OWNER’S MANUAL SUPPLEMENT
2000 XPEDITION 425
PN 9914929
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 neutra l. 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.
6. To downshift, reverse sequence 4. Remember
to release the throttle each time you shift to the
next lower gear.
Gear Shift Pedal
5
4
3
2
1
N
To shift to a higher gear,
raise the pedal one full
stroke.
N
1
2
34
5
To downshift, depress the
pedal one full stroke.
1
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.
HAPPEN
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.
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 425
Body Style IV
Gross Vehicle Weight 1135 lbs.
Fuel Capacity 4 gallons
Engine Oil 5.5 quarts
Front Rack
C
(Maximum - Capacity)
A
Rear Rack 180 Lbs.
P
A
Tongue Weight 30 lbs.
Tow H i t ch Standard
I
T
Tow Capacity 850 lbs.
Turn Radius 65²
E
S
Ground Clearance 7.25²
Height 47²
Length 81²
Seat Height 34²
Weight 647 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 25 x 8 - 12
I
Rear Tire 25 x 11 - 10
R
E
Tire Pressure (front) 4psi
S
Tire Pressure (rear) 3psi
3
Xpedition 425
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 EH42PLE03
Engine Type 4 Stroke, Single Cycle
Lubrication Wet Sump
Bore x Stroke 87.9 x 70
E
Displacement 425
Compression Ratio 9.2:1
G
I
Engine Cooling Liquid cooled with fan assist
Alternator Output (watts) 200 Watts
E
Carburetion 34mm Mikuni (CV Type)
Main Jet 150
C
Pilot Jet 42.5
Needle Jet P-8
O
L
Cutaway Not Applicable
I
Pilot Screw 25/8
N
G
Jet Needle 4HB41-3
Ignition CDI
Timing 30° BTDC @ 3500 rpm
Spark Plug Gap 0.7 mm / .028 in
Spark Plug Type NGK BKR5ES
Exhaust USFS Approved
LIHeadlight (grille) 30 / 30
6.5²
G
Taillight (watts) 8.26
H
T
Brake Light (watts) 26.9
S
4
Xpedition 425
F
T
E
3-Point Hitch Accessory
Battery Standard
DC Plug In - Rear Standard
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 Standard
Tool Kit Standard
1999 Xpedition 425
(Engine - EHPLE03
Carburetor Jetting
Altitude Ambient
Meters
(Feet)
Temperature
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700
(6000-9000)
2700-3700
(9000-12000)
Below 0°F
(Below --18°C)
0° to 40°F
(-- 18°Cto
+5°C)
162.5 157.5 150 145
157.5 152.5 147.5 140
155 147.5 142.5 137.5
150 142.5 137.5 132.5
- Pilot screw in 1/2 turn
Gear Ratio
1 4.182
2 2.562
3 1.522
4 1.036
5 0.758
Reverse 4.484
Primary 2.406
Secondary (at chain) 1.333
Secondary (at bevel drive) 1.313
+40° to +80°F
(+5°Cto
+26°C)
+80°F&Above
(+26°C&
Above)
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 MAINLY FOR 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
PN 9914929 Rev 03 12/98
Printed in U.S.A.
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