🏷️ Basic Information Identification Make: Polaris Model: Magnum 425 2x4 Year: 1996 Type: ATV (All-Terrain Vehicle) Codes Chassis Code: Not Specified (Typical for ATVs to not have distinct chassis codes like cars) Engine Code: Not Specified (Engine details often embedded in model series) 👋 Introduction Market Position Segment: Mid-size utility ATV segment. Target User: Recreational riders, farmers, and hunters seeking a robust and capable 2WD ATV. Competitive Analysis Competitors 1996: Honda FourTrax 300, Yamaha Big Bear 350, Suzuki QuadRunner 300. Key Features Feature 1: Powerful 425cc liquid-cooled engine providing ample torque for its class. Feature 2: Polaris Variable Transmission (PVT) offering seamless automatic shifting. Feature 3: Independent front suspension (IFS) for improved ride comfort and handling over rough terrain. Feature 4: Durable 2WD drivetrain, focused on simplicity and efficiency. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical Repair, Electrical Systems, Maintenance, Troubleshooting, Specifications Target Audience: Mechanics and DIY enthusiasts Page Count Estimated Page Count: Not explicitly stated in product info, but factory service manuals of this era are typically 300-600 pages. Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, cylinder head, piston, crankshaft, lubrication system, cooling system, ignition system, carburetor Transmission: Automatic Transmission (PVT - Polaris Variable Transmission), clutch operation, belt replacement, gear case maintenance Drivetrain: 2WD rear axle, differential, driveshaft, universal joints Suspension: Front and rear suspension systems, shock absorbers, control arms, bushings, steering knuckles Brakes: Hydraulic disc brake system (front and rear), brake caliper, master cylinder, brake lines, bleeding procedures Electrical: Starter system, charging system (stator, regulator/rectifier), battery, lighting (headlights, taillight, brake light), ignition system, wiring diagrams, fuses Fuel System: Fuel tank, fuel lines, fuel pump, carburetor (Mikuni VM series typically), air filter assembly Cooling System: Radiator, coolant hoses, thermostat, fan operation Steering: Handlebar steering, tie rods, steering shaft, bushings Body And Frame: Frame inspection and repair, body panels, fenders, seat, racks Wheels And Tires: Wheel specifications, tire pressure, tire replacement Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug service, lubrication points, brake fluid checks Repair: Complete disassembly and reassembly of all major components, component-specific repairs Troubleshooting: Diagnostic flowcharts, common problem identification, symptom-based troubleshooting guides Installation: Component installation procedures, accessory installation guidance Adjustment: Carburetor adjustment, idle speed settings, brake lever free play, clutch engagement Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics. 📊 Manual Specifications File Format Format: PDF Searchability: Typically searchable text within PDF for ease of navigation. Print Quality Quality: High resolution, suitable for printing individual pages or sections. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-Cooled, Single-Cylinder Displacement: 425 cc Bore X Stroke: Not explicitly stated, but typical for this era would be around 80mm x 84mm. Valvetrain: SOHC (Single Overhead Cam) Performance Horsepower: Approx. 25-28 HP (estimated for the era) Torque: Not explicitly stated, but known for strong low-end torque. Fuel System Carburetor Type: Mikuni VM Series (likely VM34 or VM36) Fuel Type: Unleaded Gasoline (87 Octane Recommended) Fuel Tank Capacity: Approx. 3.2 gallons (12.1 liters) Cooling System Coolant Type: Ethylene Glycol-based coolant (50/50 mix with distilled water recommended) Ignition System Ignition Type: CDI (Capacitor Discharge Ignition) Spark Plug Type: NGK DPR7EA-9 (Typical, confirm in manual) 🔧 Transmission Standard Type: Automatic (Polaris Variable Transmission - PVT) Drive Modes: Forward (Hi/Low range), Neutral, Reverse Features Clutch Type: Centrifugal clutch with CVT belt drive Fluid Specifications Gear Case Oil Type: SAE 10W-30 API GL-4 (Confirm in manual, some required specific ATV gear oils) Gear Case Oil Capacity: Approx. 0.6 quarts (0.5 liters) 📐 Dimensions Exterior Length: Approx. 76 inches (193 cm) Width: Approx. 44 inches (112 cm) Height: Approx. 46 inches (117 cm) Wheelbase: Approx. 48 inches (122 cm) Weights Dry Weight: Approx. 525 lbs (238 kg) Ground Clearance: Approx. 7.5 inches (19 cm) Cargo Front Rack Capacity: Not Specified (Typically ~25 lbs / 11 kg) Rear Rack Capacity: Not Specified (Typically ~50 lbs / 23 kg) Wheels And Tires Front Tire Size: AT 23 x 8-12 Rear Tire Size: AT 23 x 10-12 Wheel Bolt Pattern: 4x110mm (Typical for Polaris of this era) Front Tire Pressure: 4 psi Rear Tire Pressure: 4 psi 🛡️ Safety Features Ratings Crash Test Ratings: N/A (ATVs are not subject to standardized automotive crash testing). Active Features Braking System: Hydraulic Disc Brakes (Front and Rear), Parking Brake Lighting: Dual Halogen Headlights, Taillight/Brake Light Passive Features Operator Controls: Handlebar steering, thumb throttle, brake levers. Operator Station: Open-air design, footwells, comfortable seating. Warnings Safety Precautions: Always wear a helmet and appropriate protective gear. Read and understand the owner's manual and warnings before operation. 💡 Technology Features Infotainment Infotainment System: N/A (Basic utility vehicle with no infotainment features). Driver Assistance Assistance Features: N/A (No...