Polaris 425 Magnum 6x6 1996-97 ATV Repair Manual Clymer

Models Covered:

1998-1999 POLARIS Big Boss 500 6x6

1996-1998 POLARIS Magnum 425 2X4

1996-1998 POLARIS Magnum 425 4X4

1996-1997 POLARIS Magnum 425 6X6

CHAPTER ONE / GENERAL INFORMATION

CHAPTER TWO / TROUBLESHOOTING

CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride checklist / Service intervals / Maintenance schedule / Battery / Tires 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

CHAPTER FOUR / ENGINE
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

CHAPTER FIVE / 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

CHAPTER SIX / COOLING SYSTEM
Polaris variable transmission ( PVT ) cooling system / Engine cooling system / Hoses and clamps / Coolant pump / Engine gaskets and seals / Thermostat / Temperature sensors

CHAPTER SEVEN / CLUTCHAND DRIVE BELT SYSTEM
Drive unit / Drive pulley / Driven pulley / Drive belt / Clutch inner cover

CHAPTER EIGHT / TRANSMISSION
Mainshaft / Countershaft / Shift selector / Shift selector and linkage

CHAPTER NINE / 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

CHAPTER TEN / 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

CHAPTER ELEVEN/ FRONT SUSPENSION AND STEERING
Front wheel and hub / Strut / Control Arm / Tie rods / Handlebar / Steering shaft

CHAPTER TWELVE / REAR SUSPENSION
Wheels and hub /Rear axle / Center axle / Center eccentric / Drive chain / Driven sprocket / Shock absorber / Swing arm

CHAPTER THIRTEEN / BRAKES
Front middle and rear brake pads / front middle rear brake caliper / Output shaft caliper / Master cylinder / Brake discs / Fluid / Bleeding

CHAPTER FOURTEEN / BODY
Seat / Fuel tanks cover and side cover / Headlight cover / Fenders / Rack / Bumper / Cargo Box

INDEX

WIRING DIAGRAMS