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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 | Mechanicís 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.

PRODUCT DETAILS:

• Publisher: Clymer Manuals 2008
• Author: Clymer Staff
• Binding: Paperback 7 x 10 inches
• Pages: 341 Hundreds of b&w photos and illustrations
• ISBN: 9781599692241

$28.31