2000 Polaris Xpedition 325 4X4 - The Ultimate Owner'S Survival Guide

Ever look at your trusty, time-tested ATV and feel a sense of pride? If you own a 2000 Polaris Xpedition 325 4×4, you know exactly what I’m talking about. These machines are from an era when things were built to last, a perfect blend of utility and trail-tackling fun that modern ATVs sometimes miss.

But let’s be honest, a machine of this vintage needs a little extra love to stay reliable. You’re probably here because you want to keep that workhorse running strong, tackle a nagging issue, or just learn the ins and outs of your specific quad.

You’ve come to the right place. We promise this complete 2000 polaris xpedition 325 4×4 guide will give you the confidence to wrench on your own rig. We’ll cover everything from essential maintenance and troubleshooting common problems to smart upgrades and best practices that will keep you on the trail for years to come.

What Makes the 2000 Polaris Xpedition 325 4×4 a Trail Legend?

Before we grab the wrenches, it’s worth appreciating what you’ve got. The Xpedition 325 wasn’t the fastest or flashiest quad of its day, but it earned a reputation for being an absolute tank. It was designed as a do-it-all machine, and it excels at it.

At its heart is a reliable, air-cooled 325cc four-stroke engine. It’s not a powerhouse, but it delivers smooth, predictable torque that’s perfect for navigating technical terrain or hauling gear around the property. This simplicity is one of the key benefits of 2000 polaris xpedition 325 4×4 ownership—fewer complex systems mean fewer things to break.

Paired with the Polaris Variable Transmission (PVT) and its famous On-Demand All-Wheel Drive (AWD), you get a machine that’s incredibly easy to operate. There’s no complex shifting, and the 4×4 system engages automatically the second the rear wheels slip, giving you traction right when you need it. It’s a simple, effective system that just plain works.

Key Specifications at a Glance:

Engine: 325cc, 4-Stroke, Air/Oil-Cooled Single Cylinder
Transmission: Polaris Variable Transmission (PVT) Automatic F/N/R
Drive System: Shaft Drive with On-Demand AWD/2WD
Suspension (Front): MacPherson Strut with 6.25″ of travel
Suspension (Rear): Progressive Rate Swing Arm with 7.5″ of travel
Fuel Capacity: 4.25 Gallons (16.1 L)

Your Essential 2000 Polaris Xpedition 325 4×4 Care Guide

Consistent maintenance is the secret to keeping any older machine alive. Following this 2000 polaris xpedition 325 4×4 care guide will prevent most common headaches and save you a fortune in shop bills. Think of it as an investment in future trail time.

The Pre-Ride Check: Your 5-Minute Lifesaver

Never, ever just hop on and go. A quick walk-around can spot a problem before it leaves you stranded. We call it the T-CLOC check:

T – Tires & Wheels: Check for proper air pressure (usually 3-5 PSI, check your sidewall). Look for cuts or punctures. Grab each wheel and check for wobbly bearings.
C – Controls & Cables: Test your throttle for smooth operation (it should snap back when released). Check your brake levers for a firm feel. Make sure your shifter moves cleanly through its range.
L – Lights & Electrics: Turn the key on. Test your headlights (high and low beam), taillight, and brake light. A flickering light could be a loose connection.
O – Oil & Fluids: Pull the engine oil dipstick, wipe it, and re-insert to get an accurate reading. Check your brake fluid reservoir—the fluid should be clear, not dark and murky.
C – Chassis & Suspension: Look for any loose nuts or bolts. Push down on the front and rear racks to check the suspension. Look for leaking shocks or torn CV boots on the front axles.

Engine & Drivetrain TLC

The heart of your machine needs clean fluids to survive. This is non-negotiable.

For engine oil, use a quality Polaris PS-4 0W-40 or 5W-50 synthetic oil. Change it and the oil filter (a common one is the Purolator PL14610 or equivalent) at least once a season, or more if you ride in very dusty or wet conditions.

Your air filter is your engine’s only defense against dirt. Pop the seat, open the airbox, and inspect it. If it’s a foam filter, wash it with filter cleaner, let it dry completely, and re-oil it with foam filter oil. If it’s paper, tap it out or replace it if it’s filthy.

Brakes and Suspension: Staying in Control

Good brakes are a must. Check your brake pad thickness. If you have less than 1/8th of an inch of pad material left, it’s time for new ones. If your brake lever feels spongy, you likely need to bleed the brake lines to remove air bubbles.

Look for small grease fittings, called zerks, on your suspension A-arms and other pivot points. Use a grease gun with all-purpose marine grease to pump in fresh grease until you see the old, dirty grease push out. This simple step keeps your suspension moving freely.

Common Problems with 2000 Polaris Xpedition 325 4×4 (And How to Fix Them)

Even with great care, things can go wrong. Luckily, this ATV is fairly simple to diagnose. Here are some of the most common problems with 2000 polaris xpedition 325 4×4 and a clear path to fixing them.

Problem: “My ATV Won’t Start or Cranks Slowly”

This is the most frequent issue. Don’t panic; work through the basics.

The Battery: The number one culprit. Use a multimeter to check the voltage. A healthy battery should read 12.6V or higher. If it’s below 12.2V, it needs a charge. If it won’t hold a charge, it’s time for a new one. Also, check that the terminals are clean and tight.
Spark: Pull the spark plug cap off, remove the plug with a spark plug socket, and plug it back into the cap. Hold the threaded part of the plug against the engine block and crank the engine. You should see a strong, blue spark. No spark? It could be a bad plug, cap, or ignition coil.
Fuel: Gas goes bad, especially ethanol-blended fuel. If the ATV has been sitting for months, drain the old fuel. The carburetor is another likely suspect. The tiny passages (jets) inside can get clogged, starving the engine of fuel. A thorough carb cleaning often solves starting and running issues.

Problem: “The 4×4 Isn’t Engaging”

You flip the switch, but only the rear wheels are spinning. Here’s how to 2000 polaris xpedition 325 4×4 4×4 issues are diagnosed:

The Polaris On-Demand system is electric over magnetic. Power goes from the switch on your handlebar to electromagnetic coils in each front hub. When energized, they engage the hubs.

Check the Fuse: Start with the easy stuff. Locate your fuse box and check for a blown AWD fuse.
Test the Switch: The handlebar switch can fail from water and dirt. You can test it with a multimeter for continuity.
Inspect Wiring: Trace the wires from the handlebar down to each front hub. Look for any breaks, pinches, or corroded connectors. This is a very common failure point.

Problem: “It’s Bogging Down or Losing Power”

If your Xpedition starts and idles fine but bogs down when you give it throttle, it’s almost always a fuel or air delivery problem.

First, check the air filter. A completely clogged filter will choke the engine. If that’s clean, you are likely looking at a carburetor issue. The main jet, which delivers fuel at higher RPMs, is probably clogged. A can of carb cleaner and some small tools are your best friends here. Disassemble the carb carefully, spray out every passage, and reassemble.

Smart Upgrades & Best Practices for Your Xpedition

Stock is great, but a few key mods can transform your machine’s capability and your confidence on the trail. This is where we get into some real 2000 polaris xpedition 325 4×4 tips.

Must-Have Mods for Trail Reliability

Better Tires: The single best upgrade you can make. A set of 6-ply all-terrain tires like the Maxxis Bighorn 2.0 or Kenda Bear Claw will offer vastly superior traction and puncture resistance.
Winch: Don’t go into the woods without one. A 2500 lb winch from a brand like Warn or Badland is a get-out-of-jail-free card for you or your buddies.
LED Lighting: The stock headlights are weak. A simple LED light bar or upgraded LED headlight bulbs will turn night into day, dramatically improving safety for evening rides.

Sustainable 2000 Polaris Xpedition 325 4×4 Ownership

Being a responsible rider is crucial. You can enjoy your machine while minimizing your impact. This is what being an eco-friendly 2000 polaris xpedition 325 4×4 owner is all about.

When performing maintenance, always capture used oil, coolant, and other fluids in a drain pan. Take them to your local auto parts store or recycling center for proper disposal—never dump them on the ground.

On the trail, follow “Tread Lightly!” principles. Stay on designated trails, avoid sensitive areas like wetlands, and pack out everything you pack in. A quiet, well-maintained exhaust also helps reduce noise pollution for wildlife and other trail users. These are the 2000 polaris xpedition 325 4×4 best practices that ensure we have places to ride for generations to come.

Frequently Asked Questions About the 2000 Polaris Xpedition 325 4×4

What kind of oil does a 2000 Polaris Xpedition 325 use?

The manufacturer recommends a 4-cycle synthetic 0W-40 or 5W-50 oil specifically designed for ATVs, like Polaris PS-4. The wet clutch system in some ATVs requires specific additives, so using a powersports-specific oil is strongly recommended over standard car oil.

What is the top speed of a 2000 Polaris Xpedition 325?

Under ideal conditions, you can expect a top speed of around 40-45 MPH. This machine was built for torque and trail work, not high-speed runs. Its real strength is in its low-end power and climbing ability.

How do I know if the 4×4 is working correctly?

The easiest way is to find a loose surface like gravel or dirt. With the 4×4 switch on, give it a moderate amount of throttle from a standstill. You should feel the front wheels pulling and see them kicking up gravel along with the rears. If only the rear wheels spin, your 4×4 system needs troubleshooting.

Is the 2000 Polaris Xpedition 325 a good beginner ATV?

Absolutely. Its automatic transmission, predictable power delivery, and stable chassis make it an excellent choice for new riders. It’s powerful enough to be fun and capable but not so powerful that it’s intimidating or easy to get into trouble with.

Your Trail-Ready Workhorse Awaits

The 2000 Polaris Xpedition 325 4×4 is more than just an old ATV; it’s a ticket to adventure and a testament to solid engineering. It’s a machine that will reward your efforts with unwavering reliability.

By following a simple maintenance schedule, learning to diagnose its common quirks, and practicing safe, responsible riding, you’re not just keeping a quad alive—you’re preserving a classic.

So grab your tools, give that rig the attention it deserves, and get out there. The trails are calling. Stay safe and have a blast!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.