Thinking about picking up a classic Polaris Xpedition 325, or maybe you’re just trying to get your trusty rig back into top shape? You know that knowing the numbers—the real specs behind the plastic—is half the battle for any DIY mechanic or serious rider.
It’s one thing to read a dusty owner’s manual, but it’s another thing entirely to understand what those numbers mean for your wrenching sessions and weekend adventures. You need to know how those specs translate to real-world capability and what to watch out for.
We promise this is the ultimate guide you’ve been searching for. We’re going to break down the complete polaris xpedition 325 specs from engine to chassis, translating the factory data into practical advice you can actually use in your garage and on the trail. In this guide, we’ll dive deep into the engine’s power, the chassis dimensions that define its handling, critical fluid capacities, and what it all means for maintenance, common problems, and trail performance.
The Heart of the Beast: Engine and Drivetrain Specs Explained
The engine and drivetrain are the core of your ATV’s personality. For the Xpedition 325, Polaris focused on reliability and usable torque over outright speed. Here’s what’s powering your ride.
Engine Type & Displacement
The Xpedition 325 is powered by a 325cc, 4-stroke, single-cylinder engine. Unlike its 2-stroke cousins of the era, this 4-stroke design is known for its durability, smoother power delivery, and broader torque curve.
It’s an air-cooled engine with a fan-assisted oil cooler. This setup is simple and effective, reducing the number of potential failure points like radiators, hoses, and water pumps. For a DIYer, this means easier maintenance and fewer systems to worry about.
Transmission and Drive System
This is where Polaris machines have always shined. The Xpedition 325 uses the legendary Polaris Variable Transmission (PVT), which is an automatic CVT-style system. It features High, Low, Neutral, and Reverse gears (H/L/N/R).
The real magic is the On-Demand True All-Wheel Drive (AWD) system. In 2WD, power goes to the rear wheels. When the system detects the rear wheels slipping, it automatically engages the front wheels to provide true four-wheel traction. This is a massive benefit, as it gives you traction when you need it without making the steering heavy and difficult on smooth trails.
Fuel System and Capacity
The 325 uses a tried-and-true 34mm Mikuni carburetor. While reliable, carbs on older machines can be finicky if they sit for a while. A key part of your polaris xpedition 325 specs care guide should be to always use fresh, stabilized fuel.
The fuel tank holds approximately 4.25 gallons (16.1 L), giving you a respectable range for a day of work or trail riding without constantly searching for a gas can.
Chassis & Suspension: Your Guide to Ride Quality and Capability
An engine is useless if the chassis can’t put the power down or handle the terrain. The Xpedition 325 was built as a utility quad first, with a focus on stability and load-carrying. This section of our polaris xpedition 325 specs guide covers the bones of your machine.
Dimensions & Weight
Understanding the size and weight of your ATV is crucial for trailering, storage, and knowing how it will handle.
- Overall Length: 81 inches
- Overall Width: 46 inches
- Overall Height: 47 inches
- Wheelbase: 50 inches
- Estimated Dry Weight: 637 lbs
That longer wheelbase and substantial weight contribute to a stable, planted feel on rough trails and when hauling loads. It’s not a nimble sport quad, but a confident workhorse.
Suspension Travel & Ground Clearance
The Xpedition 325 features a MacPherson strut front suspension with 6.7 inches of travel and a progressive-rate swingarm rear suspension with 7.5 inches of travel. This setup is designed to provide a comfortable ride while also being durable enough to handle heavy loads.
With a healthy 7.0 inches of ground clearance, you have enough room to clear most rocks, logs, and ruts you’ll encounter on typical trails. One of our top polaris xpedition 325 specs tips is to always check your tire pressure, as underinflated tires can significantly reduce your effective ground clearance.
Towing and Hauling Capacities
This is where the utility DNA of the Xpedition 325 truly shows. The specs for hauling are impressive for its class:
- Front Rack Capacity: 90 lbs
- Rear Rack Capacity: 180 lbs
- Hitch Towing Capacity: 850 lbs
One of the most common problems with polaris xpedition 325 specs is riders exceeding these limits. Overloading the racks can make the ATV top-heavy and unstable, while exceeding the tow rating puts immense strain on the transmission belt, clutch, and frame.
The Complete Polaris Xpedition 325 Specs (At-a-Glance)
Sometimes you just need the numbers. Here’s a quick-reference table covering the key factory specifications for the Polaris Xpedition 325 (model years 2000-2002).
| Category | Specification |
|---|---|
| Engine | 325cc, 4-Stroke Single Cylinder, Air/Oil Cooled |
| Fuel System | Mikuni 34mm CV Carburetor |
| Drivetrain | Automatic PVT (H/L/N/R), Shaft Drive |
| Drive System | On-Demand True AWD/2WD |
| Front Suspension | MacPherson Strut with 6.7 in (17 cm) Travel |
| Rear Suspension | Progressive Rate Swingarm with 7.5 in (19.1 cm) Travel |
| Brakes | Single-Lever Hydraulic Disc (Front/Rear) |
| Front Tires | 24 x 8-12 |
| Rear Tires | 24 x 11-10 |
| Wheelbase | 50 in (127 cm) |
| Ground Clearance | 7.0 in (17.8 cm) |
| Fuel Capacity | 4.25 gal (16.1 L) |
| Towing Capacity | 850 lbs (385.6 kg) |
How to Use Specs for Smart Maintenance: A DIY Care Guide
Knowing the specs is only useful if you apply them. This is the “how-to” portion of our guide, focusing on polaris xpedition 325 specs best practices for keeping your machine running strong.
Fluids, Fluids, Fluids
The lifeblood of your engine is its oil. The Xpedition 325 requires Polaris PS-4 Full Synthetic 5W-50 oil or an equivalent high-quality synthetic. The system holds about 2 quarts (1.9 L).
Always check the oil level on a level surface with the dipstick fully screwed in. Regular oil changes are the single most important thing you can do for engine longevity. When you do change it, practice sustainable polaris xpedition 325 specs care by taking your used oil to an auto parts store or local recycling center for proper disposal. Don’t just dump it!
Tires & Brakes
Your tires are your only connection to the trail. The stock tire sizes are 24×8-12 on the front and 24×11-10 on the rear. The recommended tire pressure is typically around 5 PSI, but check the sidewall of your specific tires.
Regularly inspect your brake fluid level in the master cylinder reservoir on the handlebars. If it’s low or looks dark and murky, it’s time for a flush and bleed. Also, visually inspect your brake pads for wear. If they’re down to the metal, replace them immediately.
Electrical System Check-up
A simple but crucial spec is the spark plug. The correct plug is a NGK BKR6E, and the gap should be set to 0.035 in (0.9 mm). A fresh, correctly gapped plug can solve a multitude of running issues.
Keep your battery terminals clean and tight. If the machine struggles to start, test the battery with a multimeter; a healthy battery should read around 12.6 volts at rest and over 13.5 volts when the engine is running.
Real-World Performance: What the Specs Mean on the Trail
Numbers on a page are one thing, but how do they translate to mud, rocks, and dirt? Here we explore the benefits of polaris xpedition 325 specs in action.
For the Trail Rider
The 50-inch wheelbase and 637-pound weight create a very stable platform. It won’t whip around corners like a sport quad, but it will feel secure and predictable on off-camber trails and rocky climbs. The On-Demand AWD gives you the confidence to point the machine up a slippery hill knowing the front wheels will pull you through.
For the Hunter or Homesteader
This is where the Xpedition 325 excels. The generous rack capacities allow you to haul gear, tools, or a harvest with ease. The 850-pound towing capacity is perfect for pulling a small utility trailer around the property to move firewood, dirt, or feed. The reliable 4-stroke engine is happy to chug along at low speeds all day long.
Frequently Asked Questions About Polaris Xpedition 325 Specs
What kind of oil does a Polaris Xpedition 325 use?
The factory recommends Polaris PS-4 Full Synthetic 5W-50 4-cycle engine oil. If you can’t find the Polaris brand, a high-quality synthetic 5W-50 oil from a reputable brand that is rated for wet-clutch use is a suitable alternative. The oil capacity is 2 quarts (1.9 L).
What is the top speed of a Polaris Xpedition 325?
The top speed of a stock Polaris Xpedition 325 is typically between 40-45 MPH. This can vary based on rider weight, tire condition, terrain, and the overall mechanical condition of the ATV, especially the clutch and belt.
Is the Polaris Xpedition 325 a reliable ATV?
Yes, when properly maintained, the Xpedition 325 is considered a very reliable utility ATV. Its 4-stroke engine and robust chassis were built for work. The most common issues stem from age-related problems like carburetor gum-up, worn belts, or neglected fluid changes—all things a diligent DIYer can manage.
What is the stock tire size for the Xpedition 325?
The stock tire sizes are 24×8-12 for the front wheels and 24×11-10 for the rear wheels. It’s important to maintain similar overall tire diameters if you upgrade to aftermarket tires to ensure the On-Demand AWD system functions correctly.
Understanding your machine is the first step to becoming a better rider and a more confident mechanic. The Polaris Xpedition 325 is a fantastic, capable ATV with specs that prove it was built to last and work hard. By knowing these numbers and what they mean, you can perform maintenance correctly, diagnose problems faster, and push your quad to its limits safely.
Now that you’re armed with this comprehensive polaris xpedition 325 specs guide, you can tackle that next project with confidence. Get in the garage, get your hands dirty, and get ready for your next adventure. Ride safe out there!
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