by James Grooms
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Polaris Magnum & Big Boss Atvs 1996 - 1999 Clymer Owners Service & Repair Manual covers the following models:
● Polaris Magnum 425 2X4 1996 - 1998
● Polaris Magnum 425 4X4 1996 - 1998
● Polaris Magnum 425 6X6 1996 - 1997
● Polaris Big Boss 500 6X6 1998 - 1999
● QUICK REFERENCE DATA
● GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Cleaning parts / Handling gasoline safely / Service hints / Torque specifications / Fasteners / Lubricants / RTV gasket sealant / Gasket remover / Threadlocking compound / Expendable shop supplies / Serial numbers / Warning and information labels / Basic hand tools / Precision measuring tools / Fabricating tools / Mechanics tips / Ball bearing replacement / Oil seals / Riding safely / Storage / Specifications
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
● LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals / Maintenance schedule / Battery / Tyres and wheels / Periodic lubrication / Engine oil and filter change / Engine oil pressure test / Transmission oil change / Rear axle housing eccentric bearings / front hub wheel bearings / Front hub / Control cable lubrication / Periodic maintenance / Drive belt inspection / drive chain and sprocket lubrication and inspection / Rear drive chain adjustment 2 x 4 and 4 x 4 models / Center and front chain adjustment 94 x 4 models / Rear axle chain and axle-to-axle drive chain 6 x 6 models / Brake fluid check and fill / Auxiliary brake testing / Electronic throttle control adjustment / Air filter / Engine breather filter / Coolant change / Fuel filter / Front wheel toe out / rear axle housing / Unscheduled inspection and maintenance / drive axle sprockets / recoil starter / Engine tune-up / Valve clearance adjustment / Spark plugs
Cylinder head and cover / Camshaft, cam chain sprocket and tensioner / Decompressor / Valves and components / Piston and rings / Cam chain, sprocket and guides / Crankcase / Crankshaft / Balancer shaft / Shaft end play measurement and shim selection / Oil pump / Oil system one-way check valve
● FUEL AND EXHAUST SYSTEMS
Air cleaner / Carburetor / Carb inspection, repair and adjustment / Throttle control and cable / Exhaust pipe and muffler / Fuel valve / Starting enrichment cable (choke) / Fuel tank
● COOLING SYSTEM
Polaris variable transmission (PVT) cooling system / Engine cooling system / Hoses and clamps / Coolant pump / Engine gaskets and seals / Thermostat / Temperature sensors
● CLUTCHAND DRIVE BELT SYSTEM
Drive unit / Drive pulley / Driven pulley / Drive belt / Clutch inner cover
Mainshaft / Countershaft / Shift selector / Shift selector and linkage
● FRONT DRIVE SYSTEM
Front hub and Hillard clutch / Front drive axle, boots and constant velocity CV joints / Center chain and sprockets / Front chain and sprockets / Front and center eccentric shafts
● ELECTRICAL SYSTEM
Charging system / Alternator stator / Voltage regulator rectifier / Capacity discharge ignition CDI / Igntion coil / Ignition stator coils / Electric driving system / Starter drive gears / Starter solenoid / Lighting / Switches
● FRONT SUSPENSION AND STEERING
Front wheel and hub / Strut / Control Arm / Tie rods / Handlebar / Steering shaft
● REAR SUSPENSION
Wheels and hub /Rear axle / Center axle / Center eccentric / Drive chain / Driven sprocket / Shock absorber / Swing arm
Front middle and rear brake pads / front middle rear brake caliper / Output shaft caliper / Master cylinder / Brake discs / Fluid / Bleeding
Seat / Fuel tanks cover and side cover / Headlight cover / Fenders / Rack / Bumper / Cargo Box
● 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.
Please note that workshop manuals are usually written for models sold in a specific country. Differences in specification can exist between models sold in different countries and items such as engines can vary. Please check that the manual will cover your model before purchase and if you are unsure please contact us first.
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