OWNER’S MANUAL SUPPLEMENT
2000 XPEDITION 325
PN 9915474
IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s
manual at all times.
Starting the Engine
The engine can only be started with the transmission in neutral.
Turn the key to “on” and ensure the stop switch is in the run position.
The neutral indicator light should be on. If it is not, shift the foot pedal down ( or up and down, if in Reverse) to find
neutral. Refer to the gear shift pedal illustrated on this page.
Once the vehicle is in neutral, start the engine by engaging the start button.
Gear Shift Control
Gear Shift Pedal
The gear shift pedal is above the left floorboard. One full
stroke of the pedal shifts the transmission to the next higher
or lower gear in the shifting sequence. The pedal
automatically returns to the horizontal position when released.
The Xpedition has five forward gears (1, 2, 3, 4, and 5). To
upshift to a higher gear, put the toe of your boot under the gear
shift pedal and raise the pedal one full stroke. To downshift,
step on the gear shift pedal and depress the pedal one full
stroke.
Shifting Gears
Start the engine and let it warm up, follow this procedure:
1. With the transmission in neutral, hold the brake lever.
2. With the throttle closed, raise the gear shift pedal one full
stroke to shift into first gear.
3. Release the brake lever and increase engine speed by
gradually opening the throttle.
4. When speed increases, release the throttle and shift to 2nd
gear by raising the gear shift pedal one full stroke.
5. Repeat sequence 4. to progressively upshift to 3rd, 4th
and 5th (top) gear.
Gear Shift Pedal
5
4
3
2
1
N
To shift to a higher gear,
raise the pedal one full
stroke.
6. T o downshift, reverse sequence 4. Remember to release
the throttle each time you shift to the next lower gear.
1
To downshift, depress the
pedal one full stroke.
N
1
2
34
5
WARNING
POTENTIAL HAZARD
Shifting gears without releasing the throttle.
WHAT CAN
Could cause loss of control or cause the ATV to overturn.
HOW TO AVOID THE HAZARD
Always release the throttle when shifting gears.
Shifting to Reverse
With the ATV running and in neutral, hold the brake lever and push the Reverse/Override button on the LH control.
Depress the gear shift pedal one stroke. The reverse indicator light will come on. Slowly release the brake lever and
press throttle control lightly. See Owner ’s manual page for reverse operation.
Shifting From Reverse to Fo rward
Be sure machine is completely stopped. Hold the brake lever, raise gear shift pedal one full stroke to engage forward
gear. NOTE: neutral is bypassed when shifting from reverse to 1st gear. To engage neutral, depress gear shift pedal
one full stroke from the 1st gear position.
To Decelerate
When slowing down or stopping, release the throttle and apply the brakes smoothly and evenly. As you slow down,
shift to a lower gear. Be certain the engine has sufficiently slowed before engaging a lower gear. Improper use of
the brakes or shifting can cause the tires to lose traction, reducing control and increasing the possibility of an accident.
HAPPEN
WARNING
POTENTIAL HAZARD
Engaging a lower gear when the engine speed is too high.
WHAT CAN
The wheels could stop rotating. This could cause loss of control, an accident and injury. It could also cause
engine or drive train damage.
HOW TO AVOID THE
Make certain the engine has sufficiently slowed before shifting to a lower gear.
HAPPEN
HAZARD
2
Specifications
P
C
I
I
V
Y
R
Xpedition 325
Body Style Gen IV
Gross Vehicle Weight 1105 lbs.
Fuel Capacity 3.75 gallons
Engine Oil 4.5 quarts
Front Rack
C
(Maximum - Capacity)
A
Rear Rack 180 Lbs.
P
A
Tongue Weight 30 lbs.
Tow H i tc h Standard
I
T
Tow Capacity 850 lbs.
Turn Radius 65²
E
S
Ground Clearance 6.75²
Height 46.5²
Length 81²
Seat Height 33.5²
Weight 635 lbs.
Wheel Base 49.75²
Width 46²
Drive System Type Shaft
D
R
Shift Type Manual 5 Speed / Reverse
I
Front Drive (ratio) 3.7/1
E
90 Lbs.
Final Drive (ratio) 3.1/1
S
Y
S
Center Drive (ratio) Not Applicable
T
E
Drive Chain Not Applicable
M
T
Front Tire 24 x 8 - 12
I
Rear Tire 24 x 11.5 - 10
R
E
Tire Pressure (front) 4psi
S
Tire Pressure (rear) 3psi
3
Xpedition 325
S
B
A
E
N
G
N
&
O
I
I
Front Susp. - Mac Strut 6.7²
S
Rear Susp. - Progressive
U
Rate Swing Arm
S
P
Shock Adjustment CAM
Front Brake Hydraulic
Rear Brake Hydraulic
R
Park Brake Hydraulic
K
Auxiliary Brake Hydraulic Foot Brake
S
Engine Model Number ES32PLE03
Engine Type 4 Stroke, Single Cyl.
Lubrication Wet Sump
Bore x Stroke 78 x 68
E
Displacement 325
Compression Ratio 9.2:1
G
I
Engine Cooling Air cooled with oil assist
Alternator Output (watts) 200 Watts
E
Carburetion BST31
Main Jet 152.5
C
Pilot Jet 47.5
Needle Jet P-0 (829)
O
L
Cutaway Not Applicable
I
Pilot Screw TBD
N
G
Jet Needle 4HB40-3
Ignition CDI
Timing 30° BTDC @ 5000 rpm±2°
Spark Plug Gap 0.9 mm / .036 in.
Spark Plug Type NGK BKR6E
Exhaust USFS Approved
LIHeadlight (grill) 30 / 30
6.5²
G
Taillight (watts) 8.26
H
T
Brake Light (watts) 26.9
S
4
Xpedition 325
F
T
E
(
)
3-Point Hitch Accessory
Battery Standard
DC Plug In - Rear Accessory
DC Socket - Forward Accessory
F
E
Electric Start Standard
A
High Beam Indicator Standard
T
U
High Temp Indicator Standard
R
Windshield Accessory
E
S
Low Oil Light Not Applicable
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Accessory
Tool Kit Standard
XPEDITION 325
(Engine - ES32PLE03)
Carburetor Jetting
Altitude
Meters
(Feet)
AMBIENT
TEMPERATURE
0-1800
(0-6000)
1800 & Above
(6000 & Above)
Gear Ratio
1 4.182 (46/11)
2 2.652 (41/16)
3 1.522 (35/23)
4 1.111 (30/27)
5 0.813 (26/32)
Reverse 4.128 (29/16 x 41/18)
Primary 2.655 (77/29)
Secondary (at chain) 1.333 (28/21)
Secondary (at bevel drive) 1.313 (21/16)
Below +40°F
(Below +5°C)
+40°F and Above
(+5°C and Above)
157.5 152.5
150 145
5
The following decal replaces the decal found on page 6 of your Owner’s Manual.
WARNING
READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE
OPERATION. SEVERE INJURY OR DEATH CAN RESULT FROM IGNORING
WARNINGS OR IMPROPER USE. IF YOU DO NOT HAVE THE OWNER’S
MANUAL FOR THIS VEHICLE. CALL 1-800-342-3764 TO HAVE ONE
PROVIDED AT NO EXTRA CHARGE.
S TO REDUCE TIPOVER RISK, BE ESPECIALLY CAREFUL WHEN
ENCOUNTERING OBSTACLES AND SLOPES, WHEN BRAKING ON HILLS
OR DURING TURNS.
S KEEP FEET ON FOOTRESTS AT ALL TIMES.
S HILL CLIMBING IS DANGEROUS, and should be attempted only by
experienced operators. Start on shallow slopes and practice procedures
described in Owner’s Manual before trying steeper terrain. Some hills are too
steep to safely stop or recover from an unsuccessful climbing attempt.
Effectiveness of brakes is significantly reduced on hills.
Never operate this ATV on grades steeper than 25 degrees . If vehicle slides
backwards down hill, apply hand brakes with gradual, even pressure to avoid
flipover. Never open throttle suddenly as flipover may result.
S REDUCE SPEED when operating this vehicle on rough or hilly terrain, or when
carrying cargo on the racks.
S REVERSE OPERATIONCAN BE DANGEROUS even at low speeds. Steering
control becomes difficult. When backing up, proceed slowly and apply hand
brakes carefully; aggressive braking may result in flipover. Avoid backing
downhill. Avoid turning at sharp angles in reverse.
S USE OVERRIDE FOR REVERSE SPEED LIMITER WITH CAUTION; It allows
full engine power and can result in excessive speeds. Never activate override
button while throttle is open, as loss of control may result.
S STOPPING DISTANCE MAY INCREASE with wet brakes or on wet surfaces.
S AUXILIARY FOOT BRAKE: The right foot auxiliary brake pedal operates the
rear brake only. When backing up or when operating on hills, avoid sudden use
of the auxiliary brake; aggressive braking may result in flipover.
S PARK BRAKE MAY RELAX WHEN USED FOR LONG PERIODS. When
parking on grades, leave the gear shift in forward and don’t leave brake
engaged for more than 5 minutes.
S VEHICLE DESIGNED MAINLYFOR WARM WEATHER USE. Throttle linkage
and brakes may stick if operated in freezing weather, causing loss of control.
Dirt, mud, water, or other contaminants can also affect operation of controls.
Check both frequently.
S ENGINE SHUT OFF SWITCH is available for use in event of throttle failure or
other emergency when engine shut off is desired.
S NEVER PERMIT A GUEST TO OPERATE THIS ATV unless the guest has
read the Owner’s Manual and all labels, and has completed a certified training
course.
25_
7078390
The following decal replaces the two clutch guard decals found on page 12 of
your Owner’s Manual.
WARNING
S MOVING PARTS HAZARD UNDER BELT-CLUTCH
GUARD. TO PREVENT SERIOUS INJURY, DO NOT
OPERATE VEHICLE WITH GUARD REMOVED.
S DO NOT MODIFY ENGINE OR CLUTCH. DOING SO
PN 9915474 Rev 01 7/99
Printed in U.S.A.
CAN CAUSE PART FAILURE, POSSIBLE
IMBALANCE, AND EXCESSIVE ENGINE RPM WHICH
CAN RESULT IN SERIOUS INJURY OR DEATH.
NO STEP
7078689
6
7
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