Hello all, i am new to the forum and will likely be back several times. I have ridden quads before but never owned one... till now. I just bought a 1996 Polaris Magnum 425 4x4. The output shaft that drives the front chain sheared off and needs replacement. It needs a few maintenance things but I have bought most everything I need. Runs good and will be fun to fix it up.

Well, I got it cranking over! Went to AutoZone and they were able to cross the OE relay ($40 on amazon) to Duralast part #19829 for $11.99. HOWEVER, turns out it's corroded wiring connections in the starter switch. Gonna go ahead and keep the new relay in it and keep the old one as an emergency backup. As far as washing all the grime off, I cleaned the exterior,the tool compartment (still has the factory tools and pouch), the battery compartment, and the entire seat. Lots of dirt, leaves and countless spiders; almost considered burning it over that last one. I also pulled and cleaned the fuel tank cover, front fender cover and handle bar cover. Eventually, I'd like to pull the rest of the body off and clean the undersides of all that, as well as power wash the engine and chassis. But that's later down the road.. when it's warmer. lol I do plan on going through much of the wiring to check for damage and wear, as well as check, clean and grease as many of the connections as I can. I do plan on putting some brighter lights on it, and possibly converting the existing ones to LED.

Good. That’s the first thing I do is wash the filth off! I always pull the plastics as well. With regard to wiring any help you may need let me know. I just spent the last few days absorbing the wiring manual for that bike. Should be a good machine when you get it all back together!

If I remember correctly, the driveshaft just slips off the bevel gear shaft. Just have to loosen the clamp on the boot. No need to take anything apart on the bevel gear housing. Just remove it from the engine. It's been a while since I did this so I checked the SM and you don't have to worry about getting into the tranny. The part on the end of the shift drum is accessible when you take the switch off. I'd check that part first before you order any parts. It's possible that the contact pin on that part is stuck. Kaw calls that part reverse stopper.

Welcome to QUADCRAZY, you'll be able to download our manuals once you hit 10 posts or content items, which happens pretty quick with some replies to topics or comments around the site.

Only need 2 more posts to unlock the cheat code...lmao

I love the old bikes! Easy to work on for the most part. Repairs are usually not costly and if they are maintained they can run forever. Just picked up a 1998 bayou 220 today for a really good price.

I think only you can decide if it is worth it or not .. Can you do the repairs yourself? What will the parts cost? how does the quad run? Motor ,transmission and tires good? Other quads around for comparable price that may be in better condition/ need less work on them? I never let the year bother in my decisions if the motor and transmission are fine . My own Quad is a 1991.