PDF Repair Manual Polaris Xpedition 325 & 425 ATV (2002) - 1 MB
Keep your 2002 Polaris Xpedition 325 or 425 ATV in top condition with this detailed repair manual.
It covers every aspect of maintenance and repair, from the engine and transmission to the suspension and electrical systems.
Step-by-step instructions and clear illustrations make it easy for anyone to service their ATV.
Save money on repairs and keep your machine ready for the trail.
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--- Page 1 ---
CHAPTER 1
GENERAL INFORMATION
1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . 1.1
Serial Number Location . . . . . . . . . . . . . . . . . . . 1.1
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . 1.2-1.3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4-1.7
Publication Numbers . . . . . . . . . . . . . . . . . . . . . 1.8
Paint Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Replacement Keys . . . . . . . . . . . . . . . . . . . . . . . 1.8
Standard Torque Specifications . . . . . . . . . . . . 1.9
Torque Conversion Table . . . . . . . . . . . . . . . . . . 1.10-1.11
Decimal Equivalent Chart . . . . . . . . . . . . . . . . . 1.12
Unit of Measure Conversion Table . . . . . . . . . . 1.13
Tap Drill Charts . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . 1.15-1.16
--- Page 3 ---
GENERAL INFORMATION
STANDARD TORQUE SPECIFICATIONS
The following torque specifications are to be used as a general guideline. There are exceptions in the steering,
suspension, and engine areas. Always consult the exploded views in each manual section for torque values of
fasteners before using standard torque.
Bolt Size Threads/In Grade 2 Grade 5 Grade 8
Torque in. lbs. (kg-m)
#10 - 24 . . . . . . . . . . . . . . 27 (.31) . . . . . . . . . . . . . . . . 43 (.50) . . . . . . . . . . . . . . 60 (.69)
#10 - 32 . . . . . . . . . . . . . . 31 (.36) . . . . . . . . . . . . . . . . 49 (.56) . . . . . . . . . . . . . . 68 (.78)
Torque ft. lbs. (kg-m)*
1/4 - 20 . . . . . . . . . . . . . . 5 (.7) . . . . . . . . . . . . . . . . . . 8 (1.1) . . . . . . . . . . . . . . . 12 (1.6)
1/4 - 28 . . . . . . . . . . . . . . 6 (.8) . . . . . . . . . . . . . . . . . . 10 (1.4) . . . . . . . . . . . . . . 14 (1.9)
5/16 - 18 . . . . . . . . . . . . . . 11 (1.5) . . . . . . . . . . . . . . . . 17 (2.3) . . . . . . . . . . . . . . 25 (3.5)
5/16 - 24 . . . . . . . . . . . . . . 12 (1.6) . . . . . . . . . . . . . . . 19 (2.6) . . . . . . . . . . . . . . 29 (4.0)
3/8 - 16 . . . . . . . . . . . . . . 20 (2.7) . . . . . . . . . . . . . . . . 30 (4.0) . . . . . . . . . . . . . . 45 (6.2)
3/8 - 24 . . . . . . . . . . . . . . 23 (3.2) . . . . . . . . . . . . . . . . 35 (4.8) . . . . . . . . . . . . . . 50 (6.9)
7/16 - 14 . . . . . . . . . . . . . . 30 (4.0) . . . . . . . . . . . . . . . . 50 (6.9) . . . . . . . . . . . . . . 70 (9.7)
7/16 - 20 . . . . . . . . . . . . . . 35 (4.8) . . . . . . . . . . . . . . . . 55 (7.6) . . . . . . . . . . . . . . 80 (11.0)
1/2 - 13 . . . . . . . . . . . . . . 50 (6.9) . . . . . . . . . . . . . . . . 75 (10.4) . . . . . . . . . . . . . 110 (15.2)
1/2 - 20 . . . . . . . . . . . . . . 55 (7.6) . . . . . . . . . . . . . . . . 90 (12.4) . . . . . . . . . . . . . 120 (16.6)
Metric
6 x 1.0 72-78 In. lbs.
8 x 1.25 14-18 ft. lbs.
10 x 1.25 26-30 ft. lbs.
*To convert ft. lbs. to kg-m multiply foot pounds by .138.
*To convert kg-m to N/m move the decimal to the right one position.
SPECIFIC TORQUE VALUES OF FASTENERS
Refer to exploded views in the appropriate section.
1.9
--- Page 4 ---
MAINTENANCE
PERIODIC MAINTENANCE CHART
Inspection, adjustment and lubrication intervals of important components are listed in the following chart.
Maintenance intervals are based upon average riding conditions and an assumed vehicle speed of approximately
10 MPH.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re-
placement parts. Always use genuine Polaris parts.
H CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by
an authorized Polaris dealer.
" Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation,
prolonged idle) should be inspected and serviced more frequently. For engine oil, short trip cold weath-
er riding also constitutes severe use. Pay special attention to oil level. A rise in oil level in cold weather can
indicate moisture collecting in the oil tank (425). Change oil immediately if oil level begins to rise.
E Emission Control System Service (California).
PERIODIC MAINTENANCE - ENGINE / COOLING SYSTEM
Frequency
(Whichever comes first)
Item Hours Calendar Miles Remarks
(Km)
E" Engine Oil - Level/Change 100 hrs 6 months 1000 (1600) Check Level Daily; Break In service at 1 month /
25 hrs / 250 miles
E Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change
E" Air Filter - Foam Pre-Cleaner Daily Daily Inspect-Clean & oil more often in dirty conditions.
E" Air Filter - Main Element Weekly Weekly Inspect - Replace if necessary
" Air Box Sediment Tube Daily Drain deposits whenever visible
EH Valve Clearance 100 hrs 12 months 1000 (1600) Inspect/Adjust
Clutch Adjustment 50 hrs 6 months 500 (800) Inspect/Adjust
Oil Cooler 50 hrs 6 months 500 (800) Inspect / Clean external surface
Oil Cooler Hoses 100 hrs 12 months 1000 (1600) Inspect
Engine Mounts 100 hrs 12 months 1000 (1600) Inspect
Drain Recoil Housing Weekly Weekly More often if operating in wet environment
Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600)
FUEL SYSTEM / CARBURETION
E Idle Speed As required As required Adjust
H Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/ 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/ air leaks
Flange
EH Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
EH Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually
ELECTRICAL
E Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary
Wiring 100 hrs 12 months 1000 (1600) Inspect for abrasion, routing, security
Ignition Timing 100 hrs 12 months 1000 (1600) Inspect
Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level
Headlight Aim As required As required Adjust if Necessary
Headlamp Inspection Daily Daily Check operation daily; Apply Polaris Dielectric
Grease to connector when lamp is replaced
Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Polaris Dielectric
Grease to socket when lamp is replaced
2.1
--- Page 5 ---
MAINTENANCE
THROTTLE OPERATION
Check for smooth throttle opening and closing in all han-
dlebar positions. Throttle lever operation should be
smooth and lever must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect
throttle cable routing and condition. If cable is routed
properly and in good condition, repeat adjustment
procedure.
5. Replace the throttle cable if worn, kinked, or damaged.
CHOKE (ENRICHER) ADJUSTMENT
If the choke knob does not stay out when pulled, adjust
the choke tension by tightening the rubber boot located
between the choke knob and nut. Firmly grasp the rubber
boot and tighten until the choke slides freely but stays out
when pulled.
Verify free play of 1/16--3/16” (1.6--4.76 mm) and smooth
operation of choke cable.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.
NOTE: Illustration of choke varies with models.
Boot
2.11
--- Page 6 ---
MAINTENANCE
BREATHER FILTER (XPEDITION 425)
1. The engine breather filter should be inspected when
the air filters are serviced. Replace if dirty or restricted.
2. Slide clamps back and remove filter.
3. Replace filter with directional arrow pointing to engine
(away from air box).
4. Reinstall clamps. NOTE: Replace clamps if they have
lost spring tension.
Breather Filter
AIR FILTER / PRE-FILTER SERVICE
It is recommended that the air filter and pre filter be replaced
annually. When riding in extremely dusty conditions re- Cover
placement will be required more often.
Gasket
The pre filter should be cleaned before each ride, using the
following procedure.
1. Lift up on the rear of the seat. Pre-filter
2. Pull the seat back and free of the tabs. NOTE: When
reinstalling seat, make sure the slots in the seat engage Main Element
the tabs in the fuel tank.
3. Remove clips (6) from air box cover and remove cover.
Inspect the gasket. It should adhere tightly to the cover
and seal all the way around.
4. Loosen clamp and remove air filter assembly.
Cleaning
5. Slip the pre-filter element off of main element. Clean
the pre filter with high flash point solvent, followed by
hot soapy water.
6. Rinse and dry thoroughly.
7. Inspect element for tears or damage.
8. Apply foam filter oil or clean engine oil and squeeze
until excess oil is removed.
9. Inspect main element and replace if necessary. If the
filter has been soaked with fuel or oil it must be Note: Grease Collar
replaced.
Installation
10. Reinstall pre-filter element over main filter. Be sure the Proper Filter Placement
element covers entire surface of main filter without
folds, creases, or gaps. Main Filter
NOTE: The air filter should rest on the filter support.
Proper placement of the air filter is important to prevent Filter Support
rattles and air leaks. See Illustration.
11. Install air box cover and secure with clips.
NOTE: Apply a small amount of general purpose grease Air Box
to the sealing edges of the filter before reinstalling. Front
2.21
--- Page 7 ---
MAINTENANCE
TOE ALIGNMENT -- METHOD 1: STRAIGHTEDGE OR STRING
Be sure to keep handlebars centered. See note below.
NOTE: String
should just touch
side surface of rear
tire on each side of
machine.
Measure from string
to rim at front and
rear of rim.
Rear rim measure-
ment (A) should be A
1/16〉 to 1/8〉 (.2 to
.3 cm) more than
front rim measure-
ment (B).
B
NOTE: The steering post arm (frog) can be used as an indicator of whether the handle-
bars are straight. The frog should always point straight back from the steering post
when handlebars are straight.
2.31
--- Page 8 ---
CHAPTER 3
ENGINE / GENERAL
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . 3.1-3.2
Torque Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2-3.3
Piston Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Engine Service Data . . . . . . . . . . . . . . . . . . . . . . . . . 3.4-3.6
Cooling System Specs (325) . . . . . . . . . . . . . . . . . . 3.7
Cooling System (425) . . . . . . . . . . . . . . . . . . . . . . . . 3.8-3.9
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10-3.12
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
Cylinder Honing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Engine Lubrication and Pressure Test . . . . . . . . . . 3.15
Engine Oil Flow Chart (325) . . . . . . . . . . . . . . . . . . 3.16-3.17
Engine Oil Flow Chart (425) . . . . . . . . . . . . . . . . . .
Spark Plug Fouling Checklist . . . . . . . . . . . . . . . . .
3.18-3.19
3.20
3
Transmission Troubleshooting . . . . . . . . . . . . . . . . 3.21-3.22
Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 3.23-3.24
Cooling System Troubleshooting (425) . . . . . . . . . 3.25
--- Page 9 ---
ENGINE/GENERAL
RECOMMENDED COOLANT -- XPEDITION 425
Use only high quality antifreeze/coolant mixed with dis-
tilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area. CAUTION:
Using tap water in the cooling system will lead to a
buildup of deposits which may restrict coolant flow and
reduce heat dissipation, resulting in possible engine
damage. Polaris Premium 60/40 Antifreeze/Coolant is
recommended for use in all cooling systems, and
comes pre-mixed and ready to use.
COOLING SYSTEM SPECIFICATIONS -- XPEDITION 425
Fan Switch (Off) 165⎪ F (74⎪ C) 8⎪
Fan Switch (On) 185⎪ F (85⎪ C) 7⎪
Hot Light On 221⎪ F (105⎪ C)
System Capacity 2.25 Quarts
Radiator Cap Relief Pressure 13 PSI
Thermostat Starts opening 176⎪ F (80⎪ C)
Open 8mm @ 205⎪ F (96⎪ C)
COOLING SYSTEM BLEEDING -- XPEDITION 425
Refer to Maintenance section Page 2.19
3.9
--- Page 10 ---
ENGINE/GENERAL
EH42PLE04 OIL FLOW DIAGRAM
B
D A
C
Crankcase
Sump
Screen
(Bottom of Sump)
Chain Room Sprocket Small End
Pressure Relief Crankcase Chain Bearing
Valve Oil Passage
Transmission
Countershaft Cylinder Sleeve
& Gears
Oil Pump Cam Shaft Rocker Arm
(Feed) Journal Rocker Shaft Main Bearing
(PTO)
Oil Feed Pipe Oil Feed Pipe Cam Lobe Large End
(A) (B) Bearing
Through Cylinder Cam Shaft Indirect
Stud Front Left Lubrication Oil Jet
Journal
Stator Plate & Crank Pin
Bypass Oil Filter Crankshaft
Oil Feed Pipe RH Crankcase
(C) Oil Passage
Oil Feed Pipe Transmission Gears &
Main Shaft Clutch
(D)
3.19
--- Page 11 ---
ENGINE/UPPER
U
ES32PF
Upper-
Engine
Service
4.1
--- Page 12 ---
ENGINE/UPPER
U
AUTOMATIC COMPRESSION RELEASE REMOVAL/INSPECTION
NOTE: The automatic compression release mecha-
nism can be inspected and serviced without removing
the camshaft from the cylinder head.
1. Check release lever shaft for smooth operation
throughout the entire range of rotation.
2. Remove release lever shaft and return spring Lobe
(spacer).
3. Inspect shaft for wear or galling.
4. Inspect lobe on end of release lever shaft for wear
and replace if necessary.
AUTOMATIC COMPRESSION RELEASE INSTALLATION
1. Slide spring onto shaft.
2. Apply engine oil to release lever shaft.
4.11
--- Page 13 ---
ENGINE/UPPER
U
VALVE SEAT RECONDITIONING, CONT.
7. Remove valve and check where the Prussian Bluet
or black marker indicates seat contact on the valve
face. The valve seat should contact the middle of the
valve face or slightly above, and must be the proper
width (A). (B)
S If the indicated seat contact is at the top edge of
the valve face and contacts the margin area (B)
it is too high on the valve face. Use the 30⎪ cutter
to lower the valve seat. (A)
S If too low use the 60⎪ or 75⎪ cutter to raise the
seat. When contact area is centered on the valve
face, measure seat width.
S If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
S If the seat is too narrow, widen using the 45⎪ cutter Proper Seat Contact On Valve Face
and re-check contact point on the valve face and
seat width after each cut.
NOTE:When using an interference angle, the
seat contact point on the valve will be very narrow,
and is a normal condition. Look for an even and
continuous contact point on the black marker, all
the way around the valve face. Seat
Width
Valve Seat Width:
Intake Std: .039I (1.0 mm)
Limit: .055I (1.4 mm)
Exhaust Std: .059I (1.4 mm)
Limit: .071I (1.8 mm)
Bottom - 60⎪ or 75⎪ Seat - 45⎪ or 46⎪
Top - 30⎪
8. Clean all filings from the area with hot soapy water,
rinse, and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the face
of the valve. Lapping is not required with an
interference angle.
4.21
--- Page 14 ---
ENGINE/UPPER
U
CYLINDER INSTALLATION
1. Position the piston support block PN 2870390 (A)
beneath the piston skirt to support the piston during
cylinder installation. A
2. Apply clean engine oil to the ring compressor (Snap
Ont PN RCL30 or equivalent) and install the
compressor following manufacturer’s instructions.
Verify all ring end gaps are correctly located.
3. Apply clean engine oil liberally to the cylinder bore and
tapered area of the sleeve. Install the cylinder with a
slight rocking motion until the rings are captive in the
sleeve.
4. Remove the ring compressor and support block.
5. Push the cylinder downward until fully seated on the
base gasket.
NOTE: If cam chain is installed, hold it up while rotating
the engine to avoid damage to the chain, drive sprocket
teeth, or tensioner blade.
6. Install the two 6 mm bolts, but do not tighten.
4.31
--- Page 15 ---
ENGINE/UPPER
U
EH42PLE04 CYLINDER HEAD EXPLODED VIEW
7-8 ft. lbs.
(9-11 Nm)
12-14 ft. lbs.
(16-20 Nm)
7-8 ft. lbs.
(9-11 Nm)
6-7 ft. lbs.
(8-10 Nm)
7-8 ft. lbs.
(9-11 Nm)
Refer to Page
4.73 for torque
procedure 8-10 ft. lbs.
(11-13 Nm)
4.41
--- Page 16 ---
ENGINE/UPPER
U
CAMSHAFT INSPECTION
1. Visually inspect each cam lobe for wear, chafing or
damage.
2. Thoroughly clean the cam shaft, making sure the oil
feed holes are not obstructed.
3. Measure height of each cam lobe using a micrometer.
Compare to specifications.
Cam Lobe Height (Intake & Exhaust): Lubrication holes
Std: 1.2884-1.2924I (32.726-32.826 mm)
Limit: 1.2766I (32.426 mm) Lobe height
4. Measure camshaft journal outside diameter (O.D.)
Journal O.D.
Camshaft Journal O.D.:
Mag & PTO End: 1.4935-1.4941I
(37.935-37.950 mm)
5. Measure ID of camshaft journal bore.
Journal
Camshaft Journal I.D.:
Mag & PTO End: 1.4963-1.4970I
(38.005-38.025 mm)
6. Calculate oil clearance by subtracting journal OD from
journal bore ID. Compare to specifications.
Camshaft Oil Clearance:
Std: .0022-.0035I (.055-.090 mm)
Limit: .0039I (.10 mm)
Replace camshaft if damaged or if any part is worn past the
service limit.
Replace cylinder head if camshaft journal bore is damaged
or worn excessively.
4.51
--- Page 17 ---
ENGINE/UPPER
U
VALVE SEAT RECONDITIONING, CONT.
10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the
valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated, and
repeat process for the other valve(s).
12. Clean cylinder head, valves, and camshaft oil supply
passage (A) thoroughly. A
13. If oil passage blind plug was removed, apply 3 Bond
1215 or equivalent sealer to the threads and install,
torquing to 8 ft. lbs. (1.1 kg-m). CAUTION: Do not
allow sealant to enter oil passage.
14. Spray electrical contact cleaner into oil passage and
dry using compressed air.
CYLINDER HEAD ASSEMBLY
CAUTION: Wear eye protection during assembly.
NOTE: Assemble the valves one at a time to maintain
proper order.
1. Install new valve seals on valve guides.
2. Apply engine oil to valve guides and seats.
3. Coat valve stem with molybdenum disulfide grease.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.
4.61
--- Page 18 ---
ENGINE/UPPER
U
PISTON INSTALLATION
1. Clean the gasket surfaces on the cylinder and
crankcase. Remove all traces of old gasket material.
2. Make sure the cylinder mounting bolt holes are clean
and free of debris.
3. Install a new circlip on one side of the piston with the
end gap facing up or down, and tang outward.
Tang Outward
CAUTION: Circlips become deformed during the removal
process. Do not re-use old circlips. Do not compress the
new clip more than necessary upon installation to prevent
loss of radial tension. Severe engine damage may result
if circlips are re-used or deformed during installation.
4. Apply clean engine oil to the piston rings, ring lands,
piston pin bore, piston pin, and piston skirt. Lubricate
the connecting rod (both ends), balancer drive gear,
and crankshaft main bearing area.
5. Install the piston on the connecting rod with the arrow
or : mark facing the magneto (RH) end of the
crankshaft. The piston pin should be a push fit in the
piston.
6. Install the other circlip with the gap facing up or down
and tang outward. (See Caution with Step 3 above).
Push the piston pin in both directions to make sure the
clips are properly seated in the groove.
Mag
or :
4.71
--- Page 19 ---
ENGINE/LOWER
L
ES32PFE03 CRANKCASE / CRANKSHAFT EXPLODED VIEW
14-15 ft. lbs.
Crankcase (19-21 Nm)
Sealant Loctitet 242
14-15 ft. lbs. (PN 2871557)
(19-21 Nm)
See Page 5.48
for procedure 36-43 ft. lbs.
(49-59 Nm)
6.5-11 ft. lbs.
(9-15 Nm)
14-17 ft. lbs. 14-15 ft. lbs.
(19-23 Nm) (19-21 Nm)
See Page 5.48
for procedure
29-33 ft. lbs.
(39-45 Nm)
5.1
--- Page 20 ---
ENGINE/LOWER
L
CENTRIFUGAL CLUTCH REMOVAL, CONT.
3. Remove centrifugal clutch weight assembly and clutch
drum.
4. Remove the primary drive gear and shim from the
crankshaft.
CENTRIFUGAL CLUTCH INSPECTION
1. Hold the clutch drum and rotate the clutch weight
assembly. You should only be able to turn it
counterclockwise.
2. Check the rollers for excessive wear.
3. Remove the clutch weight assembly and one-way
clutch from the clutch drum.
5.11
--- Page 22 ---
ENGINE/LOWER
L
RELEASE LEVER INSPECTION, CONT.
2. Inspect spring, replace e-clip.
3. Inspect lifter bearing assembly for worn or damaged
parts.
4. Inspect lifter ramps and replace if worn.
5.21
--- Page 23 ---
ENGINE/LOWER
L
CRANKCASE SEPARATION
1. Remove (13) bolts (Xpedition 325), or (12) bolts
(Xpedition 425) from the reduction cover side (RH).
325
Only
Reduction Cover Side
2. Remove (2) bolts from the clutch cover side (LH).
Clutch Cover Side
3. Remove right hand crankcase from left hand.
5.31
--- Page 24 ---
ENGINE/LOWER
L
TRANSMISSION REMOVAL / DISASSEMBLY, CONT.
4. Remove (main shaft) shift fork.
Main Shaft
Shift Fork
5. Remove shafts as an assembly.
TRANSMISSION INSPECTION
1. Disassemble all gears and keep in order for
reassembly. Common inspection points of
transmission gears:
A. Measure inside diameter of gears. A
B. Inspect dog slots for wear (rounding of slot). D
C. Inspect dogs for wear (rounding of dog).
D. Inspect gear teeth for worn, chipped, cracked, or
broken teeth.
2. Inspect all gears and shafts as outlined on the following
page. Compare to specifications.
B C
5.41
--- Page 25 ---
ENGINE/LOWER
L
CRANKSHAFT END PLAY ADJUSTMENT, CONT.
4. Measure the distance from the Magneto
crankcase mating surface to the main bearing
using the same method and record.
5. Subtract the thickness of the straightedge from
the measurement obtained in Step 4 and record.
Mag Case Depth
6. Add the readings recorded in Step 3 and Step 5
and record below.
Total Case Width
7. Measure the width of the crankshaft at the bearing
seats with a micrometer or dial caliper and record.
Crankshaft Width
8. Subtract the Crankshaft Width measured in Step
7 from the Total Case Width recorded in Step 6,
and record below.
Xpedition 325 Shown
Total End Play
9. Subtract the thickness of the existing shim from
the result of Step 8 to determine if a different shim Crankshaft End Play:
is required. The result must be within the specified
range listed. .0020〉-.0079〉 (.05-.20 mm)
5.51
--- Page 26 ---
ENGINE/LOWER
L
CHANGE CLUTCH INSTALLATION
1. Apply molybdenum disulfide grease to the inner
and outer surfaces of the clutch outer guide.
Install the clutch outer guide on the main shaft.
2. Install the clutch outer and thrust washer.
Thrust Washer
Clutch Outer
3. Assemble the clutch pressure plate, discs, plates
and clutch center, and install them in the clutch Clutch Center
outer.
NOTE:SStack the discs and plates alternately. Clutch Plate (5)
SCoat new clutch discs with engine oil.
SBe sure the clutch center and pressure plate
grooves are properly aligned.
Clutch Disc (6)
Clutch Pressure Plate
5.61
--- Page 27 ---
CHAPTER 6
FUEL SYSTEM/CARBURETION
Jetting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Main Jet Selection . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2