 A00CK32AA
8
2
3
9
4
5
1
6
10
7
Ref. Part No.
1
2
3
4
5
6
7
3085544
2870725
3082657
3085001
3085002
3083612
2682572
Qty.
1
1
1
1
1
1
1
Description
Asm., Tool Kit (Incl. 3-7)
Gauge, Tire Pressure
Screwdriver
Wrench, Open 8-10mm
Wrench, Open 12-14mm
Wrench, Box, Special
Pouch, Tool Kit
Ref. Part No.
8 2871515
9 9915299
9915474
10 2871095-067
11 2460442
11
Qty.
Description
1 Lube, U-Joint, 3 oz., Case
1 Owner’s Manual, ‘00 ATV
1 Supplement, Owner’s Manual, ’00
Xpedition 325
1 Wrench, Spanner, Cam
1 Pigtail, Power
3/00
D11
PRINTED IN THE USA
PARTS MANUAL PN 9915489 and MICROFICHE PN 9916574 3/00
G
F
E
D
C
B
A
1
cover
1
2
x
toc
2
3
3
4
4
Changed pages in 9915489
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14