This Manual is 258.5 MBytes with lots high quality pictures.

Models Covered:

Magnum 425 2X4 (1996-1998)
Magnum 425 4X4 (1996-1998)
Magnum 425 6X6 (1996-1997)
Big Boss 500 6x6 (1998-1999)

This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.
Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

Manual Contents:

0. QUICK REFERENCE DATA

1. 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

36. 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

49. 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

94. 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

149. 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

165. 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

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

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

214. 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

226. 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

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

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

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

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

332. WIRING DIAGRAMS


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