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

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

The engine is equipped with a dry sump lubrication system that contains only a small amount of oil. The various components of the engine are lubricated by the oil as it is circulated through the engine.

Engine heat is transferred to the oil, then the oil is allowed to cool while it is in the oil tank (A, Figure 3).

The oil flows through a screen in the bottom of the oil tank, then through the supply hose to the oil pump. The oil pump forces oil through a one-way check valve that keeps the oil from draining from the oil tank into the engine when it is not running.

After passing the check valve, oil flows to the oil filter. If the oil filter (B, Figure 3) is obstructed, a bypass valve in the filter allows the oil to pass without being filtered.

After flowing through (or around) the oil filter, the oil is divided into two separate paths.

• General Information
• Troubleshooting
• Lubrication, Maintenance and Tune-Up
• Engine
• Fuel and Exhaust Systems
• Cooling System
• Clutch and Drive Belt
• Transmission
• Front Drive
• Electrical System
• Front Suspension and Steering
• Rear Suspension
• Brakes
• Body
• Wiring Diagrams