Segment:
Mid-size utility ATV segment.
Target User:
Recreational riders, farmers, and hunters seeking a robust and capable 2WD ATV.
Competitors 1996:
Honda FourTrax 300, Yamaha Big Bear 350, Suzuki QuadRunner 300.
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.
Primary Coverage:
Mechanical Repair, Electrical Systems, Maintenance, Troubleshooting, Specifications
Target Audience:
Mechanics and DIY enthusiasts
Estimated Page Count:
Not explicitly stated in product info, but factory service manuals of this era are typically 300-600 pages.
Type:
Factory Service Repair Manual
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
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
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed electrical diagnostics.
Engine Type:
4-stroke, Liquid-Cooled, Single-Cylinder
Bore X Stroke:
Not explicitly stated, but typical for this era would be around 80mm x 84mm.
Valvetrain:
SOHC (Single Overhead Cam)
Horsepower:
Approx. 25-28 HP (estimated for the era)
Torque:
Not explicitly stated, but known for strong low-end torque.
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)
Coolant Type:
Ethylene Glycol-based coolant (50/50 mix with distilled water recommended)
Ignition Type:
CDI (Capacitor Discharge Ignition)
Spark Plug Type:
NGK DPR7EA-9 (Typical, confirm in manual)
Type:
Automatic (Polaris Variable Transmission - PVT)
Drive Modes:
Forward (Hi/Low range), Neutral, Reverse
Clutch Type:
Centrifugal clutch with CVT belt drive
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)
Length:
Approx. 76 inches (193 cm)
Width:
Approx. 44 inches (112 cm)
Height:
Approx. 46 inches (117 cm)
Wheelbase:
Approx. 48 inches (122 cm)
Dry Weight:
Approx. 525 lbs (238 kg)
Ground Clearance:
Approx. 7.5 inches (19 cm)
Front Rack Capacity:
Not Specified (Typically ~25 lbs / 11 kg)
Rear Rack Capacity:
Not Specified (Typically ~50 lbs / 23 kg)
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
Crash Test Ratings:
N/A (ATVs are not subject to standardized automotive crash testing).
Braking System:
Hydraulic Disc Brakes (Front and Rear), Parking Brake
Lighting:
Dual Halogen Headlights, Taillight/Brake Light
Operator Controls:
Handlebar steering, thumb throttle, brake levers.
Operator Station:
Open-air design, footwells, comfortable seating.
Safety Precautions:
Always wear a helmet and appropriate protective gear. Read and understand the owner's manual and warnings before operation.
Engine Oil Change:
Every 100 hours or annually, whichever comes first.
Air Filter Cleaning:
Check every 20 hours, clean as needed, replace as needed.
Spark Plug Replacement:
Inspect every 100 hours, replace every 300 hours or as needed.
Transmission Oil Change:
Every 200 hours or annually.
Brake Fluid Flush:
Recommended every 2 years or as needed for performance.
Belt Inspection Pvtt:
Inspect every 50 hours for wear and damage.
Engine Oil Type:
SAE 20W-50 API SG or higher (Confirm in manual, sometimes 10W-40 was specified)
Engine Oil Capacity:
Approx. 2.1 quarts (2.0 liters) with filter change.
Brake Fluid Type:
DOT 3 Hydraulic Brake Fluid
Common Issue 1:
PVT Belt Wear: Early belts could wear prematurely if subjected to excessive abuse or improper adjustment. Regular inspection is key.
Common Issue 2:
Carburetor Gumming: Like many carbureted vehicles of this age, if left to sit without fuel stabilizer, the carb can clog.
Common Issue 3:
Cooling System Leaks: Hoses can degrade over time, leading to coolant leaks.
Common Issue 4:
Starter Solenoid Failure: A common wear item on many electrical systems of this era.
Polarishistory:
Polaris Inc. has a long history in powersports, originating in snowmobiles and expanding into ATVs and motorcycles.
Magnum Series:
The Magnum series was a key line for Polaris in the 1990s, offering a balance of performance and utility. The 425 was a significant step up in engine size for the brand at the time.
Production Years:
Magnum 425 models were produced throughout the mid-to-late 1990s, with variations like 2x4 and 4x4.
Manufacturing Location:
Polaris vehicles are manufactured in the USA.
