97 425 magum 4x4 Refurbish :P

[venix12]

Hey guys, im new here but I figured I'll be around quite a bit.... I just picked up a 97 425 magnum that needs a bit of work.

I got to test drive the bike before I bought it but it does have a nice list of issues :0

-Doesn't seem to be charging the battery. It has no pull start, just electric and after I boost the bike and get it going it will run. But when i go back to drive it or start it again , theres usually not enough power in the battery to turn over the motor.

- The AWD isnt working,

**-High, and low seem to work fine, Reverse makes a horrible noise if you give it gas when its in R. You can shift to reverse without any noises or stiffness, and if you reverse with very very little throttle it will slowly backup with no noises, but if you had to backup a hill or you actually backup at a normal speed it makes sort of a grinding noise. (transmission issue?????? i can get a whole 400 scrambler parts bike dirt cheap if the parts interchange)

-also if i press the reverse over-ride it seems to have no effect . (maybe the previous owner had it removed)

I'll try and get some pics up over the next couple days any help or advise would be greatly appreciated.



oh yeah last thing... i need a clutch case, as mine is cracked... i know someone who has one from a 400 sportsman.... would that clutch case and backplating fit my bike?


Thanks again

[4getful2]

the outer clutch cover should fit ,but the inner will not,2 stroke to four stroke inners are not the same.
the transmission are different on the scramblers,you have low range. if you live close i might be interested in that scrambler parts bike.

[venix12]

im in atlantic canada... probably a bit far for you. He only wanted 300 bucks for the bike, it was a 96 scrambler... guess it not good for me.

My 425 magnum would be a 4 stroke i'm pretty sure and so are the 400 sportsman's ( or maybe they aren't)... i dont mix my gas/oil.

[atvjunkie821]

I feel your magnum pain! Sounds like you need to adjust your shifter linkage out a little for reverse. Does the AWD light come on when the button is pressed in? Check voltage when running at battery. Should be around 14 volts, If not you might need a regulator But I'd check the wires good for connections.

[cam101311]

yea rebuilt magnum here too.....as far as your clutch cover...ebay has a ton of them 50 to 100 bucks ive been looking at one for my wifes xplorer 400.

[venix12]

hey guys, im thinking im going to have to pull the tranny in the beast....... anyone know of an online thread or guide with photos?..... how easy is is to take out.... remember mines a 97 425 (chain driven)


thanks

[atvjunkie821]

I've had mine out, twice! Not too bad it just takes time. I don't have any pic of the procedure though, sorry. I can give you tips to help if you need.

[venix12]

hmmm.... Well my reverse is works, but it grinds under any load at all.... anyone familiar with these trannys know what could be wrong...... would it be worth just trying to find another tranny instead of cracking mine open?

Also if anyone could point me to which tranny's would fit in my back , it would be greatly appreciated.... im guessing sportsmans, xplorer, and magnum 97 and under? would it matter what engine size bike the tranny comes from?

[atvjunkie821]

Originally Posted by venix12

hmmm.... Well my reverse is works, but it grinds under any load at all.... anyone familiar with these trannys know what could be wrong...... would it be worth just trying to find another tranny instead of cracking mine open?

Also if anyone could point me to which tranny's would fit in my back , it would be greatly appreciated.... im guessing sportsmans, xplorer, and magnum 97 and under? would it matter what engine size bike the tranny comes from?

The 400l and trail blazer models will fit too. Any chain drive Polaris trans 4x4 with low range is the same.