Quantcast
Jump to content

2002 Polaris Xpedition

kramme24

By kramme24
in Polaris ATV Forum

 Share

Recommended Posts

kramme24 Newbie

kramme24

Posted
Posted

Hey guys, I'm new to this so I hope someone is willing to help me out. I have a 2002 Polaris Xpedition 425 and it is shifting hard. I have taken the clutches out to replace the shift lever that snapped off on me. It is shifting very hard and it was even before I took things apart. I got it back running again, but I am wondering if there is a clutch adjustment screw on the bike that I adjust how hard it shifts? I have been looking around but have been unable to locate it. I'm afraid I will break the shaft again if I have to keep shifting it as hard as I do. Any help would be much appreciated. A pic of the location would be helpful if possible. Thank you in advance for your help.

Mech Grand Master

Mech

Posted
Posted

Cant find any adjustment instructions, but if there is an adjustment I'd think it would be by undoing nut #29 and perhaps the bolt/shaft in it might be slotted.. I'd look there and if the shaft #29 is on is slotted I'd have a play around if it was me.

canvas.png

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

×
 Share
Go to topic listing


  • Popular Now

  • Similar Forum Topics

    • Cj Winds
      2009 Honda Rancher TRX420FA with shifting problems
      By Cj Winds
      I have a 2009 Honda Rancher TRX420FA with shifting problems.
      Usually it shifts ok when cold but after couple minutes it will stop shifting with no codes.
      The 1st shift clutch oil pressure when in first gear is 74psi. The 2nd shift clutch oil pressure when in second gear is 74psi.
      The 1st shift clutch oil pressure when in neutral is zero. The problem is when the tranny is in neutral the 2nd shift clutch pressure starts around 10-15psi and builds to 20psi. Is this normal?
    • LashinWheeler
      2006 Polaris Sawtooth No Spark
      By LashinWheeler
      Hello all, I have a 2006 Polaris Sawtooth with no spark. It has a dead battery but with a jump pack on it, it will still not Spark. Plug is good, Throttle ETC is not closed, Stator pick up coil seems to Ohm out in the correct range, Unsure how to properly check the CDI. And when ignition is on the Neutral and reverse light come on but after cranking just the neutral stays on. 
       
      Any help would be great,
       
      Thanks!
    • cruteg8
      Bell Crank Orentation 2000 Polaris Scrambler 400 2x4
      By cruteg8
      Does anyone know  the orientation of the bell crank for scrambler 400 2x4 it was not hooked up when I bought quad the way  i put it high goes into reverse and vise versa I flipped it 180 but that put  the shift rod at big angle and it just kinda grinds into gears so dnt think that is right either pretty sure it has to be the exact orientation and the rod adjusted accordingly but I cant seem to find it anyone knows please help 
    • Admin
      2013-2016 Polaris RZR 570 Service Manual
      By Admin
      View File 2013-2016 Polaris RZR 570 service manual
      Download the 2013-2016 Polaris RZR 570 service manual PDF for complete factory repair, maintenance, troubleshooting, and diagnostic procedures. This comprehensive Polaris RZR 570 repair manual covers all major systems including engine service, EFI fuel injection, transmission and clutch repair, drivetrain maintenance, suspension, steering, brakes, electrical troubleshooting, wiring diagrams, torque specifications, and factory maintenance schedules.
      Designed for RZR owners, mechanics, trail riders, racers, and DIY enthusiasts, this factory-style service manual provides detailed step-by-step instructions and diagrams for maintaining, troubleshooting, repairing, and rebuilding the Polaris RZR 570 side-by-side UTV.
      Topics covered include:
      Polaris RZR 570 engine repair
      EFI fuel injection diagnostics
      CVT clutch and transmission troubleshooting
      Drivetrain and differential service
      Suspension and steering maintenance
      Brake system repair
      Electrical troubleshooting and wiring diagrams
      Oil change procedures and maintenance intervals
      Torque specs and factory service data
      Polaris RZR diagnostic procedures
      Popular related searches:
      2013 Polaris RZR 570 service manual PDF
      Polaris RZR 570 repair manual
      RZR 570 wiring diagram
      Polaris RZR torque specs
      RZR 570 clutch problems
      Polaris RZR maintenance schedule
      Polaris UTV factory service manual PDF
      This Polaris factory repair manual is ideal for owners looking to maintain, troubleshoot, repair, or upgrade their RZR 570 for trail riding, recreational off-roading, hunting, racing, and utility use. Whether you're performing routine maintenance or a complete rebuild, this manual provides the factory information needed to keep your Polaris RZR 570 running at peak performance.
      Submitter Admin Submitted 05/30/2026 Category Polaris UTV  
    • Admin
      2016-2026 Polaris Youth ATV 110 EFI Service Manual
      By Admin
      View File 2016-2026 Polaris Youth ATV 110 EFI service manual
      Download the 2016-2026 Polaris Youth ATV 110 EFI service manual PDF for complete factory repair, maintenance, troubleshooting, and diagnostic procedures. This comprehensive Polaris Youth ATV repair manual covers all major systems including engine service, EFI fuel injection, transmission and drivetrain maintenance, suspension, steering, brakes, electrical troubleshooting, wiring diagrams, torque specifications, and factory maintenance schedules.
      Designed for parents, mechanics, ATV owners, and DIY enthusiasts, this factory-style service manual provides detailed step-by-step instructions and diagrams for maintaining, troubleshooting, repairing, and rebuilding Polaris Youth 110 EFI ATV models.
      Topics covered include:
      Polaris 110 EFI engine repair
      EFI fuel injection diagnostics
      Transmission and drivetrain service
      Suspension and steering maintenance
      Brake system repair
      Electrical troubleshooting and wiring diagrams
      Oil change procedures and maintenance intervals
      Torque specs and factory service data
      Polaris ATV diagnostic procedures
      Starting and performance troubleshooting
      Popular related searches:
      2016 Polaris 110 EFI service manual PDF
      Polaris Youth ATV repair manual
      Polaris 110 EFI wiring diagram
      Polaris 110 EFI troubleshooting
      Polaris Youth ATV maintenance schedule
      Polaris ATV torque specs
      Polaris ATV factory service manual PDF
      This Polaris factory repair manual is ideal for maintaining and repairing Polaris Youth ATV 110 EFI models used for recreational riding, trail riding, beginner ATV training, and family off-road adventures.
      Submitter Admin Submitted 05/28/2026 Category Polaris ATV  

COMMUNITY SECTIONS

ATV FORUMS

QUADCRAZY MEMBERSHIP

Be a part of best online community of ATV riders and join thousands of people who love ATVs! Share your ATV photos, videos, ATV rides, get help with your ATV and more. Not a member?

SIGN UP TODAY

ADVERTISE WITH US

FOLLOW US ON

  • Automotive Webmaster
×
×
  • Create New...