6 Common Polaris Magnum 425 4×4 Problems (With Solutions)

The Polaris Magnum 425 4×4 is a powerful ATV designed for off-road performance. 

Unfortunately, many owners have experienced problems with this ATV. 

If you own a Polaris Magnum 425 4×4 or are considering purchasing one, familiarizing yourself with these common problems can help you fix them quickly if they arise.

Let’s get started!

Polaris Magnum 425 4×4 Problems

Polaris Magnum 425 4x4 Problems

1. Transmission Problem

Transmission problems are one of the most common problems experienced by owners of the Polaris Magnum 425. 

This is usually caused by a lack of lubrication or debris blocking the transmission.

The symptom of this problem is the shifter lever won’t budge at all after being left overnight. This can be due to moisture seeping into the shifter handle housing and causing it to become “locked up”. 

To fix this, you should check the shifter handle housing for water and then change both the transmission oil and gear case oil with thinner oils specifically designed for ATVs.

Another cause of transmission issues is when debris accumulates inside the transmission, which prevents it from properly shifting gears. 

Again, changing out your transmission oil and gear case oil with thinner oils will help reduce this issue over time. 

Also, performing routine maintenance on your ATV will ensure your ATV remains running.

If you are unable to troubleshoot yourself, it may be time to take it to the dealer because he can fix this problem correctly.

2. Starting Problem

Starting problem is also common in this ATV. The most common problem is due to the starter motor not receiving enough voltage. 

This can be due to a faulty battery, corroded or worn-out wiring, or a faulty starter solenoid.

To check for these issues, start by inspecting the wiring harness and connections to the starter and battery. Make sure all wires and terminals are securely fastened and if any corrosion is present use a wire brush or emery cloth to remove it. 

Then check that the battery is providing adequate voltage (at least 12V) when cranking the engine. If not, replace the battery.

If everything appears okay but it still isn’t starting, then you may need to replace the solenoid or starter itself. 

If that’s the case, you should take your ATV to the dealer.

Also, other causes of starting problems can be clogged fuel lines, clogged air filters, incorrect spark plug gap settings, or fouled spark plugs. 

All of these are relatively easy fixes but should be fixed as soon as possible.

3. Fuel Pump Problem

The fuel pump problem is one of the most frustrating issues for Polaris Magnum 425 4×4 owners. 

A faulty fuel pump can cause a variety of symptoms, in which poor performance and hard starting or even stalling are included.

The most common cause of a failed fuel pump is due to failure of its internal components, such as seals, valves, or diaphragms that are designed to maintain proper pressure in the system. 

These components can become worn over time due to high heat or vibrations. 

Also, debris within the system can accumulate and restrict fuel flow, causing similar symptoms.

To fix this problem, you should begin by inspecting all the hoses and connections between the tank and engine for any signs of cracks. 

If no physical damage is present it may be necessary to check your ATV’s manual for specific procedures for testing your vehicle’s electrical systems in order to determine if there is power being sent from the battery through the wires going to your fuel pump.

If you suspect that your Polaris Magnum 425 4×4 is experiencing an issue with its fuel pump, it would be best to take it to a dealer who will have specialized knowledge on how to handle this type of repair safely. 

They will also be able to replace any damaged parts quickly while ensuring they are properly sealed.

4. Sputter and Backfires at Higher Speed

Sputtering and backfiring at higher speeds are among the common problems of this ATV. 

The most common cause of this issue is due to a faulty spark plug or worn-out wires, which can cause misfires as the engine RPMs increase. 

To fix this problem, you should check the spark plug gap and replace it if you think the current one is faulty. You should also inspect the wires for any signs of damage or corrosion and replace them if needed.

Another possible cause can be an air-fuel mixture that is too rich or too lean. When this happens, it can cause sputtering and backfiring at higher speeds due to an incorrect fuel-to-air ratio in the combustion chamber. 

To fix this, you will need to adjust the carburetor settings on your ATV until you find the correct balance between fuel and air.

A bad ignition coil can also cause this problem by failing to produce enough voltage to fire the spark plugs correctly. 

To solve this, you should use a multimeter to measure each coil’s resistance when heated up. 

If one of your ignition coils shows a low reading then you need to replace that coil.

5. AWD Stopped Working

Many owners reported in various forums that their ATV AWD stopped working. This issue is mostly due to worn-out parts, lack of lubrication, or electrical issues. 

Common symptoms include hard starting, poor performance at higher speeds, or the ATV not engaging in AWD mode.

One possible cause for AWD not working is a faulty Hilliard clutch. The Hilliard clutch is responsible for transferring power from the engine to the rear axle when AWD is engaged. 

To fix this issue you should first check that all bearings and spacers are in place and tighten any loose nuts and bolts. 

Then rotate the axle while engaging the AWD mode to observe whether the magnet attracts the armature plate, which will provide resistance when it contacts the magnet. 

If it does not move then you should replace your Hilliard clutch.

Another cause of this issue is a lack of lubrication in the drivetrain system. Over time dirt and debris can accumulate in the drivetrain and reduce its efficiency if it’s not regularly cleaned and oiled. 

To prevent this from happening, you should inspect your entire drivetrain on a regular basis and make sure everything is clean and lubricated. 

Electrical issues can also stop AWD from working due to wiring connections or power supply problems. You should start by checking all wiring connections between the starter and battery to make sure they’re securely fastened. 

You should also make sure that your battery provides adequate voltage when cranking your engine; at least 12V is required for proper operation.

6. Reverse Gear Problem

Some owners also reported that their ATVs produce clunking noise when they put them in reverse. 

It is due to damage to the drive chain or gears.

In order to solve this problem, you should first inspect all of the parts located in the transmission. This includes checking for signs of wear or corrosion on both the chains and gears, which could indicate that they need to be replaced. 

Also, if there are any loose bolts or other hardware problems then these should also be addressed before continuing with any repairs.

After this has been done, you may find that your reverse gear runs more smoothly without making unwanted noises. 

If not, then you may need to consider replacing other components inside your transmission such as bearings and seals.

Is Polaris Magnum 425 4×4 Worth Buying?

The Polaris Magnum 425 4×4 is a great choice for anyone looking for an ATV that is reliable and easy to maintain. 

The four-wheel drive system makes it very capable of tackling rough terrain, which means you don’t have to worry about getting stuck in mud or sand. 

One advantage of the Magnum 425 is its power. It has a powerful engine with enough torque to easily move heavy loads. 

Because of these great features, we can say this ATV is worth buying.

What Users Say About Polaris Magnum 425 4×4 ATV?

A lot of users said that this is a reliable all-terrain vehicle. Many owners praise its impressive power and acceleration, noting that it can quickly climb hills and traverse tough terrain with ease. 

They also appreciate the smooth ride quality, comfortable seating position, and adjustable suspension system. 

Also, some users comment on the low maintenance costs compared to other ATVs. 

Overall, most users are very satisfied with their purchase of this model ATV from Polaris.

Here are some reviews of this ATV users.

“I’m loving this atv, after fixing some of the problems it is holding up very well! Just need some new tires soon and replace the front shocks (they are leaking) (and maybe a DG exhaust and uni or k&n air filter) it will be a close to flawless machine!!”

“They’re excellent four wheelers. I have two of them. Easy to work on, good solid machines. And I like the solid rear axle. My oldest one has 5600 miles on it and going strong. I bought it in 1998, and have never had a serious maintenance issue with it. You take care of yours, and it’ll take care of you.”


The Polaris Magnum is a powerful ATV that can tackle any terrain. Unfortunately, some riders have experienced problems with this ATV. 

These are difficulty in changing gears, starting, backfiring, AWD, and reverse gear noise problems. 

If you are experiencing any of these problems, you should fix them quickly. 

We hope this article has been helpful to you. If you have any questions or comments about the ATV, please leave them in the comment section below. 

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