1996-1999 Polaris Magnum Big Boss 425 500 6x6 4x4 Clymer Repair Manual M3622This new
Clymer Repair Manual is for the Polaris
Magnum & Big Boss ATVs spanning 1996-1999. It covers the Magnum 425 2x4 &
4x4 (1996-1998), Magnum 425 6x6 (1996-1997) and Big Boss 500 6x6 (1998-1999)
models.
Models Covered:
Featuring just as much detail as our ATV model
specific manuals, this repair manual will give you everything you need for
repair and maintenance. Clymer ATV repair manuals are considered to be the
only ATV repair manuals worth owning. They are used by some of the most
prestigious professionals to your average everyday ATV owner. Along with
superior design Clymer ATV repair manuals always provide the most up-to-date
information available for your ATV.
Like all Clymer motorcycle repair manuals, this book
also contains:
- Hundreds of original photographs and
illustrations developed from a complete disassembly and assembly of the
ATV
- Step-by-step instructions and two column text
with large print are user friendly
- Detailed and exploded views and photos
- Bold figure numbers to quickly match instructions
with illustrations and photos
- Easy-to-follow wiring diagrams
- Thumb-tabbed chapters for quick access
- Two-column layout with large print
- Numbered table of contents and extensive index
- Extensive research, allows Clymer to achieve an
un-matched level of detail, accuracy & clarity
Clymer manuals provide step-by-step procedures based
on the complete disassembly of the machine. This hands-on experience
combined with extensive research results in a manual that is both detailed
and user friendly. Accurate, clear and concise text, combined with detailed
illustrations and photography, make it possible for the novice motorcycle
enthusiast to safely and enjoyably service their vehicle. At the same time,
the in-depth coverage provides indispensable information for those tackling
more complicated procedures.
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
Specifications: