MotorBookGuy.Com

Home > Motorcycles & ATV's > Polaris ATV Manuals >   Polaris Magnum 425, Big Boss 500 Repair Manual 1996-1999
	Lowest Price Guaranteed! List Price: $32.95 Our Price: $22.42 You save $10.53! Availability:: Usually Ships in 24 Hours Product Code: CL-M362-2

Description   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 | MechanicÌs 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

Related Products... Polaris Repair Manual: Big Boss 6x6, Magnum, Scra Our Price: $23.74 Add Polaris 400, Boss, Cyclone, Magnum, Scrambler, Sp Our Price: $23.74 Add Polaris Scrambler 500 Repair Manual 1997-2000 Our Price: $22.42 Add ATV Service Manual Vol. 2 - Honda, Kawasaki, Polar Our Price: $25.95 Add ATV Service Manual Vol. 1 1974-1987 Our Price: $25.95 Add

Share your knowledge of this product with other customers... Be the first to write a review

Browse for more products in the same category as this item: Motorcycles & ATV's > Polaris ATV Manuals Clymer > Polaris ATV Make > POLARIS Model > Big Boss Year > 1996 Make > Polaris Year > 1997 Year > 1998 Year > 1999 Model > MAGNUM Motorcycles & ATV's Clymer Year Make Model