Ever get that feeling of satisfaction from keeping a classic machine alive and kicking? There’s something special about a rig that’s seen a few seasons but still refuses to quit. The 2000 Polaris Xpedition 325 is exactly that kind of ATV—a tough, no-nonsense workhorse from an era of simpler, more robust engineering.
You probably know that these older ATVs, while reliable, have their own set of quirks and needs. Finding clear, practical advice can be a challenge, leaving you scrolling through forgotten forums for answers.
We promise this guide will be your one-stop shop for keeping your Xpedition 325 running like it just rolled off the line. We’ve been wrenching on these machines for years, and we’re here to share everything we’ve learned.
In this ultimate 2000 Polaris Xpedition 325 guide, we’ll cover everything from its core specs and a bulletproof maintenance schedule to troubleshooting the most common problems you’ll face. We’ll even dive into some smart upgrades and eco-friendly best practices to make your ownership experience even better.
What Makes the 2000 Polaris Xpedition 325 a Trail Legend?
Before we grab the wrenches, let’s appreciate what we’re working with. The Xpedition 325 wasn’t built to be the fastest or flashiest quad on the trail. It was built to be a dependable partner for work and play, and that’s one of the key benefits of 2000 polaris xpedition 325 ownership.
Its design philosophy was centered around reliability and utility, making it a favorite for hunters, farmers, and trail riders who valued function over frills.
Core Specifications and Features
- Engine: A solid 325cc, 4-stroke, single-cylinder engine. It’s air-cooled with an oil cooler, which means fewer complex cooling system parts to fail.
- Drivetrain: The legendary Polaris On-Demand All-Wheel Drive (AWD). This system automatically engages the front wheels when the rear wheels slip, providing seamless traction.
- Transmission: An automatic Polaris Variable Transmission (PVT) with High, Low, Neutral, and Reverse gears. Simple and effective for trail riding and utility work.
- Suspension: Up front, you’ll find a MacPherson strut with 6.7 inches of travel. The rear features a progressive-rate swingarm with 7.9 inches of travel, providing a surprisingly comfortable ride for its time.
- Simplicity: One of its biggest strengths is its lack of complex electronics. A simple carburetor and straightforward wiring make it a fantastic machine for the DIY mechanic to learn on and maintain.
The Essential 2000 Polaris Xpedition 325 Care Guide
Consistent maintenance is the secret to longevity for any machine, especially one that’s over two decades old. Following this 2000 polaris xpedition 325 care guide will prevent most major headaches and keep you out on the trail instead of stuck in the garage.
Pre-Ride Inspection Checklist (The T-CLOCS Method)
Before every ride, take five minutes to run through this checklist. It’s the single best habit you can develop for safety and reliability.
- T – Tires & Wheels: Check for proper air pressure, look for cuts or punctures, and make sure lug nuts are snug.
- C – Controls & Cables: Test your throttle for smooth operation. Check brake levers for proper feel and ensure all cables move freely without binding.
- L – Lights & Electrics: Test your headlights (high and low beam), taillight, and brake light. Check the 4WD switch.
- O – Oil & Fluids: Check the engine oil level. Give a quick visual inspection under the machine for any new drips or leaks (coolant, gearcase fluid, etc.).
- C – Chassis & Suspension: Look over the frame for any cracks. Check suspension components for damage and ensure your chain is properly tensioned and lubricated.
- S – Stand: Check your kickstand (if applicable) for proper operation.
Engine Oil and Filter Change
This is the lifeblood of your engine. Don’t skip it. Aim to change the oil and filter every 25 hours of use or at least twice a year.
- Warm up the engine for a few minutes to get the oil flowing.
- Place a drain pan under the engine and remove the drain plug from the bottom of the oil tank.
- Once drained, remove the oil filter. A small filter wrench might be needed.
- Wipe the filter sealing surface clean and apply a thin coat of new oil to the gasket of the new filter.
- Install the new filter and tighten it hand-tight plus another quarter-turn. Do not overtighten.
- Reinstall the drain plug and fill with the recommended oil (Polaris PS-4 0W-40 or a suitable equivalent). Check the manual for the exact capacity, but add slowly and check the dipstick.
Air Filter Maintenance
A dirty air filter is a quick way to kill performance. Since these machines see a lot of dust, check your air filter frequently.
The stock filter is a foam element. Carefully remove it, wash it in a solvent like kerosene or a dedicated filter cleaner, and then rinse thoroughly with soap and water. Let it dry completely before re-oiling it with foam filter oil. Squeeze out the excess until it’s tacky but not dripping.
Tackling Common Problems with the 2000 Polaris Xpedition 325
Even with great care, you’ll eventually run into issues. The good news is that most common problems with 2000 polaris xpedition 325 models are well-documented and relatively easy to fix for a DIYer.
Starting and Carburetor Issues
The most frequent complaint is “it won’t start” or “it runs rough.” 90% of the time, the issue lies with the fuel system or spark.
- The Carburetor: The Mikuni BST34 carburetor is notorious for getting clogged pilot jets, especially with modern ethanol-blended fuel. If the ATV has been sitting, you’ll likely need to remove the carb, disassemble it, and give the jets a thorough cleaning with carb cleaner and compressed air.
- Spark Plug: A fouled or old spark plug is another common culprit. They’re cheap—replace it first. Check the plug wire and cap for good connection.
- Fuel Issues: Old gas loses its potency and can clog things up. Always use fresh fuel and consider a fuel stabilizer if you don’t ride often. Ensure the fuel petcock is in the “ON” or “RES” position and that fuel is flowing freely.
4WD System Not Engaging
If you hit the 4WD switch and nothing happens, don’t panic. The On-Demand system is electric over magnetic.
First, check the simple stuff. Is the fuse for the AWD system good? Is the switch on the handlebar working (you can test it with a multimeter)?
The most common failure points are the electromagnetic coils inside the front hubs or the wiring leading to them. You can do a quick test: with the key on and the ATV in gear with the 4WD switch engaged, hold a wrench near the hub’s fill plug. You should feel a magnetic pull. If not, you likely have a wiring or coil issue to track down.
Weak Brakes and Spongy Levers
The hydraulic brakes on the Xpedition require maintenance. If your brake lever feels spongy or travels all the way to the handlebar, you have air in the lines. You’ll need to bleed the brake system. This involves opening a small “bleeder valve” at the caliper while squeezing the brake lever to force the air out. You’ll need a friend to help or a vacuum brake bleeder kit. Also, regularly check your brake pad thickness and the brake fluid level in the master cylinder reservoir.
How to Boost Performance: Smart Upgrades for Your Xpedition 325
Looking for some practical 2000 polaris xpedition 325 tips for better performance? While it’s not a race machine, a few smart mods can significantly improve its capability and your enjoyment. This is how to 2000 polaris xpedition 325 ownership goes from maintenance to enhancement.
Clutching for Better Power Delivery
The single best performance upgrade you can make is a clutch kit. The stock clutching is a compromise. A quality aftermarket clutch kit (from brands like EPI or Dalton) comes with different springs and weights to recalibrate your PVT system. This can give you much better low-end torque for towing or snappier acceleration on the trail, especially if you’ve added larger tires.
Tires and Wheels
Upgrading your tires will transform how your ATV handles. Choose a tire based on your primary riding terrain. Aggressive mud tires for swampy areas, or all-terrain tires with tougher sidewalls for rocky trails. Be mindful that going to a much larger or heavier tire will put more strain on your drivetrain and may make a clutch kit a necessity.
Lighting and Utility Upgrades
The stock headlights are weak by modern standards. Swapping the bulbs for bright LED replacements or adding a small LED light bar is an easy and affordable safety upgrade for riding after dusk. Another essential mod for any off-roader is a winch. A 2500 lb. winch is plenty for the Xpedition 325 and can be a lifesaver if you get stuck.
Sustainable 2000 Polaris Xpedition 325 Ownership: Best Practices
Being a responsible rider means taking care of the trails and the environment. Practicing sustainable 2000 polaris xpedition 325 ownership ensures our riding areas stay open for generations to come. These eco-friendly 2000 polaris xpedition 325 tips are easy to follow.
Responsible Fluid Management
When changing oil or other fluids, always use a drain pan to prevent spills. Never dump used oil or coolant on the ground or in a storm drain. Take them to your local auto parts store or municipal recycling center; most accept them for free. On the trail, carry a small spill kit or some absorbent rags in case of an unexpected leak.
Tread Lightly Principles
This is one of the most important 2000 polaris xpedition 325 best practices. The “Tread Lightly!” philosophy is simple: leave the trail better than you found it. Stay on designated routes to prevent erosion, avoid sensitive areas, and cross streams only at designated crossings. Pack out everything you pack in, including any trash you find along the way.
Frequently Asked Questions About the 2000 Polaris Xpedition 325
What kind of oil does a 2000 Polaris Xpedition 325 take?
The factory recommendation is Polaris PS-4 Full Synthetic 0W-40 or 5W-50 engine oil. It’s specifically designed for the wet-clutch system in these ATVs. Using standard automotive oil can cause transmission issues.
How do I check the 4WD on my Xpedition 325?
Safely lift the front end of the ATV so the wheels are off the ground. Start the engine, put it in gear, and engage the 4WD switch. Slowly give it some throttle. The rear wheels will spin, and the front wheels should engage and spin as well. You can also perform the magnetic test described earlier in the article.
What is the top speed of a 2000 Polaris Xpedition 325?
In stock condition, you can expect a top speed of around 40-45 mph on a flat, level surface. It was designed more for torque and utility than for high-speed runs.
Are parts still available for this model?
Yes! While some specific cosmetic parts might be hard to find, most mechanical and maintenance parts are readily available. You can find engine components, brake parts, bearings, and filters from Polaris dealers and a wide range of aftermarket suppliers.
What’s a common reason it won’t start when it’s hot?
If your Xpedition starts fine when cold but struggles to restart after it’s been running for a while, this can be a sign of a failing ignition coil or stator. As these components heat up, their internal resistance can change, causing a weak or no-spark condition. Another possibility is improper valve lash, which can affect compression when the engine is hot.
Owning a 2000 Polaris Xpedition 325 is a rewarding experience. It’s a connection to a simpler era of off-roading and a testament to engineering that was built to last. With the right care, a bit of wrenching, and a healthy dose of respect for the machine and the trails, your classic quad will be serving you faithfully for many more years.
Get those knuckles greasy, stay safe out there, and keep that vintage Polaris roaring down the trail!
- Getting Polaris 570 Error Codes – Your Ultimate DIY Diagnostic Guide - November 20, 2025
- All Polaris Error Codes – The Ultimate Guide To Diagnostics & Fixes - November 20, 2025
- Polaris Red Paint Code – Your Ultimate Guide To Flawless Touch-Ups - November 20, 2025