Target Audience:
Owners and technicians of 1996-1999 Polaris Magnum and Big Boss ATVs seeking comprehensive service information.
Value Proposition:
Provides in-depth technical guidance, troubleshooting, and repair procedures essential for maintaining and repairing these specific ATV models, saving time and money on repairs.
Manual Features:
Detailed step-by-step instructions, torque specifications, diagnostic procedures, component diagrams, and extensive troubleshooting guides.
Usage Recommendation:
Recommended for routine maintenance, preventative measures, and complex repair tasks to ensure longevity and optimal performance of the ATV.
Powertrain:
Engine, Transmission, Drive Axles, Drivetrain Components (Chains, Sprockets, CV Joints)
Chassis:
Frame, Front Suspension, Rear Suspension, Steering, Brakes, Wheels and Tires
Electrical:
Charging System, Ignition System, Starting System, Lighting, Switches, CDI Unit, Wiring Diagrams
Fuel System:
Air Cleaner, Carburetor, Fuel Tank, Fuel Valve, Throttle Control, Exhaust System
Cooling System:
Engine Cooling System, PVT Cooling System, Coolant Pump, Thermostat, Sensors
Body:
Body Panels, Fenders, Racks, Seat, Covers
Maintenance:
Pre-ride checks, Service Intervals, Lubrication, Oil Changes, Filter Replacements, Battery Maintenance, Tire Pressure, Chain Adjustments, Valve Clearance Adjustments, Tune-ups
Troubleshooting:
Engine Starting Difficulties, Charging System Issues, Ignition Problems, Fuel System Malfunctions, Overheating, Noises, Power Train Issues, Steering Problems, Brake Issues
Repair Rebuild:
Engine Overhaul (Cylinder Head, Piston, Crankshaft, Oil Pump), Carburetor Rebuild, Transmission Disassembly/Assembly, Clutch Service, Brake Caliper/Master Cylinder Rebuild, Suspension Component Replacement, Steering Shaft Repair, Electrical Component Testing/Replacement
Diagnostics:
Cylinder Leak Down Test, Oil Pressure Test, Electrical System Testing (Stator, Regulator/Rectifier, CDI)
Depth:
Comprehensive from basic maintenance and troubleshooting to complete engine, transmission, and drivetrain rebuilds. Suitable for DIY enthusiasts and professional technicians.
Engine Type:
4-stroke gasoline engine (specific configurations vary by model, typically single-cylinder for Magnum, twin-cylinder for Big Boss 500)
Engine Displacement:
425cc for Magnum models, 499cc for Big Boss 500 (approximate, specific bore/stroke will be in manual)
Cooling System:
Liquid-cooled
Horsepower:
Approx. 25-30 HP (estimate, specific rating varies by model and year)
Torque:
Not specified in product info, but detailed torque specs for all fasteners will be in the manual.
Carburetor:
Single or dual carburetor (details specific to model covered)
Fuel Type:
Unleaded gasoline (recommended octane to be detailed in manual)
Transmission Type:
Automatic, Continuously Variable Transmission (CVT) with belt drive system (Polaris Variable Transmission - PVT)
Drive Modes:
Selectable 2WD, 4WD, and 6WD (depending on specific model covered)
Gear Selection:
Forward, Neutral, Reverse (F-N-R) selector
Transmission Fluid:
Specific type and capacity for PVT and final drive/axle housings will be detailed in the manual.
Wheelbase:
Varies by model; e.g., Magnum typically around 48-50 inches, Big Boss 6x6 longer due to 6 wheels.
Dry Weight:
Varies by model and drivetrain (2x4, 4x4, 6x6); Magnum typically 500-600 lbs, Big Boss 6x6 heavier due to 6WD system.
Towing Capacity:
Typically around 600-750 lbs for Magnum, potentially higher for Big Boss (specifics in manual).
Payload Capacity:
Front and rear racks typically rated for a combined payload of 250-300 lbs (specifics in manual).
Crash Test Results:
N/A for ATVs in the traditional sense; safety focus is on operational design and manual guidance.
Braking System:
Hydraulic disc brakes (front and rear), potentially an auxiliary brake lever or foot pedal.
Speed Limiter:
Electronic speed limiter and throttle control system mentioned in troubleshooting chapter.
Rollover Protection:
N/A (ATVs are open-frame vehicles; emphasis on rider skill and safe operation).
Warning Labels:
Manual covers warning and information labels installed on the vehicle.
Infotainment System:
N/A (Basic ATV instrumentation: speedometer, odometer, indicator lights).
Driver Assistance Features:
None beyond standard ATV operational controls and safety features.
Connectivity Features:
N/A
Ignition System:
CDI (Capacitor Discharge Ignition) system, with details on ignition stator coils and ignition coil provided.
Throttle Control:
Electronic throttle control system is mentioned, indicating a level of electronic engine management.
Oil Change Interval:
Typically 50-100 hours or annually (specific interval and oil type detailed in manual).
Air Filter Maintenance:
Frequent checks, especially in dusty conditions; cleaning/replacement based on usage and inspection.
Drive Belt Inspection:
Regular inspection for wear, cracks, and proper tension is critical for CVT longevity.
Engine Oil:
SAE 10W-30 or 10W-40 (specific viscosity and API classification to be found in the manual).
Coolant:
Ethylene glycol-based antifreeze (specific mix ratio and type will be specified).
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid (specific type required for system).
Cvt Belt Wear:
Common issue across many CVT systems; proper belt tension, alignment, and avoiding excessive slipping prolong life.
Carburetor Cleaning:
Can be prone to clogging from fuel degradation or debris; regular cleaning and proper fuel storage are recommended.
Drive Chain Adjustment:
Requires periodic adjustment to maintain proper tension, preventing wear on sprockets and drivetrain components.
Eccentric Bearing Maintenance:
Rear axle and front hub eccentric bearings require periodic lubrication and inspection to prevent premature failure, especially in wet or dirty conditions.
Polariss Atv History:
Polaris has been a pioneer in the ATV industry since the 1980s, known for innovation in 2WD, 4WD, and 6WD systems. The Magnum and Big Boss lines represented significant advancements in their respective eras.
Magnum Line:
The Magnum line was Polaris's popular utility ATV, offering a balance of power, comfort, and capability. Mid-to-late 90s models saw advancements in suspension and engine technology.
Big Boss Line:
The Big Boss was Polaris's premium, high-capacity workhorse, particularly the 6x6 models, which offered exceptional traction and load-carrying capabilities for demanding tasks.
Manufacturing Era:
These models represent the robust utility ATVs of the late 1990s, a period of significant growth and refinement for Polaris in the off-road vehicle market.
