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!

 

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

 

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!

 

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.

 

Where is this reverse limiter located? Thanks for the good info!

 

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..

 

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!

 

These are dealer parts along with the float arm and float pin. Diaphragms aren't usually a problem,but hold the slide up to light and check the diaphragm for wear spots or cracks. If the float arm is wobbly,I'd replace the float arm and pin.They're not that expensive.The nipples on the side of the carb,one is for the fuel pump vacuum line,the other an atmospheric vent. Look on the right upper frame behind the carb. Could be a hole. On some models the vent line went from the nipple to the the frame hole. If there isn't a hole, you can run the line through the hole in the right fuel tank mounting bracket.That's where most of them terminated.

 

I know the 98 magnum like not too many do make sure to keep on maintenance or you'll pay for it. Carbs are touchy they like to backfire nothing to do with carb make sure you have air filters oil properly. Start with a washed pre filter then lightly oil and try if runs awesome good if not and backfires keep adding light amounts of filter oil until it stops payed thousands in trying to figure that out at the shop you shouldn't need a fuel pump unless diaphragm is majorly stretched or ripped .Always run non oxygen 91 gas and don't turn fuel shut off on and off or yjy will be replacing that lots I've always been able to leave on on all my rides if you can't leave on cause it carb leaks you have carb problems need fixing. And make sure bottom screw on carb bowl turn open to drain setiment every so often to keep carb clean when you turn screw to close turn till it just stops leaking have to where it almsot starts leaking constantly .