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MAGNUM 325 4X4
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Model #A00CD32AA
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Model #A00CD32CA
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Rev. 01
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PARTS MANUAL PN 9914940 and MICROFICHE PN 9916182 9/99
TABLE OF CONTENTS
Magnum 325 4X4 A00CD32AA and Magnum 325 4X4 A00CD32CA
Parts Manual
A G
A-ARM/STRUT MOUNTING . . . . . . . . . . . . . . . . . B12 GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . C10
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 GEARCASE SELECTOR MOUNTING . . . . . . . . . . C11
B H
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11
BREATHER BOX . . . . . . . . . . . . . . . . . . . . . . . . . D12
I
C INTAKE and EXHAUST . . . . . . . . . . . . . . . . . . . . D4
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . D7-8
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . C1
M
CONTROLS - MASTER CYLINDER/BRAKE LINE . B9 MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
CONTROLS - THROTTLE ASM./CABLE . . . . . . . . B8 MAIN GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . C7-8
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . D1 O
CRANKSHAFT and PISTON . . . . . . . . . . . . . . . . . D3
OIL COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
CV JOINT - BTB . . . . . . . . . . . . . . . . . . . . . . . . . . B3
OIL PUMP and OIL FILTER . . . . . . . . . . . . . . . . . . D6
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
P
D PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . D14-E6
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10 PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . B13
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . B14 R
REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . C3-4
E REAR CAB and SEAT . . . . . . . . . . . . . . . . . . . . . A5-6
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . . . . . C2 REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . C9
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . A13-14 REAR RACK MOUNTING . . . . . . . . . . . . . . . . . . . A8
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . A12 REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . C5
RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . D5
F S
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . B7 SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . . . . . C13
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . D10
FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . C6 STEERING POST . . . . . . . . . . . . . . . . . . . . . . . . . B10
FRONT RACK and BUMPER MOUNTING . . . . . . . A9 SWING ARM/REAR GEARCASE MOUNTING . . . . C12
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . B5
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . B6 T
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11 TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1 TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . C14
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
2000 MAGNUM 325 4x4 SPECIFICATIONS
BRAKES ENGINE
Type - Front Hydraulic Disc Engine Model Number ES32PFE01
Type - Rear Hydraulic Disc Engine Type 4 Stroke, Single Cylinder
Type - Auxiliary Hydraulic Disc Lubrication Type Wet Sump
Type - Parking Hydraulic Lock, All Wheel Bore & Stroke (mm) 78x68
Displacement (cc’s) 325
CAPACITIES Compression Ratio 9:2 Full Stroke
Fuel Tank (gallon) 3.75 Cooling Air w/Fan Assisted Oil Cooler
Gearcase Oil (ounces) 400 (ml) Alternator Output (watts) 200
Engine Oil (quarts) 0W40 1.9 Elec. Start w/Recoil Back Up Standard
Engine Counter Balance N/A Carburetors (no. of/size) 1/BST31 (CV Type)
Oil (quarts) Injector N/A Main Jet 142.5
Rack, Front (pounds) 90 Pilot Jet 50
Rack, Rear (pounds) 180 Needle Jet P-0 (829)
Tongue Weight 30 Cut Away N/A
Tow Hitch Standard Pilot Screw 2
Tow Weight 850 Jet Needle 5F14-2
Ignition CDI
DRIVE TRAIN Ignition (Type & Deg. BTDC) 30@3500
Spark Plug Gap (inches) .028
Type Shaft Ride System
Spark Plug (Type) NGKBKR5E
DRIVE CLUTCH Exhaust USFS Appr. Pending
Drive System Type PVT GRAPHICS
Center Distance (inches) 10
Clutch Offset (inches) 1/2 Bumper Caps/Polyprop. N/A
Clutch Weight (grams) 16 MH Cargo Box or Bed N/A
Spring Color Blue/Green Fender, Front Eddie B. Green
Fender, Rear Eddie B. Green
DRIVEN CLUTCH Footwell Black
Frame/Steel Black
Helix Angle Compound Front Cover Eddie B. Green
Outside Diameter (inches) 9.5 Handlebar Cover Black
Spring Position Black 2-2 Headlight/Dash Pod Black
DIMENSIONAL FEATURES Rack, Front Black
Rack, Rear Black
Approx. Turning Radius (inches) 65 Rims Aluminum
Box, Tool Volume (Cu. Inches) 588 Seat Vinyl Sable Brown
Box Dimensions (inches) N/A Side Panel Eddie B. Green
Ground Clearance (inches) 7.25 Spring, Front Black
Height (inches) 46 Spring, Rear Black
Length (inches) 81 Tank Cover N/A
Seat Height (inches) 34 Tool Box Cover N/A
Weight (dry) 620 w/lettering Color
Wheel Base (inches) 49.75
Width (inches) 46
ELECTRICAL
GEARCASE Headlight - Front Hood (watts) N/A
Trans. Number and Type PRD Headlight - Grill (watts) 2 Single Beam/30 W
Shift Type Side Lever Taillight (watts) 12 V/8.26 W
Gear Reduction - Low 7.46/1 Brake Light (watts) 12 V/26.9 W
Gear Reduction - Reverse 5.12/1 Indicator Bulb 12 V/1.0 W
Gear Reduction - High 3.3/1 Battery 12 V/14 AH
Front Drive (ratio) 3.7/1
Final Drive (ratio) 3.1/1 SUSPENSION
Center Drive (ratio) N/A Front Type - MacPherson Strut
Axle to Axle N/A Front Travel (inches) 6.7
Chain Type N/A Rear Type - Progressive Rate Swing Arm
TIRES & WHEELS Rear Travel (inches) 6.5
Shock 2″ Gas Charged Monotube
Tire Manufacturer Titan Adjustment Cam
Tire Size - Front 24x8-12
Tire Size - Rear 24x11.5-10
Tire Size - Center N/A
Tire Pressure - Front 4
Tire Pressure - Rear 3
Tire Pressure - Center N/A
Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.
2000 ATV PUBLICATION NUMBERS
15
14
6 7 16
13
8 17
5
19
9 18
10 12
11
1 4
39
3 40 20
2
41 6 21
38 3
43
37
31 22 23
24
42 36
35
25
34
33 26
32 27
28
29
30
31
A5
REAR CAB and SEAT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A6
FRONT CAB
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1 4
2
12
2 6
8
7
9
11
10
2
6
2
14 13
15
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2632084-195 1 Asm., Panel w/Foam, LH, E.B. Green 9 5431798 1 Guard, Mud, Front, LH
2632101-195 1 Asm., Panel w/Foil, RH, E.B. Green 5431799 1 Guard, Mud, Front, RH
2 7512232 12 Screw 10 7541925 2 Nut, Nylok
3 5432088-195 1 Cover, Front, E.B. Green 11 7555792 2 Washer
4 7670085 2 Clip, Spring 12 7512085 2 Screw
5 2632031-195 1 Cab, Front w/Warning Decals, E.B. 13 7555931 2 Washer
Green 14 7542122 2 Nut, Nylok
6 7670057 10 Nut, U-Type Speed 15 7670088 4 Clip, Dart
7 7670009 2 Nut, Push-on 16 5811489 2 Shield, Deflector
8 7661645 4 Rivet
11/98
A7
REAR RACK MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
5
6
7
10
11
6
10
9 12
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A8
FRONT RACK and BUMPER MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
3
4
8
7
6
14
13
15 12
11 9
10
16
17
18
6
4
19
26
27
20
25 21
24
23
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A9
DECALS
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3 6
4 5 7
8
11
RH
10
14
13 17
12 18
15 16 4 19
LH
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A10
OIL COOLING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3
1 1
2
3
1
1 7
8
4
1
7
5
19 6
9
19 18 15
20
16
15 14
17
15
13
15 1
12 10
21 1
5
11
1 1
12
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A11
EXHAUST SYSTEM
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3
4
5
6
8
7
12
15
9 17
10 12
16
11 13 12
14
10 15
11
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A12
ENGINE MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
9
8 10
3 6 7 11
2
5
4
5
13 12
36
34 35
32 31
32
32
14 15
16
31 33 31
32
30
17
29
5
6 22
23 21
5 24
25
28 26 13 18
27 19 6
5
20
19
A13
ENGINE MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
A14
FUEL TANK
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3 4
6
5 7
8
21
10
19
20
11
18
18
17
17
12
16
15
14
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B1
AIR BOX
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
26
2
5
6
7
25
8
12
24
9
23
10
11
22
12
21 18
13
14
17
20
19
9
16
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B2
CV JOINT - BTB
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
BTB
6
2 3 4 5 8 9 10
1
11
12
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B3
PROP SHAFT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
4
1 5
2
3
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B4
FRONT STRUT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
26
1
25
24
23 2
6
3 7
5
4
22
21
20 10
11 8
4
9
19 18 13
17
12
14 11
16
10
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B5
FRONT WHEEL
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1 2
3 10 11 12 13 14
4
5
6
7
9
15
16
25
24 7 19
6
17
18
20
21
23
22
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B6
FRONT BRAKE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
2 3
4
1
5 6 7
8
13
12
11
9
10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1910271 1 Asm., Front Brake Caliper, LH 6 5410780 1 Ring, Molded Square (.103 x .134)
(Incl. 1-8,10,11) 7 5020506 1 Piston, Caliper
1910264 1 Asm., Front Brake Caliper, RH 8 5910026 1 Insulator, Caliper
(Incl. 1-8,10,11)
9 2200465 1 Kit - Front Brake Pad, General Duty
1 7080352 1 Screw, Bleeder 2200901 1 Kit - Front Brake Pad, Severe Duty
2 7515489 1 Screw, Socket Set 2201149 1 Kit - Front Brake Pad, Soft Duty
3 5131115 1 Caliper, Brake, LH 10 1910265 1 Mount, Caliper
5131116 1 Caliper, Brake, RH 11 5410495 1 Boot, Bushing
1930642 1 Kit - Front Brake Boot
12 5410494 1 Boot, Pin Seal
4 1930665 1 Kit - Piston and Insulator Seal
(Incl. 5-8) 13 ––––––– 4 Screw (See Front Strut Pg. B5, Ref. 7)
5 5410779 1 Ring, Molded Square (.094)
11/98
B7
CONTROLS – THROTTLE ASM./CABLE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B8
CONTROLS – MASTER CYLINDER/BRAKE LINE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
14 13
15
28 12 5
6
27 11
16
26
25
17
22
7
18
24 20 8
19
9
21
22 10
23
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2050078 1 Asm., Master Cylinder (Incl. 1-13) 13 ––––––– 1 Ring, Square, Reservoir
2200809 1 Kit - Master Cylinder Reservoir 14 5411297 1 Boot, Rubber Brake Line
(Incl. 1-3,13) 15 5410988 2 Seal
1 1930797 2 Bolt, Cap 16 4110164 1 Switch
2 1930796 1 Cap, Reservoir 17 1910286 1 Line, Hand Brake, Front
3 1930795 1 Diaphragm 18 7621462 1 Rivet
4 2200808 1 Kit - Master Cylinder Clamp 19 7080539 1 Clamp, Nylon
5 1930799 1 Asm., Master Cylinder Piston 20 8360031-30 1 Conduit, Convoluted
6 1930804 1 Rivet 21 1930752 1 Line, Brake, Left Front w/Fittings
7 2201034 1 Kit - Brake Lever w/Parking Latch 22 7080138 8 Cable Tie
(Incl. 6-9)
8 ––––––– 1 Spring, Flat 23 7512084 2 Screw
9 2201090 1 Kit - Park Brake Lever (Incl. 6,8) 24 8360011-38 1 Tubing, Convoluted
10 1930806 1 Nut 25 1930753 1 Line, Brake, Right Front w/Fittings
11 1930792 2 Bolt, Reservoir 26 7052237 1 Fitting, Cross
12 1930805 1 Bolt, Lever 27 1930816 1 Line, Brake
28 1930674 1 Bolt, Banjo
11/98
B9
STEERING POST
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
16
2
15
14
13
12
5
6 11
10
6
5
7
5
8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B10
HANDLEBAR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
10
4 9
23 7 8 11
12
21
19 20 6
22 5
22
18
13
14
17 14
15
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B11
A–ARM/STRUT MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1 4
5
6
7
2
8
9
3
29
28
27 26 10
11
12
27 21
26 22 13
25 14
23 24 15
22
21 17
18
16
12
19
20
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B12
DRIVE CLUTCH
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
5 8
3 4 7
1 2
6
13 12 10
11
9
5
14
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B13
DRIVEN CLUTCH
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
16
17
15
4
14 5
3
13 6
12
11
10
3 9
8 7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
B14
CLUTCH COVER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2 5
4 6
3
7
8
10 11
12
9
25
13
14
24
23
22 21
20 15
16
19
18
17
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C1
ELECTRICAL/TAILLIGHT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
3 4
1
5
2 6 13
7 14 15
8 16
9 12
34 17
11
10
33 10 11 21 18
22 20
23 19
32
31
30
27
26
28 24
25
29
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C2
REAR BRAKE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
2 9
6 10
3
5
8 11
4
7
12
13
5
14
15
16
19
17
18
7
13
18 19
17
22
5 21 20
30
24
28 27
29
21
27 22
26
19
9
24
25 23
C3
REAR BRAKE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2201189 1 Kit - Brake Pad (Incl. Spacer and Pin) 16 1930854 1 Reservoir, Brake, Rear
2 7515406 2 Screw 17 7080003 2 Clamp, Hose
3 7555806 2 Washer 18 1910331 1 Hose, Reservoir
4 1910270 1 Asm., Brake Caliper, Rear 19 7512240 3 Bolt
5 5410988 6 Seal 20 1012753-067 1 Pivot, Brake Mount, Rear
6 1910286 1 Line, Brake, Front Hand 21 7542122 2 Nut, Nylok
7 1910288 1 Line, Brake, Rear Foot 22 7558301 2 Washer
8 7080573 1 Clamp 23 1012752-067 1 Rod, Brake
9 7517386 2 Screw 24 7555919 2 Washer
10 7080762 3 Clip, Brake Line 25 7661401 1 Pin, Cotter
11 7661048 2 Rivet 26 7556090 1 Washer
12 7080816 1 T-Clip, Dual 27 5433189 2 Bushing, Pedal Pivot
13 1930674 3 Bolt, Banjo 28 7515158 2 Screw
14 7542403 2 Nut 29 1910311 1 Master Cylinder, Foot
15 7542153 1 Nut, Nylok 30 7041750 1 Spring, Torsion
6/99
C4
REAR WHEEL DRIVE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
4
5
1
9
10
8
11 6
7
12
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C5
FRONT HOUSING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
9
10
11 21 2
14 20
12 16 19
15 17 18
13
22
1
8 12 24 23
7 11
5
4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C6
MAIN GEARCASE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
9
6 38
37
40
36 39
7
35
8
9 25 27 41
34 24
33
30
32 9
31
42
30
10 28 43
11
29
12 44
45
13 27
14 26 46
15
47
16 25
48
23 24
17 22 17
18 9
49
54 55 2
19 5 25 51 52 53
50 5
1 56
20
21 58
4 57
66 65 1
64 63
62 61 60 59 5
C7
MAIN GEARCASE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341296 1 Asm., Gearcase, Main (Incl. 1-66) 34 3233533 1 Engagement Dog, H/R, HLR
1 3233248 3 Seal 35 3233600 1 Gear, 30T
2 3233252 17 Screw 36 3233613 1 Spacer
3 3233610 1 Gearcase, LH 37 3233708 1 Gear, Helical, 36T
4 3233529 4 Pipe, Knock 38 3233309 1 Bracket, Interlock
5 3233019 4 Bearing, Ball 39 3233032 1 Spring, Shifting, Interlock
6 3233604 1 Shaft, Input, 31T 40 3233308 2 Pin, Interlock
7 3233036 1 Chain, Silent 41 3233033 2 Screw
8 3233603 1 Gear, 16T w/22T Spline 42 3233709 1 Gear, Helical, 48T
9 3233018 4 Bearing, Ball 43 3233608 4 Screw
10 3233055 2 Nut, FLEXLOC 44 3233609 1 Cover, Bearing, Center
11 3233054 2 Washer, Flat 45 3233106 1 Ring, Retaining
12 3233153 2 Bellcrank 46 3233607 1 Bearing, Ball
13 3233045 2 Ring, Retaining 47 3233606 1 Shaft, 10T, Spiral Bevel
14 3233040 2 Washer 48 3233605 1 Fork, Shift, Low
15 8360009-600 AR Line, Vent 49 3233617 1 Switch, 2 Position
16 3233037 1 Tube, Vent 50 3233620 1 Sprocket, 12T w/18T Spline
17 3233616 8 Screw 51 3233621 1 Gear, Spiral, Bevel, 31T
18 3233615 1 Switch, 3 Position 52 3233622 1 Shaft, Rear Output
19 3233614 1 Gearcase, RH 53 3233582 1 Button, Thrust
20 3233325 1 Plug 54 3233583 1 Shim
21 3233324 1 Washer 55 3233623 1 Cover, Output
22 3233628 1 Washer 56 3233253 1 Plug, Drain
23 3233629 1 Engagement Dog, Low 57 3233254 1 Washer
24 3233306 2 Ring, Retaining 58 3233611 1 Shim
25 3233619 3 Washer, Thrust 59 3233625 1 Shaft, Front Output
26 3233631 1 Gear 60 3233093 1 Sprocket, 12T
27 3233103 2 Bearing, Needle 61 3233626 1 Chain, Roller
28 3233602 1 Fork, Shift, H/R 62 3233552 1 Bushing, Garlock
29 3233598 1 Shaft, Reverse 63 3233624 1 Shaft, Shift, Low
30 3233012 2 Washer, Thrust 64 3233627 1 Shaft, Shift, H/R
31 3233014 1 Bearing, Needle 65 3233548 2 O-Ring
32 3233599 1 Sprocket, 24T 66 3233618 2 Ring, Retaining
33 3233029 1 Ring, Retaining
11/98
C8
REAR HOUSING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
3
7
26
8 25
10
11
12
13 8
15 14
16
17
2
17
16
21 24
18 19 20 22 23 3
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C9
GEAR SELECTOR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3
4
6
10
16 11
7
15
9
10
11
14
12
13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C10
GEARCASE SELECTOR MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2 4
6
5
2
8
2
12 7
6 9
2
11
10
9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C11
SWING ARM/REAR GEARCASE MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
9
10 11
1 12 19
2 13 14
15 18
4 16 17
3
6
5 7 15
8 14 13
38 12 10
36 11
37 9
35
34 20
33 5 21
32 20
28
31
30 29
23 22
25 24
26
27
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C12
SHOCK MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
4
5
7
11
9
10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
C13
TRANSMISSION MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1 2
4
3
5
1
8 5 6
9
7 7
8
11
9
10
2
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
––––––– 1 Asm., Main Gearcase (See Main 6 5242819-067 1 Mount, Rear Transmission
Gearcase Pg. C8 for Details) 7 7517289 4 Screw
1 7515417 2 Screw 8 7552603 4 Washer
2 7547108 6 Nut 9 7515522 4 Bolt
3 7515398 2 Screw 10 5242820-067 1 Mount, Transmission
4 7542321 2 Nut 11 1012960-067 1 Mount, Engine,Rear
5 7555976 3 Washer
11/98
C14
CRANKCASE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
6
5
7
8
3
4
9
2
1
10
11
12
22
21
20
19
13
18
14
15
16
17
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
D1
CYLINDER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
2
1 3
4 5
27
2 1
26
6
6 9 11
7 10
25 8 8
21
12 9
24 22
23
13
14
15
9
14 16
15
20
17
19
18
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
D2
CRANKSHAFT and PISTON
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
4
2
3
4
5 5
14
7
8
16
8
9
10
11
12
13
14
6
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3
2 4
1
2
5 6
6 7 10
7 9
8
11
8
12
19 18
17
20
21
22
16
13
23
14
24
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
D4
RECOIL STARTER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
5
4
3
1 2
6
7
8
15
11
10
12
14
8 13
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
D5
OIL PUMP and OIL FILTER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3
4
6
11
10
9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
D6
CARBURETOR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
1
2
3 52
4
51
5
50
6 7
8
44
45
46
47
9 49 42
48 43
41
10 40
11
39
37
12 36 38
13 12
14
15 35
26
34
27
16 25 33
28
29
24 32
30
31
17
23 22
18
21
20
19
D7
CARBURETOR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3/99
D8
MAGNETO
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
2
1
10
9
11 4
12
13 6
14
7
8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3086483 1 Asm., Ignition Coil (Incl. 1,2) 7 3081657 5 Bolt and Washer
3086484 1 Ignition Coil (If built before 3/1/99) 8 3084973 1 Seal, Oil
3086807 1 Ignition Coil (If built after 3/1/99) 9 3081256 1 Screw and Washer
2 3086463 1 Cap, Spark Plug (If built before 3/1/99 only)
3 3084997 1 Plug, Spark 10 3086464 1 CDI System
4 3084978 1 O-Ring 11 3083073 2 Nut
5 3086460 1 Bearing, Dry 12 3080077 2 Washer, Spring
6 3086458 1 Asm., Plate (Incl. 5,8)(Incl. 9 if built 13 3085521 1 Switch, Magnetic
before 3/1/99 only) 14 3086457 1 Flywheel w/Ring Gear
6/99
D9
STARTING MOTOR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
3
5
1
2
6
7
11
8
11
12
13
10
14
9
15
17
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3 2
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
D11
BREATHER BOX
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
6
5
2 4
5
3
1 7
16 13
8
15
17
14
18
5
7 14
9
23
5
19
22
20
21 13
12
10
11
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1
8
9
4
10
6
11
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3085544 1 Asm., Tool Kit (Incl. 2-7) 7 2690016 1 Pouch, Tool Kit
1 2870725 1 Gauge, Tire Pressure 8 2871515 1 Lube, U-Joint, 3 oz., Case
2 3085001 1 Wrench, Open 8-10mm 9 9915299 1 Owner’s Manual, ‘00 ATV
3 3085002 1 Wrench, Open 12-14mm 9914939 1 Supplement, Owner’s Manual, ’00
Magnum 325 4x4
4 3085567 1 Wrench, Box
5 3085569 1 Puller, Spark Plug (Wrench Handle) 10 2871095-067 1 Wrench, Spanner, Cam
6 3082657 1 Screwdriver 11 2460442 1 Pigtail, Power
11/98
D13
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
D14
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
E1
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
E2
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
E3
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
E4
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
E5
PART NUMBER INDEX
MAGNUM 425 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
Part Ref. Grid Part Ref. Grid Part Ref. Grid
No. No. No. No. No. No. No. No. No.
E6
In order to better serve you, this postage-paid mailer is
provided for your convenience to report an error or or FAX your report to:
relay a suggestion relative to any Polaris Publication. 218-463-4580
Name
Company
Address
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– Mailing Instructions –
Please fold the top portion down first then fold the bottom portion up second so the
open edge is located at the top. Tape the open edge.
4/94 Rev. 04
9912263
NO POSTAGE
NECESSARY IF
MAILED
IN THE UNITED
STATES
Name
Company
Address
City, State, Zip
– Mailing Instructions –
Please fold the top portion down first then fold the bottom portion up second so the
open edge is located at the top. Tape the open edge.
4/94 Rev. 04
9912263
NO POSTAGE
NECESSARY IF
MAILED
IN THE UNITED
STATES
Name
Company
Address
City, State, Zip
– Mailing Instructions –
Please fold the top portion down first then fold the bottom portion up second so the
open edge is located at the top. Tape the open edge.
4/94 Rev. 04
9912263
NO POSTAGE
NECESSARY IF
MAILED
IN THE UNITED
STATES