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This Polaris ATV manual is 352 pages.
QUICK REFERENCE DATA
CHAPTER ONE / 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
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 / 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
Models covered:
1998 1999 Polaris Big Boss 500 6x6
1996 1997 1998 Polaris Magnum 425 2X4
1996 1997 1998 Polaris Magnum 425 4X4
1996 1997 Polaris Magnum 425 6X6
Clymer Manuals Polaris Magnum 425 2X4 Manual
Clymer Manuals Polaris Magnum 425 4X4 Manual
Clymer Manuals Polaris Magnum 425 6X6 Manual
Clymer Manuals Polaris Big Boss 500 6x6 Manual
Magnum 425 2X4 (1996-1998)
Magnum 425 4X4 (1996-1998)
Magnum 425 6X6 (1996-1997)
Big Boss 500 6x6 (1998-1999)