xpedition 325 model #a00ck32aa rev. 01pi54.com/corp/manuals/parts/9915489r01.pdf · titan 24x8-12...

PARTS MANUAL PN 9915489 and MICROFICHE PN 9916574 3/00

XPEDITION 325Model #A00CK32AA

Rev. 01

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSXPEDITION 325 A00CK32AA

Parts ManualA

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

CCARBURETOR C12-13. . . . . . . . . . . . . . . . . . . . . .CLUTCH D7-10. . . . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/BRAKE

LINE B9. . . . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B8. . . .CRANKCASE C8. . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON C10. . . . . . . . . . . . .CV JOINT - BTB B3. . . . . . . . . . . . . . . . . . . . . .CYLINDER C9. . . . . . . . . . . . . . . . . . . . . . . . . .

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

EELECTRICAL/TAILLIGHT B14. . . . . . . . . . . . . . .ENGINE MOUNTING A12-13. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A11. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B7. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C4. . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A9. . .FRONT STRUT B5. . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B6. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D6. . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B1. . . . . . . . . . . . . . . . . . . . . . . . .

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

IINTAKE and EXHAUST C11. . . . . . . . . . . . . . . .

MMAGNETO D4. . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLER A14. . . . . . . . . . . . . . . . . . . . . . . .OIL FILTER D3. . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP D2. . . . . . . . . . . . . . . . . . . . . . . . . .

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

RREAR BRAKE C1-2. . . . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A5-6. . . . . . . . . . . . . . . . .REAR HOUSING C5. . . . . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . . . . . . .REAR WHEEL DRIVE C3. . . . . . . . . . . . . . . . .RECOIL STARTER C14. . . . . . . . . . . . . . . . . . . .

SSHOCK MOUNTING C7. . . . . . . . . . . . . . . . . . .STARTING MOTOR D5. . . . . . . . . . . . . . . . . . .STEERING POST B10. . . . . . . . . . . . . . . . . . . . .SWING ARM/REAR GEARCASE MOUNTING C6

TTOOL KIT D11. . . . . . . . . . . . . . . . . . . . . . . . . .

WWATER PUMP D1. . . . . . . . . . . . . . . . . . . . . . .

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

2000 XPEDITION 325 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

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

NA3.754.5N/AN/A9018030

Standard850

DRIVE TRAINType Shaft Ride System

CLUTCHDrive System Type 5 Speed

DIMENSIONAL FEATURES

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

65588N/A6.254681

33.5635

49.7546

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

5 Speed ManualFoot Lever

4.1822.5621.5221.1110.8134.1282.6551.3331.3133.7/13.1/1N/AN/AN/A

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

Titan24x8-12

24x11.5-10N/A43

N/A

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

Main JetPilot JetNeedle JetCut AwayAir ScrewJet Needle

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

ES32PLE034 Cycle, Single Cylinder

Wet Sump78x68325

9:2/1 Full StrokeAir Cooled/Oil Asist

200Standard

1/BST31 (CV Type)152.547.5

P-0(829)N/ATBD

4HB40-3CDI

[email protected]

BKR6EUSFS Appr. Pending

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

w/lettering Color

N/AN/A

Desert DuneDesert Dune

BlackBlack

Desert DuneBlack

Desert Dune/BlackBlackBlackSilverBlack

Desert DuneBlackBlackN/AN/A

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

N/AN/A

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

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)ShockAdjustment

MacPherson Strut6.7

Progressive Rate Swing Arm6.5

1 5/8� TwintubeCam

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

2000 XPEDITION PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUALSUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

XPEDITION 325 A00CK32AA 9915299 9915474 9915489 9916574 9915510

A5

REAR CAB and SEATXPEDITION 325 A00CK32AA

2726

4

10

5

9

7

1213

17

16

18

19

20

4243

15

22

23

24

34

8

38

1

2

3

41

39

146

40

21

5

33

36

32

11

29

25

37

28

9

31

30

30

35

E 2000 Polaris Sales Inc.

A6

REAR CAB and SEATXPEDITION 325 A00CK32AA

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

1 7670057 12 Nut, U-Type Speed2 5431796

543179711

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

3 7661645 10 Rivet4 7511930 2 Bolt5 7555792 4 Washer6 5811107 1 Foil, Rear Cab, Rear7 5411042 1 Grommet8 5432117-282 1 Cab, Rear, Desert Dune9 7541925 4 Nut, Nylok10 5224592 1 Retainer, Seat Latch11 5811308 1 Foil, Tape, Rear Cab12 7512242 4 Screw13 7555859 4 Washer14 7512085 2 Screw15 5431786 1 Box, Tool16 7621403 2 Rivet17 5211033 2 Bracket, Lever Retainer18 1040387 1 Latch, Seat19 7041370 1 Spring, Latch20 2682441-070

2681747-07058111045811105

1111

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

21 5410414 8 Bumper, Rubber

22 7517599 2 Screw23 5431787 1 Cover, Tool Box24 5410896 1 Cap, Drain25 ------ -- -- -- -- 1 Asm., Front Gearcase

(See Front Housing Pg. C4 for Details)26 7552603 4 Washer27 7512492 4 Bolt28 5433435 1 Guard, Rock29 7556065 7 Washer30 7517386 9 Screw31 7558301 2 Washer32 7542122 8 Nut33 5411548 8 Mount, Rubber34 7515111 4 Screw35 7512297 4 Screw36 1013119-067 1 Frame, Main37 5433391-070

5433392-07011

Footwell, LH, BlackFootwell, RH, Black

38 7512232 12 Screw39 5811111 1 Foil, Foam, Rear Fender40 5811106 2 Foil, Rear Cab, Front41 5811087 1 Foil, Foam42 7077446 1 Decal - Filter Element43 7073761 1 Decal - Carb Information

3/00

A7

FRONT CABXPEDITION 325 A00CK32AA

7

89

10

1112

14

32

20

21

1819

1615

1710

1

5

5

5

6

13

4


1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5811210 1 Foil, Foam, Side Panel3 2632084-282

2632147-28211

Asm., Panel w/Foam, LH, Desert DuneAsm.,Panel w/Foil, RH, Desert Dune

4 5811798 1 Foam5 7512232 12 Screw6 5811801 1 Foam, Cab, Front7 5432088-282 1 Cover, Front, Desert Dune8 7670085 2 Clip, Spring9 2632133-282 1 Cab, Front w/Warning Decals, Desert

Dune10 7670057 10 Nut, U-Type Speed

11 7670068 2 Nut, Push-on12 7661645 4 Rivet13 7517312 2 Screw14 5431798

543179911

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

15 7541925 2 Nut, Nylok16 7555792 2 Washer17 7512085 2 Screw18 7555931 2 Washer19 7542122 2 Nut, Nylok20 7621509 4 Rivet, Plastic21 5811917 2 Shield, Deflector

3/00

A8

REAR RACK MOUNTINGXPEDITION 325 A00CK32AA

4

3

1

2

8

6

9

11

1210

10

6

5

7

2


1 7517686 2 Screw2 7517685 4 Screw3 2670174 1 Asm., Rack, Rear

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

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

1040525-06711

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

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

3/00

A9

FRONT RACK and BUMPER MOUNTINGXPEDITION 325 A00CK32AA

13

14

15

1617

18

12

6

5

8

910

19

20

21

2223

24

2

3

4

11

4

7

1

6

4


1 7517685 4 Screw2 2670180 1 Asm., Front Rack

(Incl. Ref. 3 and Warning Decal)3 2670071 2 Reflector, Amber4 7515399 8 Screw5 2200775 1 Kit - Front Rack Mount6 7542324 4 Nut, Nylok7 7558403 2 Washer8 5432155-070 1 Bumper9 7515391 2 Screw10 7515390 2 Screw11 7555954 4 Washer12 1013210-067

1013211-06711

Support, Front Rack, LHSupport, Front Rack, RH

13 7517386 4 Screw

14 243101124310124030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

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

5241399-06711

Extension, Frame, LHExtension, Frame, RH

19 5241583-067 1 Guard, Brush20 5240591-067 1 Grill, Brush Guard21 7621330 7 Rivet22 7670094 6 Nut, U-Type23 7512097 6 Screw24 5431814

543181511

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

3/00

A10

DECALSXPEDITION 325 A00CK32AA

12 3

5

4

6

78

4

19 1817

14

16

15

12

11LH

RH

109

1

13


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution, 4W3 7078022 1 Decal - “4x4” Shaft Ride System, RH4 7078452 2 Decal - ‘‘POLARIS” Side Panel5 7078451 1 Decal - Tank Side, RH6 7074935 1 Decal - Warning, AWD Switch7 7078390 1 Decal - Discretionary Warning8 7078577 1 Decal - Drain Recoil9 7078315 1 Logo - 45th Anniversary10 7078015 1 Decal - “325” Four Stroke, Front Cover

11 7074220 1 Decal - “Macpherson Strut”12 7077919 1 Decal - Warning, General, CPSC13 7078551 1 Decal - 5 Speed14 7078018 1 Decal - “4x4” Shaft Ride System, LH15 7078004 1 Decal - Tire Pressure16 7077920 1 Decal - Passenger Warning17 7078253 1 Decal - Age Warning, ATV18 7078450 1 Decal - Tank Side, LH19 7078336 1 Decal - Reverse Switch

7/99

A11

EXHAUST SYSTEMXPEDITION 325 A00CK32AA

8

14

3

1

10

9

2

11

6

4

16

5

7

12

12

12

13

1110

17

16

15


1 7542324 1 Nut, Nylok2 7555716 1 Washer3 5410436 1 Washer, Rubber4 7555863 1 Bushing5 5132295 1 Bushing6 5411790 1 Dampener, Vibration7 7515339 1 Bolt8 1260961-029 1 Silencer, Exhaust9 7512666 1 Bolt

10 3110064 2 Mount, Torque Stop11 7542301 2 Nut12 7041804 4 Spring, Exhaust13 7042029 1 Spring, Exhaust14 1260987-029 1 Headpipe15 7041789 1 Spring, Exhaust16 5243517 2 Seal, Exhaust17 1261011-029 1 Manifold

7/99

A12

ENGINE MOUNTINGXPEDITION 325 A00CK32AA

18

13

6

1

33

14

2

26

84

11

12

3

17

15

5

7

10

2524

19

9

36

20

21 22

2728

2930

31

37

39

23

3435

41

16

32

42

38

9

4

44

4

44

4

27

26

29

40

28

A13

ENGINE MOUNTINGXPEDITION 325 A00CK32AA


1 7517756 2 Screw2 5243829-067 1 Strap3 7080003 4 Clamp4 7547108 6 Nut, Lock, Flange5 7517386 1 Screw6 4010132 1 Cable, Ground, Engine7 7552901 2 Washer8 7512315 2 Screw9 8450003-1525 AR Line, Vent10 7052075 1 Fitting, Tee11 7542122 1 Nut, Nylok12 7558301 1 Washer13 5244058-067 1 Bracket, Mount, Carburetor14 3084205 2 Screw15 3110050 1 Mount, Rubber16 7555823 1 Washer17 3021108

3021180

1

1

Mount, Motor. Rubber(If built before 8/21/99)Mount, Engine (If built after 8/21/99)

18 5244075-0675244517-067

11

Mount, Engine, Top(If built before8/26/99)Mount, Engine, Top(If built after8/26/99)

19 5243586-067 1 Lever, Reverse20 7517653 1 Screw21 5132141 1 Mount, Actuator, Reverse22 7517652 3 Screw

23 4010265 1 Actuator, Reverse24 7555746 3 Washer25 7510504 3 Screw26 5411927 2 Mount, Rubber27 7515406 1 Screw28 7555806 1 Washer29 3110045 2 Mount, Engine, Rubber30 7512492 2 Screw31 7552603 2 Washer32 5242984-067 1 Mount, Lower, Rear33 5242905-067 1 Mount, Engine. Lower34 7517388 3 Screw35 5631054-067 1 Lever36 5411364 1 Pad37 7512225 1 Screw38 3086945 1 Engine (ES32 PLE 03) NOTE: The

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

39 8360009-600 AR Line, Fuel40 7080816 1 Clip41 8450040-60 AR Line, Fuel42 2530009 1 Filter, Fuel

3/00

A14

OIL COOLERXPEDITION 325 A00CK32AA

23

41

5

67

89

10

12

7

7

8

8

8

8

86

13

11


1 5411787 1 Hose, Outlet2 7080474 2 Clamp3 5411892 1 Hose, Inlet4 7080862 2 Clamp5 5243783-067 1 Bracket, Top6 7512276 4 Screw7 7542122 8 Nut, Nylok

8 7558301 12 Washer9 3110032 4 Mount, Rubber10 1240074

401028211

Cooler, OilSwitch Thermal

11 7080869 1 P-Clamp12 1013302 1 Bracket, Lower13 7547133 2 Nut

6/01

B1

FUEL TANKXPEDITION 325 A00CK32AA

24

5

22 23

9

17

15

1

11

2

13

3

18

16

14

7

4

21

8

6

16

12

10

20

19


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Fuel Cap3 5811899 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517451 2 Bolt7 7552801 2 Washer8 7558301 2 Washer9 5222154-067

5222155-06711

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

10 5811939 1 Foam, Intake, Splash11 5332457 2 Spacer12 7547069 4 Nutsert

13 5810317 2 Pad, Fuel Tank Bracket14 7517505 1 Screw15 5432559 1 Knob, Fuel Valve16 7080003 4 Clamp, Hose, Red17 5432733 1 Nut, Fuel Valve18 7052161 1 Valve, Fuel, 3-Way19 7661637 2 Rivet20 5240577-067 1 Bracket21 8450040-600 AR Line, Fuel22 7052149 1 Fitting, Fuel Outlet, Reserve23 7052146 1 Fitting, Fuel Outlet, Main24 2520174 1 Asm., Fuel Tank (Incl. 5,22,23)

7/99

B2

AIR BOXXPEDITION 325 A00CK32AA

22

12

25

11

14

6

2

19

5

26

24

23

4

13

15

7

13

27

21

3

1

20

8

17

8

16

9 10

18


1 7517541 4 Screw2 5432859 1 Duct, Inlet3 5411422 1 Gasket, Intake4 5432868 1 Cover, Air Box5 5811482 1 Seal, Cover6 7515180 2 Screw7 7558301 2 Washer8 5243694 6 Clip, Low Profile9 7080534 1 Clamp10 5433396 1 Cap11 5830128 1 Gasket, Duct12 5433180 1 Duct, Carburetor, Inlet13 7080413 2 Clamp14 5411810 1 Boot, Carburetor

15 7080511 1 Clamp16 7080694 1 Clamp17 5411866 1 Hose, Breather, Formed18 7080699 1 Clamp19 5433678 1 Box, Air20 5431863 2 Insulator21 5811650 1 Foil, Box, Air22 5432377 1 Plug23 8450059-150 AR Line, Fuel24 7080650 1 Clamp, Hose25 5432601 1 Collar, Inlet, Carburetor26 7080595 1 Filter, Air27 5811633 1 Filter, Sleeve, Precleaner

7/99

B3

CV JOINT - BTBXPEDITION 325 A00CK32AA

BTB

1012 3 4 5

6

7

8 9

12

11

13


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

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

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

10/98

B4

PROP SHAFTXPEDITION 325 A00CK32AA

12 3

45

6


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

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

10/98

B5

FRONT STRUTXPEDITION 325 A00CK32AA

1

2

35

67

9

10

1112

13

15

16

14

17

18

19

21

4

20

2223

24

2526

27

1112

44

8


1 5411608 2 Bumper, Strut2 7041761 2 Strut, Front3 5211115 2 Washer, Spring Retainer4 7558402 10 Washer5 7080573 2 Clamp, Rubber Coated6 7542303 4 Nut, FLEXLOC7 7517445 4 Screw8 7552901 4 Washer, Lock9 5810439 2 Retainer, Strut Casting Wire10 ------ -- -- -- -- -- 1 Asm., Front Brake Caliper, RH (See

Front Brake Pg. B7 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 2201311

2201312

1

1

Asm., Hubstrut, LH (32mm)(Incl. 9,12-15,23)Asm., Hubstrut, RH (32mm)(Incl. 9,12-15,23)

17 7041375-067 2 Spring, Coil18 5243364 2 Retainer, Spring, Top19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer, Threaded22 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve BTB

(See CV Joint Pg. B3, Ref. 13)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, FLEXLOC

3/00

B6

FRONT WHEELXPEDITION 325 A00CK32AA

10 11 12 14

1 2

34

5

79

8

15

1625

24 7

17 18 2021

23

13

6

6

22

19


1 7512325 8 Bolt2 5211869 2 Disc, Brake3 3610019 2 Seal, Front Hub4 5211148 2 Plate, Armature5 1520281 2 Clutch, Front Hub, Elec./Mech.6 3554506 4 Bearing, Tapered Roller Cone7 3554507 4 Bearing, Tapered Roller Cup8 7515523 8 Stud9 1520243 2 Asm., Hub w/Bearing Race (Incl.3,7,8)10 3250028 2 Cage, Roll11 3250010 12 Roll12 3250032 2 Spring, Garter13 1321814 2 Spacer

14 3250030 2 Cam15 7052045 2 Plug, Magnetic Drain16 5411709 2 Tire (24x8-12)17 7556004 2 Washer18 7542810 2 Nut, Slotted19 7661401 2 Pin, Cotter20 5410470 2 O-Ring21 5432611 2 Cap, Hub22 7512027 6 Screw23 7542459 8 Nut, Lock24 1520269-117 2 Rim, Front, Silver25 1525017 2 Valve, Rim

3/00

B7

FRONT BRAKEXPEDITION 325 A00CK32AA

1

2 3

89

11

10

12

4

5 6 7


1910271 1 Asm., Front Brake Caliper, LH(Incl. 1-7,9,10)

1910264 1 Asm., Front Brake Caliper, RH(Incl. 1-7,9,10)

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

51311161930642

111

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

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

5 5410779 1 Square Ring, Molded (.094)

6 5410780 1 Square Ring, Molded (.103 x .134)

7 5132294 1 Piston, Long8 2200465

22009012201149

111

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

9 1910412 1 Mount, Caliper10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 ------ -- -- -- --

-- -- -- -- -- -- ---- -- -- -- -- -- --

444

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

B8

CONTROLS - THROTTLE ASM./CABLEXPEDITION 325 A00CK32AA

3

1

6

5

4

2


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

4 7080857 1 Cable, Throttle Control5 2010188 1 Asm., Throttle Control (Incl.1,3,6)6 2010191 1 Asm., Throttle Clamp

3/00

B9

CONTROLS - MASTER CYLINDER/BRAKE LINEXPEDITION 325 A00CK32AA

2

3

5

10

6

4

12

1

11

13

23

27

17

20

21

22

22

25

24

2616

1819

28

15

14

9

8

7


20500782200809

11

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

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

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

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

10/98

B10

STEERING POSTXPEDITION 325 A00CK32AA

1

16

1514

2

3

4

13

9

125

6

10

5

5

8

11

6

7


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

9 7661633 1 Pin, Cotter10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Grease, Steering13 7080433 1 Fitting, Lubrication14 5433416 1 Bushing, Steering, Console15 5222999-067 1 Bracket, Upper Steering Bushing16 7542324 2 Nut, Nylok

7/99

B11

HANDLEBAR and HEADLIGHT PODXPEDITION 325 A00CK32AA

2176

5

15

1

2

3

11

4

8

9

10

14

16

17

19

20

22

18

12

13

15

19

B12

HANDLEBAR and HEADLIGHT PODXPEDITION 325 A00CK32AA


1 5432247-070 1 Cover, Logo2 7512024 2 Screw3 5432246-070 1 Panel, Instrument4 7080229 1 Nut, Choke5 7517216 4 Screw6 5241397-067 1 Bracket, Panel, Instrument7 7080726 1 Cable, Choke8 5432926 1 Spacer, Switch, LH9 4010262 1 Switch, Handlebar, HI/LO/Rev. Over-

ride10 5431030 2 Grip, Handlebar11 5432952 1 Plug12 7517625 1 Screw, Set13 ------ -- -- -- -- 1 Asm., Master Cylinder

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

14 5224715-067 1 Handlebar15 5630629 4 Block, Handlebar16 7542122 4 Nut, Nylok

17 7080631 1 Clip18 ------ -- -- -- -- 1 Asm., Throttle Control

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

19 41102644010278

4010321

11

1

Switch, Ignition (Incl. Key)Blank, Key, Series 2000, 6700, 6800NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

20 5433534 1 Cover, Key21 4040054

40400535430467

111

Indicator - Neutral/ReverseIndicator - “HOT TEMP.”Plug

22 2460728 1 Harness, Pod, Headlight

10/00

B13

A-ARM/STRUT MOUNTINGXPEDITION 325 A00CK32AA

1 45

6

7

89

3

12

1314

27

15

16

181719

21

25

26

2423

22

2829

29 28

2322

20

31 30

2

14

9

11

10


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820567

1820805

2

2

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

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

706105422

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

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

755609944

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

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

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

543114911

Shield, CV Joint, LHShield, CV Joint, RH

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

220062811

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

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

(See Front Strut Pg. B5, Ref. 16)28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Bolt31 7515415 1 Screw

10/00

B14

ELECTRICAL/TAILLIGHTXPEDITION 325 A00CK32AA

13 4

5

67

89 12

11

10

24

23

13

22

14 1516

17

18

19

29

28

26

25

20

21

27

2

12

12


1 2460798

2460849

1

1

Harness, Wire, Main(If built before 1/01/00)Harness, Wire, Main(If built after 1/01/00)

2 2201795 1 Kit - Circuit Breaker, 10 AMP3 2432034 1 Asm., Taillight w/Brake Light (Incl. 4-9)4 4032046 1 Lens, Taillight5 4032029 2 Screw, Taillight6 4030043 1 Bulb, Taillight7 4032045 1 Gasket, Taillight8 4032064 1 Backing, Taillight/Brake Light9 7670054 2 Nut, Speed10 7541925 2 Nut, Nylok11 7571602 2 Washer12 7512027 7 Screw13 5810290 3 Pad, Battery

14 2200361 1 Kit - Battery Bolt, Short15 4010095 1 Cable, Battery/Engine16 7010032 2 Hook, Strap, Battery17 5410424 1 Strap, Holddown, Battery18 5432077 AR Tube, Vent, Battery19 4140006 1 Battery20 7670102 1 Clip21 7080367 1 Clamp22 5431769 1 Cover, Battery23 4010094 1 Cable, Battery/Solenoid24 4010093 1 Cable, Solenoid/Starter25 5132214 1 Sink, Heat26 4060191 1 Rectifier, Regulator, LR 3527 4010285 1 Switch, LR-8428 4020149 6 Clip, Rosebud29 7670109 3 Clip, Routing

3/00

C1

REAR BRAKEXPEDITION 325 A00CK32AA

30

4

27

9

29

8

7

10

12

26

18

1

65

17

13

20

23

21

3

2

24

16

19

5

7

13

5

1817

252622

22

15

19

19

21

928

14

11

C2

REAR BRAKEXPEDITION 325 A00CK32AA


1 220118919103391930860

111

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

2 1910367220142822014672201385

1111

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

3 7515406 2 Screw4 7555806 2 Washer5 5410988 6 Seal6 1910286 1 Line, Front Hand Brake7 1910288 1 Line, Rear Foot Brake8 7080573 1 Clamp9 7517386 1 Screw10 7080762 3 Clip, Brake Line11 7512084 1 Screw12 7670113 1 Clip, Dual13 1930674 3 Bolt, Banjo

14 7542403 2 Nut

15 7542153 1 Nut, Nylok, Flange16 1930854 1 Reservoir, Brake, Rear17 7080003 2 Clamp18 1910331 1 Hose, Reservoir19 7512240 3 Bolt20 1012753-067 1 Pivot, Mount, Brake, Rear21 7542122 2 Nut, Nylok22 7558301 2 Washer23 1012991-067 1 Rod, Brake24 7041750 1 Spring25 7555919 1 Washer26 5433189 2 Bushing, Pedal Pivot27 7661401 1 Pin, Cotter28 7556090 1 Washer29 7515158 2 Screw30 1910311 1 Master Cylinder, Foot

9/02

C3

REAR WHEEL DRIVEXPEDITION 325 A00CK32AA

67

1011

1

12

4

8

2

3

5

9


1 7661404 2 Pin, Cotter2 7542714 8 Nut3 5131777 2 Hub, Wheel, Rear4 7512673 8 Stud5 7670081 8 Pushnut6 5411710 2 Tire, 24x11.5-10

7 1525017 2 Valve, Rim8 1520183-117 2 Rim, Rear, Silver9 7555745 2 Washer10 7555796 2 Washer, Cone11 7543005 2 Nut, Castle12 5411164 2 Cover, Dust, Hub

3/00

C4

FRONT HOUSINGXPEDITION 325 A00CK32AA

2

1

3

4

5

6

7

8 13

2314

192017

21 22

25 24

2

12

16 18

11

15

1

1213

10

9


1341253 1 Asm., Front Gearcase (Incl. 1-8,12-25)1 3233319 2 Seal, Oil2 3233252 11 Screw3 3233573 1 Cover, Input, Front Housing4 3233588 1 O-Ring5 3233574 1 Nut, Lock6 3233589 1 Bearing, Ball7 3233590 1 Shaft, Input, Front Housing8 3233591 1 Bushing9 7080307 1 Clamp10 7080756 1 Clip11 8450003-1525 AR Line, Vent12 3233253 2 Plug, Drain

13 3233254 2 Washer14 3233524 1 Tube, Vent Hose15 3233592 1 Gearcase, Front Housing16 3233593 1 Bushing17 3233594 1 Gear, 37T, Bevel18 3233595 1 Shaft, Output, Front Housing19 3233020 1 Bearing, Ball20 3233554 1 Shim21 3233596 1 O-Ring22 3233597 1 Cover, Output, Front Housing23 3233248 1 Seal24 3233583 1 Shim25 3233582 1 Button, Thrust

7/99

C5

REAR HOUSINGXPEDITION 325 A00CK32AA

9

16

7

4

1

15

21

6

5

23

2

2019

14

3

12

18 22

2417

825

10

8

317

2

26

11

16

13


1341309

1341321

1

1

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

1 3233585 2 Screw2 3233252 10 Screw3 3233256 2 Seal4 3233584

3233741

1

1

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

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

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

3233740

1

1

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

11 7670102 3 Clip12 8450003-1525 AR Line, Vent

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

3233739

1

1

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

16 3233711 2 Plug17 3233324 2 Washer18 3233577 1 Bushing19 3233707

3233738

1

1

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

20 3233575

3233714

1

1

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

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

3/00

C6

SWING ARM/REAR GEARCASE MOUNTINGXPEDITION 325 A00CK32AA

13

27

33

11

21

18

23

28

2624

34

16

9

30

11

37

910

10

16

22

75

5

35

8

32

1

17

29

20

2

3

14

15

3613

12

14

15

12

31

25

64

22

19

19


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

(See Rear Brake Pg C2, Ref. 2)3 3513523 2 Bearing, Ball4 5411653 1 Shield, Brake Line5 7517604 3 Bolt6 7512084 2 Screw7 7555721 3 Washer8 7542703 3 Nut, FLEXLOC9 5411532 2 Cap, Pivot, Swing Arm10 5131863 2 Nut11 5131864 2 Pivot, Shaft12 5131848 2 Bushing13 3610072 2 Seal, Pivot, Swing Arm14 3554506 2 Bearing, Roller Cone15 3554507 2 Bearing, Roller Cup16 1541323

541160212

Asm., Swing Arm (Incl. 15,16)Seal, Pivot, Swing Arm

17 1012839-067 1 Arm, Swing, Rear18 5132201

708043311

Coupling, Prop Shaft, Rear, GreasedFitting, Lubricating

19 5411092 2 O-Ring

20 1380154 1 Asm., Rear Prop Shaft21 7517585 8 Bolt22 7553201 8 Washer23 5131862 1 Axle, Rear24 7710482 1 Ring, Hog25 7517612 3 Screw26 1012881

5242851-0675811716

111

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

27 5131930 1 Collar, Rear Axle28 5411707 1 O-Ring29 ------ -- -- -- -- 1 Asm., Rear Gearcase (See Rear

Housing Pg. NO TAG for Details)30 5411531 1 O-Ring31 7072533 1 Decal - Hitch32 1012740-067 1 Tube, Axle, LH33 7515481 3 Screw34 7710471 1 Ring, Retaining35 5132075 1 Spacer, Bearing36 3610071 1 Seal, Outer Axle37 5211849 1 Disc, Brake, Rear

3/00

C7

SHOCK MOUNTINGXPEDITION 325 A00CK32AA

3

8

4

711

5

6

1

9

2

10

1


1 7542439 2 Nut, Nylok2 5433213 2 Bushing3 7515415 1 Screw4 5132022 1 Tube5 5241147 1 Retainer, Shock6 7041849-067 1 Spring

7 7041890 1 Shock8 5630551 1 Cam, Adjuster9 5132021 1 Tube10 5433212 2 Bushing11 7515438 1 Screw

7/99

C8

CRANKCASEXPEDITION 325 A00CK32AA

4

15

8

11

7

16

10

5

1312

2526

24

14

6

17

23

7

9

21

3 22

3

21

20

19183

3


1 3083568 1 Bolt2 3086881 1 Plate, Partition3 3084840 10 Pin, Dowel4 3085815 2 Bearing, Ball5 3084838 2 Pin, Straight6 3086193 1 Bush7 3080103 2 Pin, Dowel8 3086879 1 Asm., Crankcase (Incl. 7,6,4-14,11,10)9 3085850 1 Pipe Comp.10 3084841 12 Bolt, Flange11 3083669 1 Bush, Starter12 3082956 1 Gasket13 3083453 1 Plug

14 3085295 2 Bolt, Flange15 3086191 1 Bearing, Needle16 3086192 1 Seal, Oil17 3086194 1 Ball, Steel18 3086880 1 O - Ring19 3086882 2 Union20 3086397 1 Plug21 3084862 1 Plug, Blind22 3084849 1 Pump, Union Oil23 3086197 1 Bush24 3086195 1 Pin, Stopper25 3081890 2 Screw26 3086196 1 Bearing, Plate

3/00

C9

CYLINDERXPEDITION 325 A00CK32AA

3

19

18

12

8

266

4

7 10

14

12

20

21

5

9 11

27

17

2223

24

25

13

16

15

6

8

12

1415

4

9

9


1 3086413 2 Cover, Valve2 3086414 2 O-Ring3 3086412 4 Bolt, Flange4 3084874 6 Bolt, Flange5 3086417 1 Plug, Cylinder Block6 3086410 2 Pin, Straight7 3084858 1 Seal, Intake Valve8 3084994 2 Guide, Valve9 3084798 3 Fin Damper A10 3084859 1 Seal, Exhaust Valve11 3086418 4 Bolt and Washer12 3086796 1 Asm., Cylinder Head (Incl. 3,4,6-10,

12,14,26)13 3086421 1 Gasket, Exhaust

14 3085326 2 Stud15 3080530 2 Washer16 3080285 2 Nut17 3084838 2 Pin, Straight18 3086407 1 Gasket, Cylinder19 3086883 1 Cylinder20 3086415 1 Gasket, Head21 3086416 1 Gasket, Cam22 3086885 1 Adapter23 3083166 1 Asm., Adapter Band (Incl. 24)24 3081497 1 Screw25 3081330 2 Bolt26 3086884 1 Cover, Rocker27 3086419 2 Bolt, Flange

8/99

C10

CRANKSHAFT and PISTONXPEDITION 325 A00CK32AA

7

6

5

15

14

10

8

11

2

1

4

9

1312

5

146

4

8

3

16


1 308577430857753085776

111

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

2 308680030868013086802

111

Piston Set (STD)(Incl. 3,4))Piston Set (0.25 O/S)(Incl. 3,4)Piston Set (0.50 O/S)(Incl. 3,4)

3 3086846 1 Pin, Piston4 3084167 2 Clip5 3086425 2 Bolt6 3087017 1 Asm., Connecting Rod (Incl. 5,15)7 3086886 1 Crankshaft, Complete (Incl. 16)8 3240168 2 Key, Woodruff

9 3086888308688930868903086891

1111

SpacerSpacerSpacerSpacer

10 3086492 1 Sprocket 111 3085528 1 Nut12 3083904 1 Washer13 3083905 1 Nut14 3086427

30867983086799

222

Bearing (STD)Bearing (0.05 U/S)Bearing (0.25 U/S)

15 3086426 2 Nut16 3085024 1 Ball, Steel

4/00

C11

INTAKE and EXHAUSTXPEDITION 325 A00CK32AA

11

12

19

910

1314

8

76

4

2

16

20

2

15

23

1817

2122

24

1

31

76

8

5


1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1,2)4 3086442 1 Shaft, Rocker5 3085836 1 Washer6 3084908 4 Collet, Valve7 3086893 2 Retainer, Spring8 3086892 2 Spring, Valve9 3086439 1 Lever, Release10 3086804 1 Spring, Return11 3086803 1 Camshaft (Incl. 9,10,12)12 3084899 1 Pin, Dowel

13 3085778 1 Valve, Intake14 3086441 1 Valve, Exhaust15 3086445 1 Guide, Chain16 3086444 1 Chain, Timing17 3086448 1 Gasket, Tensioner18 3086493 1 Tensioner19 3083361 2 Bolt, Flange20 3086443 1 Sprocket 221 3083663 1 Washer22 3086449 1 Bolt, Flange23 3086446 1 Lever24 3084924 1 Bolt, Pivot

8/99

C12

CARBURETORXPEDITION 325 A00CK32AA

50

41

38

9

53

5

52

12

4

6

4445

42

40

1939

1819

1716

25

23

31

34

33

30

1110

3

26

24

20

28

22

29

15

27

54

4748

87

49

43

3736

35

32

21

51

46

15

1213

14

C13

CARBURETORXPEDITION 325 A00CK32AA


1 3130507 1 Ring2 3130508 1 E-Ring3 3130962 1 Needle, Jet (J8-4HB40)4 3130752 1 Ring5 3130732 1 Asm., Diaphragm6 3131130 1 Jet, Needle7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3130570 1 Jet, Main (#152.5)12 3131115 1 Diaphragm13 3131116 1 Spring14 3131117 1 Cover15 3130535 6 Screw16 3130519 1 Cap17 3130518 1 E-Ring18 3130517 1 Packing19 3130515 2 Seal20 3130361 1 Pin, Float21 3130594 1 Plate22 3130532 1 O-Ring23 3130520 4 Screw24 3130590 1 Asm., Float Body25 3130521 1 Screw26 3130529 1 Asm., Float27 3130591 2 Screw

28 3130531 1 Valve, Needle (1.5)29 3130533 1 O-Ring30 3131226 1 Jet, Pilot (#47.5)31 3130522 1 O-Ring32 3130523 1 Washer33 3130525 1 Spring34 3131131 1 Adjuster35 3130546 1 Screw, Adjust36 3130545 1 Ring37 3130544 1 Spring38 3131126 1 Valve, Throttle (120)39 3130589 1 Spring40 3130514 1 Ring41 3130501 2 Screw42 3130513 1 Asm., Throttle Shaft43 3130543 1 Guide, Cable44 3130511 1 Cover45 3130512 1 O-Ring46 3130199 1 Holder, Guide47 3130538 1 Spring48 3131228 1 Asm., Plunger49 3131229 1 Jet, Air (#100)50 3131225 1 Asm., Carburetor

(Incl. 1-14,16-42,46-54)51 3084205 2 Screw and Washer52 3131129 1 Spring53 3131127 1 Asm., Cover54 3130592 4 Screw

8/99

C14

RECOIL STARTERXPEDITION 325 A00CK32AA

14

6

4

7

10

5

31 2

11

8

12

13

15

9

8

7


1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3086896 1 Plate, Friction6 3086897 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bush, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bush12 3086898 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3086894

308689511

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

15 3085083 1 Asm., Rope

8/99

D1

WATER PUMPXPEDITION 325 A00CK32AA

6

10

9

4

2

1

8

5

11

3

7


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

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

2/99

D2

OIL PUMPXPEDITION 325 A00CK32AA

8

1

3

2

6

5

79

4

10


1 3086899 1 Cover, Oil Pump2 3086220 1 Rotor, Outer Feed3 3086499 1 Pump, Inner Oil4 3086900 6 Screw, Counter Sunk5 3083453 1 Plug

6 3082956 1 Gasket7 3086223 1 Spring, Relief Valve8 3086222 1 Valve, Oil Relief9 3086454 1 Strainer, Oil10 3083568 1 Bolt, Flange

8/99

D3

OIL FILTERXPEDITION 325 A00CK32AA

1

65

5

3

4

2

2

2

5


1 3084963 1 Filter, Oil2 3086228 3 Bolt, Banjo3 3086903 1 Pipe 6, Oil Delivery

4 3085359 1 Bolt, Flange5 3083482 6 Gasket, Aluminum6 3086902 1 Pipe 5, Oil Delivery

8/99

D4

MAGNETOXPEDITION 325 A00CK32AA

14

6

5

8

9

4

7

1

2

10

13

3

1112


1 30864833086807

11

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

2 3086463 1 Cap, Plug, Spark3 3084997 1 Plug, Spark4 3084978

3086992

1

1

O-Ring, Black(Must replace with same color)O-Ring, Red(Must replace with same color)

5 3086460 1 Dry, Bearing6 3086904 1 Asm., Plate (Incl. 5,6,8)

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086239 1 Stator10 3086905 1 CDI System11 3083073 2 Nut12 3080077 2 Washer, Spring13 3086236 1 Switch, Magnetic14 3086238

308645711

Asm., Magneto (Incl. 5,6,8,14)Flywheel w/Ring Gear

1/00

D5

STARTING MOTORXPEDITION 325 A00CK32AA

1

9

7

11

6

12

3

18

13

17

16

15

14

5

4

10

8

7

1

3

3

3

1

2


1 30862403084405

12

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

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

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

10/98

D6

FUEL PUMPXPEDITION 325 A00CK32AA

5

2

4 3

3

5

1


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

4 3084591 4 Screw5 3084998 1 Diaphragm Gasket Set

10/98

D7

CLUTCHXPEDITION 325 A00CK32AA

2

15

6

8

7

119

14 1312

3 5

4

10

1

1

1617

18

19

20

21

2223

24

22

25 26

27

2829

30

31

32

33

34

22

12


1 30869133086914

11

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

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

3086264308626530862663086267308626830862693086270

11111111

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

10 3086261 1 Bearing, Ball11 3086908

3086909

1

1

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

12 3086258 2 Seal, Oil13 3086288 8 Bolt, Flange14 3086502 1 Plug

15 3086260 1 O-Ring16 3084179 2 Bolt, Flange17 3086915 1 Gasket, Reduction Cover18 3086503 1 Bearing, Ball19 3086287 4 Bolt, Flange20 3086916 1 Gasket, Clutch Cover21 3086911 1 Drum, Outer22 3086910 1 Asm., Clutch (Incl. 21-23)23 3086912 1 Asm., Plate24 3086381 1 Washer, Lock25 3086378 1 Nut, Lock26 3086254 1 Bearing, Ball27 3086906

3086907

1

1

Asm., Clutch Cover(Incl. 26,27,29,31-34)Cover, Clutch

28 3086255 1 Plug, Blind29 3086253 1 Nut, Flange30 3084874 16 Bolt, Flange31 3086248 1 Bush, Flange32 3086251 1 Pin, Clutch Cover33 3086252 1 O-Ring34 3086250 1 Lever, Release

3/00

D8


9

7

3

4

1112

14

2928

2

18

19

1

5

6

10

1615

8

17

13

22

2324

2526

27

21

20

3031

3233

34

35

34


1 3086330 1 Key2 3086324 1 Shaft, Output3 3086327 1 Seal, Oil4 3086306 1 Spring, Reverse Arm5 3086919 1 Asm., Reverse Arm6 3086322

308650711

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

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

3086290308629130862923086293308629430862953086296

11111111

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

12 3086923 1 Holder, Bearing13 3086332 4 Bolt, Flange14 3086917 1 Asm., Reverse Cam15 3086920 1 Switch, Position16 3084566 2 Bolt, Flange

17 3086314 1 Washer, Lock18 3086310 1 Nut, Lock19 3086304 1 Chain20 3086303 1 Sprocket, Driven21 3086321 1 Bearing, Ball22 3086922

30863193086320

1

11

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

23 3086380 1 Washer24 3086918 1 Gear, Primary25 3086302 1 Arm, Stopper26 3086311 1 Bolt27 3086301 1 Arm, Release28 3086317 1 Spacer29 3086316 1 Spacer30 3086307 1 Spring, Return31 3086308 1 Spring, Stopper Arm32 3086312 1 Key, Woodruff33 3086298 1 Asm., Shift Shaft34 3086309 2 Spring, Shift35 3086315 1 Spacer

3/00

D9


7

8

20

17

21

2223

2426

34

39

38

37

42

44

19

6

41

5

13

2

43

25

10

36

45

4

32

14

1235

33

1

31

3

40

11

9

16

33

15

3029

28

27

1

1716

29

29

30

46

18

22

D10



1 3086375 2 Shaft, Shift Fork2 3086377 2 Fork, Shift, Driven3 3086370 1 Bolt, Lock4 3086369 1 Washer5 3086368 1 Cam, Shift6 3086373 1 Bearing, Ball7 3086371 1 Pin8 3086938

308693911

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

9 3086379 1 Pin, Dowel10 3086376 1 Fork, Shift, Drive11 3086348 1 Bearing, Ball12 3086350 1 Washer13 3086928 1 Gear, 2nd Drive14 3086345 1 Collar15 3086931 1 Gear, 5th Drive16 3086346 2 Washer17 3086349 2 Ring, Snap18 3086930 1 Gear, 4th Drive19 3086929 1 Gear, 3rd Drive20 3086926

308692711

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

21 3086372 6 Pin22 3086347 2 Bearing, Ball23 3086382 1 Bush, Flange24 3086313 1 Washer

25 3086286 1 Washer, Lock26 3086285 1 Nut, Lock27 3086937 1 Gear28 3086934 1 Gear, 3rd Driven29 3086363 3 Ring, Snap30 3086359 3 Washer31 3086935 1 Gear, 4th Driven32 3086936 1 Gear, 5th Driven33 3086933 2 Gear, 2nd Driven34 3086357 1 Clutch35 3086364 1 Washer36 3086941 1 Spacer37 3086374 1 Sprocket, Drive38 3231513 1 Washer39 3086932

3086352

1

1

Asm., Counter Shaft(Incl. 22,27-35,38-41)Shaft, Counter

40 3086362 1 Bearing, Ball41 3086365 1 Plug42 3086337 1 Pin43 3086338 1 Pin44 3086925 1 Gear45 3086336 1 Collar46 3086924

308633411

Asm., Reverse Shaft (Incl. 42-46)Shaft, Reverse

3/00

D11

TOOL KITXPEDITION 325 A00CK32AA

1

3

7

2

9

4

5

11

8

10

6


1 3085544 1 Asm., Tool Kit (Incl. 3-7)2 2870725 1 Gauge, Tire Pressure3 3082657 1 Screwdriver4 3085001 1 Wrench, Open 8-10mm5 3085002 1 Wrench, Open 12-14mm6 3083612 1 Wrench, Box, Special7 2682572 1 Pouch, Tool Kit

8 2871515 1 Lube, U-Joint, 3 oz., Case9 9915299

991547411

Owner’s Manual, ‘00 ATVSupplement, Owner’s Manual, ’00Xpedition 325

10 2871095-067 1 Wrench, Spanner, Cam11 2460442 1 Pigtail, Power

3/00

PRINTED IN THE USA PARTS MANUAL PN 9915489 and MICROFICHE PN 9916574 3/00

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xpedition 325 model #a00ck32aa rev. 01pi54.com/corp/manuals/parts/9915489r01.pdf · titan 24x8-12...

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