Polaris Magnum 425, Big Boss 500 Repair Manual 1996-1999

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Item # M362-2  ISBN: 9781599692241




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This repair manual covers the following Polaris ATVs:

• Magnum 425 2X4 1996-1998
• Magnum 425 6X6 1996-1997
• Magnum 425 4X4 1996-1998
• Big Boss 500 6X6 1998-1999

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Safety first | Cleaning parts | Handling gasoline safely | Service hints | Torque specifications | Fasteners | Lubricants | Threadlocking compound | RTV gasket sealant | Expendable supplies | Serial numbers | Warnings and information labels | Basic hand tools | Precision measuring tools | Fabricating tools | Mechanic’s tips | Bearing replacement | Seals | Riding safety | Storage

CHAPTER TWO: TROUBLESHOOTING
Operating requirements | Starting the engine | Starting difficulties | Engine starting system | Charging system | Ignition system | Speed limiter and electronic throttle control | Fuel system | Engine overheating | Engine | Engine noises | Cylinder leak down test | Power train | Steering | Frame noise | Brakes

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP
Pre-ride checklist | Maintenance schedule | Tires and wheels | Battery | Battery electrical cable connectors | Periodic lubrication | Periodic maintenance | Unscheduled inspection and maintenance | Engine tune-up

CHAPTER FOUR: ENGINE
Engine principles | Engine cooling | Engine lubrication | Servicing the engine in the frame | Engine removal/installation | Cylinder head cover | Rocker arm assembly | Camshaft | Cylinder head | Valves and valve components | Cylinder block | Piston and piston rings | Recoil starter | Flywheel and stator plate | Camshaft chain and sprockets | Crankcase | Crankshaft inspection | Balancer shaft inspection | Shaft end play measurement and shim selection | Oil pump | Oil system one-way check valve | Break-in procedure

CHAPTER FIVE: FUEL and EXHAUST SYSTEMS
Carburetor operation | Carburetor | Throttle cable replacement | Starting enrichment (choke) cable | Fuel tank | Fuel valve | Air filter air box | Fuel pump | Exhaust system

CHAPTER SIX: COOLING SYSTEMS
Polaris variable transmission (PVT) cooling system | Engine cooling | Safety precautions | Hoses and hose clamps | Coolant pump | Engine gaskets/seals | Cooling system inspection | Thermostat | Temperature sensors

CHAPTER SEVEN: CLUTCH and DRIVE BELT SYSTEM
Drive unit | Drive pulley | Driven pulley | Drive belt | Drive pulley | Driven pulley | Clutch inner cover

CHAPTER EIGHT: TRANSMISSION SYSTEM Transmission | Shift selector | Shift linkage

CHAPTER NINE: FRONT DRIVE SYSTEM
Front hubs and hillard clutch | Front drive axle, boots and CV (constant velocity) joints | Center chain and sprockets | Front chain and sprockets | Front and center eccentric shafts

CHAPTER TEN: ELECTRICAL SYSTEM
Basic information | Charging system | Alternator stator | Voltage regulator/rectifier | Capacitor discharge ignition | Ignition coil | Ignition stator coils | Electric starting system | Starter drive gears | Starter solenoid | Lighting system | Switches | Wiring diagrams

CHAPTER ELEVEN: FRONT SUSPENSION and STEERING
Front wheel | Front hub (two-wheel drive models) | Front suspension | Front strut | Control arm | Handlebars | Tie rods | Steering shaft | Tires and wheels

CHAPTER TWELVE: REAR SUSPENSION
Rear wheels | Rear hub | Tire changing and tire repairs | Rear axle (two-wheel and four-wheel drive models) | Center and rear axle (6x6 models) | Center eccentric | Drive chain | Driven sprocket | Shock absorber (except rear axle shock on 6x6 models) | Shock absorber (rear axle shock on 6x6 models) | Rear swing arm (middle swing arm 6x6 models) | Rear swing arm (6x6 models)

CHAPTER THIRTEEN: BRAKES
Disc brakes | Front brake pad replacement (all models) and middle axle brake pad replacement (1997-1998 6x6 models) | Front caliper (all models) and middle axle caliper (1997-1998 6x6 models) | Output shaft brake pad replacement (all models) | Output shaft brake caliper (all models) | Middle axle caliper brake pad replacement (1996 6x6 models) | Middle axle calipers (1996 6x6 models) | Master cylinder | Brake hose replacement | Brake disc | Bleeding the system

CHAPTER FOURTEEN: BODY
Seat | Fuel tank cover and side covers | Headlight cover | Front fender | Front rack | Front bumper | Rear fender | Rear rack | Cargo box (6x6 models)

WIRING DIAGRAMS

Clymer ATV repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Polaris Magnum 425, Big Boss 500 Repair Manual 1996-1999