Reviving a 1995 Polaris Magnum 425 4x4 - Is it worth it?

[lbdrummer3]

This beast is quickly becoming a money pit...  Need folks input on deciding to make it run or sell it off for parts.

Background.  It's been sitting in my neighbors yard in Wyoming for an unknow number of years, at minimum, 5+ probably more.  The oil filter was last changed in 2007 if that's any indication.  It's been beat to hell, probably died and left to rot.  They were just happy to get rid of it.  

The first thing I did was checked for spark.  Figured out that the left handlebar grip switch was grounding the ignition out, fixed it and we have spark again.  Rebuilt the carb and flushed the fuel system.  In cranking it over by hand, I could tell it had great compression.  The 3 magic item to make her run.  I got a new battery, sprayed a little starting fluid down the airbox and she fired right up!  Ran it for a while and it doesn't want to rev out on the top end, more on that later.   It didn't even smoke either and I'm getting excited at this point! 

Next was the transmission, will it move under its own power?  This is where my excitement ended. The output shaft turns on the transmission side and just outside of where the sprocket goes, it is cleanly severed.  Also, when I put it in reverse, the engine dies.

Here are the things that I know are wrong with it.

1. Critical, Output shaft is broken.  Does anyone know where I can get an aftermarket output shaft?  Guessing Polaris would be pretty proud of that part if they even make it anymore.  I looked on the net for one and couldn't find anything.  Also, does this have a type I, II or III trans?  I think it is a Type III
2. Critical, Shifting into reverse kills the engine.  Could be indicative of the shifter being worn out.  I think I saw a work around for that on Youtube.
3. Critical, Cooling fan is toast.   It appears to be a sealed unit, tried looking to see if I could get it apart and I can't figure it out.
4. Front frame under the luggage rack is bent and also a down tube broken at the weld.  My family has 2 welders in it so no problem there.
5. Handlebar on off switch doesn't shut the engine off but it does turn off by using the key.
6. Critical, Gas tank is cracked, I repaired it with 2 part epoxy but that is probably a temporary fix so I may need a new tank if I keep it.
7. Critical, All of the chains are shot and need to replaced.
8. None of the dash lights work.  The light in the right 4WD handlebar switch doesn't work.
9. Missing the speedo and cable doesn't turn (not a big deal)
10. No title on it.  Not planning to go on public land though, just need a ranch quad.
11. Seat needs to be recovered.
12. Missing left side cover.
13. Rear rack is bent and broken in several spots.
14. Rear shock is pretty springy for the first several inches of travel before the oil dampens things out.
15. Critical, Engine doesn't rev out on the top end.  Starts popping and just wants to stall, could be running lean.  The clip on the needle was in the top most position though.

Things untested.

1. Critical, Don't know if the lockers on the front wheels even work.  When I hit the 4WD button, nothing happens but that could be because of the output shaft being broken.
2. The electrical system has been monkeyed with.  There is a sensor on the driver side of the cylinder with a wire coming out of it and nothing to plug into.  
3. The thermostat wires are disconnected from the main board and one side is just cut.
4. The wires to the fan were cut and a manual switch was installed to turn it on and off.  
5. Not sure what wheel bearing surprise I may find.
6. What else could be wrong inside of the tranny once I get it apart.

So far, I've just bought a battery, a new diaphragm for the carb, and an oil filter so not into it for very much.  I just need a working quad to haul stuff around my 21 acres.  It doesn't have to be pretty, just needs to work.  I am mechanically inclined and could probably rebuild the transmission myself.  I've seen some older Yamaha Warriors, Honda Formans, and Yamaha Big Bears for $1500 from time to time, sometimes a little less but the all need some love.  Is fixing all of the 7 critical problems on this going to end up costing more than I could buy something else in better shape for.  I'm not opposed to cutting bait on this thing and moving on.  The only good things is the engine runs and doesn't smoke and the tires are good and holding air.

Thanks for your input.

[Saskatchewaner]

As a fellow cattleman, I would try to find a Magnum 425 6x6 with a blow motor and drop yours in. The extra axle with the dump box is an amazing thing on the farm, I believe they're rated to haul like 900lbs. Also if you want them to do work with they go OVER pretty much anything. They don't really dig through the mud, they just drive right over it. That being said, they're no fun to play in the mud/etc. because they just drive over it.

On a tangent, my Magnum 6x6 also came with a manual switch installed for the fan. I'm currently working on fixing that and trying to see if the fan is actually working good enough. Half thinking of dropping one in from a small car.

Sorry I couldn't be more help.

[lbdrummer3]

I've been thing about a 6x6 too.  The back of my property along the fence line is all drainage so you sink to you ankles just walking though it and the fence needs some love this year.  One came up on FB marketplace a few months back for free, ad was up for 3 minutes before I replied I'll take it and it was already claimed...  You've given me a good idea though, finding something with a blown up motor might work out.  

Does anyone know if the 95 motor will interchange with any other years?  That would give me more options.

[lbdrummer3]

Spent some time looking for an output shaft and they are $450 bucks and nobody has any in stock.  Hell I don't think this quad is worth that much.  I also think that 1995 is an odd ball year.  I found a cross-reference chart for the cases and they only fit 1995 Magunums.

[Lafytafy]

you can find a lot of oem parts on partzilla or ebay thats how  get mine

 

[lbdrummer3]

I found a complete gear box used on ebay for 500, which is pretty much what Polaris wants for just the shaft.  Will check partzilla.  Thx.

 

[Gwbarm]

Just did a quick search there is only one for sale in my area at $3750, I would do it , but I like bringing things back.  I use Rockymountain ATV along with partzilla whoever has the best price.

[lbdrummer3]

Thanks for the heads up Gwbarm, checked bother and neither have an output shaft.

 

[Saskatchewaner]

So it looks like that was the first year of the 425 motor, lists as motor # EH42PL01. Until at least 1998 they still made a 425 but it lists as motor #EH42PLE01 until 1997 and then EH42PLE02 in 1998. I have no idea what the difference is between the 95 motor and the E is? I would assume the 98 has some form of major difference.