1998 Polaris 4x4 Magnum 425
I need to revive a Polaris 425 Magnum(1998) model. I need to know how to check and do a complete service job with filters, oil,lubrication etc... Also Where to purchase a carburetor & fuel pump. Has been sitting for 2 years. Thanks for any info on doing this right!
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Sitting for two years, at least a fresh tank of fuel and probably have to go through the carb. DON'T get one of cheap Chinese knock off carbs. Pull the fuel line from the carb and crank the engine over. If the fuel pump is ok should have a steady stream of fuel.Cheap fuel pups are on ebay,amazon if needed.If you have to pull the carb install a rebuild kit and make sure all passage ways are blown out.https://www.ebay.com/itm/Polaris-Mag...9UvqQ6&vxp=mtr The cheap 5 buck manual can help you on the carb rebuild along with service,help on any repairs needed,along with fluids and quantity.1998 Polaris Magnum 4X4 Service Manual PDF Download
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Got the manual, lots of good info! Are there any substitutes for the "special" fluids that the manual calls for? What are some common issues/pattern failures that I need to look out for when checking this unit over? Thanks Again!
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You can stray from the 0w40 oil mentioned to the newer Polaris engines that use 5w50,etc. Since there's no wet clutches to worry about,oil choices are basically unlimited,that is within reason. You can stay with Polaris branded oils,all brands of cycle/atv specific oils,as well as oils such as Mobil 1,Amsoil atv oil or as many have done,Rotella T6 which is a heavy duty synthetic diesel oil but also jaso rated which means suitable for motorcycle/atv use. The filter called for is basically a "universal" size oil filter used in many cycle,atv,etc applications. This filter can be crossed over to may different brands.
POLARIS 3084963 - Alternative oil filters Replacement oil filters for POLARIS 3084963: Brand Model AC-Delco PF2135 AMSOIL EAOM103 ARCTIC CAT 3201-044 ARCTIC CAT 3201-451 AUTOEDGE AL6017A Baldwin B1400 Baldwin B7285 CARQUEST 85358 CARQUEST 85365 Champ PH2876 Champ PH7015 Champ PH7028 DENSO 115010-5390 Donaldson P502067 EMGO 10-26920 EMGO 10-82230 EMGO 10-82251 Fleetguard LF3925 Fram PH6017A HASTINGS B7285 HASTINGS LF113 HIFLO HF198 HIFLO HF204 HIFLO HF303 Honda 15400-P0H-305 Honda 15400-P0H-305PE Honda 15400-PFB-004 Honda 15400-PFB-007 Honda 15400-PFB-014 Honda 15400-PJ7-015 Honda 15400-PLM-A01PE Honda 15400-PM3-405 Honda 15400-POH-305 Honda 15400-POH-305PE Honda 15400-ZJI-004 Honda 15400-ZW4-003 Honda 15410-MCJ-000 Honda 15410-MCJ-003 Honda 15410-MCJ-505 Honda 15410-MFJ-D01 Honda 15410-MM5-013 Honda 15410-MM9-003 Honda 15410-MM9-013 Honda 15410-MM9-405 Honda 15410-MT7-003 K & N KN-198 K & N KN-204 K & N KN-303 K & N KN-303C KAWASAKI 16097-0002 KAWASAKI 16097-0003 KAWASAKI 16097-0004 KAWASAKI 16097-1058 KAWASAKI 16097-1061 KAWASAKI 16097-1063 KAWASAKI 16097-1064 KAWASAKI 16097-1066 KAWASAKI 16097-1067 KAWASAKI 16097-1068 KAWASAKI 16097-1070 KAWASAKI 16097-1072 Kubota 15853-32430 LUBER-FINER PH2876 LUBER-FINER PH7015 LUBER-FINER PH7028 Mann Filter MW64 MELROE 6671057 MERCRUISER 35-822626 MERCRUISER 35-822626Q04 MERCRUISER 35-822626Q1 MERCRUISER Q03 MERCURY 35-8222626Q03 MERCURY G590000-G760299 MERCURY G760300-1B226999 MERCURY P086824-P325499 NAPA 1358 NAPA 1365 NAPA PS1358 Nissan 3R0076150M Parts Master 61358 POLARIS 2520799 POLARIS 2540086 POLARIS 3084963 POLARIS 3089996 Purolator ML16817 Purolator ML16819 ROBIN 2576730111 SIERRA 18-7902 SIERRA 18-7909 SIERRA 18-7910 SIERRA 18-7911 SIERRA 18-7911-1 SIERRA 18-7913 SILVERLINE 21358 STP PH7028 Suzuki 16097-1072 TOHATSU (Marine) 3R0076150M TRIUMPH MOTORCYCLE T1210200 TRIUMPH MOTORCYCLE T1210444 WARNER PH7015 WESTERBEKE 30220 Wix 51358.... My two cents worth,one of the best.. Wix 51365 YAMAHA 3FV-13440-00 YAMAHA 3FV-13440-00-00 YAMAHA 3FV-13440-10-00 YAMAHA 5DM-13440-00 YAMAHA 5GH-13440-00 YAMAHA 5GH-13440-00-00 YAMAHA 5GH-13440-10-00 YAMAHA 5GH-13440-20-00 YAMAHA 5GH-13440-50-00 YANMAR The main Polaris oils I'd stay with are the AGL gear case lube and Demand Drive Plus hub fluid for use in centralized and hub awd systems. As far as what to check,the hub awd system first. If you are able to jack the front and rear end up (after you do a fluid change shown in the manual) check that the front wheels kick in while in awd mode. If the don't could be an electrical problem. If only one side kicks in,could be a mechanical or electrical problem on one side. The manual goes into fairly good detail on the awd system. If you have problems on running right,low power,popping back,that could be a limiter module problem. Pull the black wire from the reverse limiter at the terminal board anyway.They always fail. If it continues to have problems,make sure the valve clearance is set right,plus check the cam exhaust lobe for wear. This model was in the year range of soft heat treatment on cams. You may be lucky on that one as not all machines were affected. |
Reverse Limiter Location
Where is this reverse limiter located? Thanks for the good info!
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1 Attachment(s)
Item#17.Terminal board is on the r/h side at the top.Or may be in the center of the panel. Doesn't really show on this model and I can't remember off hand..
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Looking at the carburetor, I see there is a diaphragm in the top part, should that be replaced, or is that a high failure part? Just a quick look at the kit, there doesn't seem to be a diaphragm included in the kit. Also, on the recoil starter side of the carb, there is a brass fitting that is open to the atmosphere,pointing to the rear, that looks like there was a hose on it at one time. What goes on that fitting? Again, Thanks!
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1 Attachment(s)
Originally Posted by texczech
(Post 3380292)
Looking at the carburetor, I see there is a diaphragm in the top part, should that be replaced, or is that a high failure part? Just a quick look at the kit, there doesn't seem to be a diaphragm included in the kit. Also, on the recoil starter side of the carb, there is a brass fitting that is open to the atmosphere,pointing to the rear, that looks like there was a hose on it at one time. What goes on that fitting? Again, Thanks!
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Originally Posted by texczech
(Post 3380114)
I need to revive a Polaris 425 Magnum(1998) model. I need to know how to check and do a complete service job with filters, oil,lubrication etc... Also Where to purchase a carburetor & fuel pump. Has been sitting for 2 years. Thanks for any info on doing this right!
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