2000 Polaris Magnum 325 Parts Manual

PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00 MAGNUM 325 4X4 Model #A00CD32AA Model #A00CD32CA 325 MAGNUM 4X4 HDS Model #A00CD32FA 325 MAGNUM 4X4 HDS II Model #A00CD32FB Rev. 02 E 2000 Polaris Sales Inc. Downloaded from www.Manualslib.com manuals search engine

TABLE OF CONTENTS Magnum 325 4X4 A00CD32AA and Magnum 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB Parts Manual A A- ARM/STRUT MOUNTING B13 ................. AIR BOX B3 ............................... B BREATHER BOX D14 ......................... C CARBURETOR D9-10 ........................... CLUTCH COVER C3 ......................... CONTROLS - MASTER CYLINDER/BRAKE LINE B10 .. CONTROLS - THROTTLE ASM./CABLE B9 ........ CRANKCASE D3 ............................ CRANKSHAFT and PISTON D5 ................. CV JOINT - BTB B4 .......................... CYLINDER D4 .............................. D DECALS A10 ............................... DRIVE CLUTCH B14- C1 .......................... DRIVEN CLUTCH C2 ......................... E ELECTRICAL/TAILLIGHT C4 ................... ENGINE MOUNTING B1-2 ....................... EXHAUST SYSTEM A13 ....................... F FRONT BRAKE B8 .......................... FRONT CAB A7 ............................. FRONT HOUSING C8 ......................... FRONT RACK and BUMPER MOUNTING A9 ........ FRONT STRUT B6 ........................... FRONT WHEEL B7 .......................... FUEL PUMP D13 ............................. FUEL TANK A14 ............................. G GEAR SELECTOR C12 ........................ G GEARCASE SELECTOR MOUNTING C13 ........... H HANDLEBAR B12 ............................ I INTAKE and EXHAUST D6 ..................... M MAGNETO D11 .............................. MAIN GEARCASE C9 ......................... MAIN GEARCASE C10 ........................ O OIL COOLING (If built after 1/1/00) A12 ............ OIL COOLING (If built before 1/1/00) A11 ........... OIL PUMP and OIL FILTER D8 .................. P PROP SHAFT B5 ............................ R REAR BRAKE C5-6 ........................... REAR CAB and SEAT A5-6 ..................... REAR HOUSING C11 .......................... REAR RACK MOUNTING A8 ................... REAR WHEEL DRIVE C7 ...................... RECOIL STARTER D7 ........................ S SHOCK MOUNTING D1 ....................... STARTING MOTOR D12 ........................ STEERING POST B11 ......................... SWING ARM/REAR GEARCASE MOUNTING C14 ..... T TOOL KIT E1 ............................... TRANSMISSION MOUNTING D2 ................. The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. Downloaded from www.Manualslib.com manuals search engine

2000 MAGNUM 325 4x4 SPECIFICATIONS BRAKES Type - Front Type - Rear Type - Auxiliary Type - Parking Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic Lock, All Wheel CAPACITIES Fuel Tank (gallon) Gearcase Oil (ounces) Engine Oil (quarts) 0W40 Engine Counter Balance Oil (quarts) Injector Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight 3.75 400 (ml) 1.9 N/A N/A 90 180 30 Standard 850 DRIVE TRAIN Type Shaft Ride System DRIVE CLUTCH Drive System Type Center Distance (inches) Clutch Offset (inches) Clutch Weight (grams) Spring Color PVT 10 1/2 16 MH Blue/Green DRIVEN CLUTCH Helix Angle Outside Diameter (inches) Spring Position Compound 9.5 Black 2-2 DIMENSIONAL FEATURES Approx. Turning Radius (inches) Box, Tool Volume (Cu. Inches) Box Dimensions (inches) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (dry) Wheel Base (inches) Width (inches) 65 588 N/A 7.25 46 81 34 620 49.75 46 GEARCASE Trans. Number and Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type PRD Side Lever 7.46/1 5.12/1 3.3/1 3.7/1 3.1/1 N/A N/A N/A TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center Titan 24x8-12 24x11.5-10 N/A 4 3 N/A ENGINE Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc’s) Compression Ratio Cooling Alternator Output (watts) Elec. Start w/Recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Pilot Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust ES32PFE01 4 Stroke, Single Cylinder Wet Sump 78x68 325 9:2 Full Stroke Air w/Fan Assisted Oil Cooler 200 Standard 1/BST31 (CV Type) 142.5 50 P-0 (829) N/A 2 5F14-2 CDI 30@3500 .028 NGKBKR5E USFS Appr. Pending GRAPHICS Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color N/A N/A Eddie B. Green Eddie B. Green Black Black Eddie B. Green Black Black Black Black Aluminum Sable Brown Eddie B. Green Black Black N/A N/A ELECTRICAL Headlight - Front Hood (watts) Headlight - Grill (watts) Taillight (watts) Brake Light (watts) Indicator Bulb Battery N/A 2 Single Beam/30 W 12 V/8.26 W 12 V/26.9 W 12 V/1.0 W 12 V/14 AH SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment MacPherson Strut 6.7 Progressive Rate Swing Arm 6.5 2 Gas Charged Monotube Cam 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. Downloaded from www.Manualslib.com manuals search engine

2000 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER’S MANUAL OWNER’S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS Magnum 325 4X4 A00CD32AA 9915299 9914939 9914940 9916574 9914942 Magnum 325 4X4 A00CD32CA 9915299 9914939 9914940 9916574 9914942 325 Magnum 325 4X4 HDS A00CD32FA 9915299 9914939 9914940 9916574 9914942 325 Magnum 325 4X4 HDS II A00CD32FB 9915299 9914939 9914940 9916574 9914942 Downloaded from www.Manualslib.com manuals search engine

A5 REAR CAB and SEAT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 28 27 2 7 3 6 9 10 14 13 15 16 17 42 41 12 19 20 21 36 5 33 44 45 1 43 39 11 4 40 18 3 35 37 34 8 30 26 38 29 6 23 22 25 31 24 32 33 E 2000 Polaris Sales Inc. Downloaded from www.Manualslib.com manuals search engine

A6 REAR CAB and SEAT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7661645 10 Rivet 2 7511930 2 Bolt 3 7555792 6 Washer 4 5811107 1 Foil, Rear Cab, Rear 5 5432117-195 1 Cab, Rear, E.B. Green 6 7541925 4 Nut, Nylok 7 5224592 1 Retainer, Seat Latch 8 5811308 1 Foil, Tape, Rear Cab 9 7512242 4 Screw 10 7555859 4 Washer 11 7512085 2 Screw 12 5431786 1 Box, Tool 13 7621403 2 Rivet 14 5211033 2 Bracket, Lever Retainer 15 1040387 1 Latch, Seat 16 7041370 1 Spring, Latch 17 2682441-276 2681747-276 5811104 5811105 1 1 1 1 Seat, Sable Brown Covering, Seat, Sable Brown Foil, Seat Base, Large Foil, Seat Base, Small 18 5410414 8 Bumper, Rubber 19 7517599 2 Screw and Washer 20 5431787 1 Cover, Tool Box 21 5410896 1 Cap, Drain 22 5243188-067 1 Guard, Clutch 23 7661637 4 Rivet 24 7621509 2 Rivet 25 5243829-067 1 Strap, Fuel Pump 26 ------- 1 Asm., Front Gearcase (See Front Gear- case Pg. C10 for Details) 27 7552603 4 Washer 28 7512492 4 Screw 29 5433435 1 Guard, Rock 30 7556065 7 Washer 31 7517386 9 Screw 32 7558301 2 Washer, Flat 33 7512232 21 Screw 34 7542122 8 Nut 35 5411548 8 Mount, Rubber 36 7517264 8 Screw 37 1012764-067 1 Frame, Main 38 5432221-070 5433219-070 1 1 Footwell, LH, Black Footwell, RH, Black 39 5811111 1 Foil, Foam, Rear Fender 40 5811106 2 Foil, Rear Cab, Front 41 7073761 1 Decal - Carb Information 42 7078396 1 Decal - Filter Element 43 5811087 1 Foil, Foam 44 7670057 12 Nut, U-Type Speed 45 5431796 5431797 7555913 2873213 1 1 8 1 Guard, Mud, Rear, LH (AA)(AB) Guard, Mud, Rear, RH (AA)(AB) Washer, Flat (FA)(FB) Kit - Mud Skirt, Full Set (FA)(FB) 2/00 Downloaded from www.Manualslib.com manuals search engine

A7 FRONT CAB MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 3 4 5 6 7 8 9 1 15 16 2 13 14 11 10 12 6 2 2 2 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 2632084-195 2632284-195 2632101-195 1 1 1 Asm., Panel w/Foam, LH, E.B. Green (If built before 3/20/00) Asm., Panel w/Foam, LH, E.B. Green (If built after 3/20/00) Asm., Panel w/Foil, RH, E.B. Green 2 7512232 12 Screw 3 5432088-195 1 Cover, Front, E.B. Green 4 7670085 2 Clip, Spring 5 2632144-195 1 Cab, Front, E.B. Green 6 7670057 10 Nut, U-Type Speed 7 7670068 2 Nut, Push-on 8 7661645 4 Rivet 9 5431798 5431799 1 1 Guard, Mud, Front, LH Guard, Mud, Front, RH 10 7541925 2 Nut, Nylok 11 7555792 2 Washer 12 7512085 2 Screw 13 7555931 2 Washer 14 7542122 2 Nut, Nylok 15 7621509 4 Rivet 16 5811917 2 Shield, Deflector 10/00 Downloaded from www.Manualslib.com manuals search engine

A8 REAR RACK MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 4 3 1 2 8 6 9 11 12 10 10 6 5 7 2 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517685 2 Screw 2 7517686 4 Screw 3 2670174 1 Asm., Rack, Rear (Incl. Ref. 4 and Warning Decal) 4 2670070 2 Reflector, Red 5 1040490-067 1 Support, Rear Rack 6 7542324 8 Nut, Nylok 7 7670096 2 Nut, Chimney 8 7512329 4 Bolt 9 1040524-067 1040525-067 1 1 Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH 10 7558402 2 Washer 11 5333332-067 4 Spacer 12 7515385 4 Screw 2/00 Downloaded from www.Manualslib.com manuals search engine

A9 FRONT RACK and BUMPER MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 13 14 15 16 17 24 12 6 5 8 9 10 18 19 20 21 22 23 2 3 4 11 4 7 1 6 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517685 4 Screw 2 2670180 1 Asm., Front Rack (Incl. Ref. 3 and Warning Decal) 3 2670071 2 Reflector, Amber 4 7515399 6 Screw 5 2200775 1 Kit - Front Rack Mount 6 7542324 4 Nut, Nylok 7 7558403 2 Washer 8 5432155-070 1 Bumper 9 7515391 2 Screw 10 7515390 2 Screw 11 7555954 2 Washer 12 1040554-067 1040555-067 1013210-067 1013211-067 1 1 1 1 Support, Front Rack, LH (If built before 11/15/99) Support, Front Rack, RH (If built before 11/15/99) Support, Front Rack, LH (If built after 11/15/99) Support, Front Rack, RH (If built after 11/15/99) 13 7517386 4 Screw 14 2431011 2431012 4030059 1 1 2 Headlight, LH Headlight, RH Bulb, Replacement, 27W 15 7515382 2 Bolt 16 7558402 4 Washer 17 5810467 1 Plug, Frame 18 5241583-067 1 Guard, Brush 19 5240591-067 1 Grill, Brush Guard 20 7621330 7 Rivet 21 7670094 6 Nut, U-Type 22 7512097 6 Screw 23 5431814 5431815 1 1 Shield, Radiator Side, LH Shield, Radiator Side, RH 24 5241398-067 5241399-067 5244623-067 5244624-067 1 1 1 1 Extension, Frame, LH (If built before 12/01/99) Extension, Frame, RH (If built before 12/01/99) Extension, Frame, LH (If built after 12/01/99) Extension, Frame, RH (If built after 12/01/99) 2/00 Downloaded from www.Manualslib.com manuals search engine

A10 DECALS MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 1 2 3 5 4 6 8 9 10 4 13 14 15 16 17 18 12 LH RH 11 7 1 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7074954 2 Decal - Rack/Warning 2 7074110 1 Decal - Load Distribution, 4W 3 7078022 1 Decal - “4x4”, Shaft Ride Sys., RH 4 7077780 2 Decal - ‘‘POLARIS” Side Panel 5 7078017 1 Decal - Tank Side, RH 6 7074935 1 Decal - Warning, AWD Switch 7 7078315 7078465 1 1 Logo, “45th Anniversary” (If built before 1/01/00) Logo, Polaris Star (If built after 1/01/00) 8 7074220 1 Decal - “Macpherson Strut” 9 7078354 1 Decal - Discretionary Warning, ATV 10 7078577 1 Decal - Drain Recoil 11 7078015 7079007 7079008 1 1 1 Decal - “325” Front Cover (AA)(AB) Decal - “325 4 Stroke HDS” (FA) Decal - “325 4 Stroke HDS II” (FB) 12 7077919 1 Decal - Warning, General, CPSC 13 7079604 1 Decal - Warning, Override, AWD 14 7078016 1 Decal - Tank Side, LH 15 7078253 1 Decal - Age Warning, ATV 16 7078018 1 Decal - “4x4”, Shaft Ride Sys., LH 17 7077920 1 Decal - Passenger Warning 18 7078004 1 Decal - Tire Pressure 10/00 Downloaded from www.Manualslib.com manuals search engine

2000 Polaris Magnum 325 Parts Manual

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