Polaris A00CD32AA - Manuals

Page 2 - TABLE OF CONTENTS; Parts Manual

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 ...

Page 4 - 000 ATV PUBLICATION NUMBERS

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...

Page 5 - REAR CAB and SEAT

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 In...

Page 7 - FRONT CAB

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...

Page 8 - REAR RACK MOUNTING

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,...

Page 9 - FRONT RACK and BUMPER MOUNTING

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 Sc...

Page 10 - DECALS; LH

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 Deca...

Page 13 - EXHAUST SYSTEM

A13 EXHAUST SYSTEM MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 13 8 14 3 1 10 9 2 11 6 4 16 5 7 12 12 12 13 11 10 15 16 17 (If built after 7/01/99) 8 16 14 13 Ref. Part No. Qty. Description Ref. Part No. Qty. Description ...

Page 14 - FUEL TANK

A14 FUEL TANK MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 24 5 22 23 9 16 15 1 11 2 13 3 17 21 14 7 4 20 8 6 21 12 20 19 18 10 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5430725 1 Cap, Gas Tank 2 5810...

Page 15 - ENGINE MOUNTING

B1 ENGINE MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 34 21 30 12 24 8 15 2 33 16 17 1 32 26 27 28 29 18 4 36 3 37 11 10 23 6 35 9 7 22 13 32 32 33 33 33 6 7 6 67 25 6 19 20 31 19 14 5

Page 17 - AIR BOX

B3 AIR BOX MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 20 23 11 24 10 13 6 2 17 5 25 22 21 4 12 15 14 7 9 12 16 26 19 3 1 18 8 9 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7517541 4 Screw 2 5432859 1 ...

Page 19 - PROP SHAFT

B5 PROP SHAFT 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 4 5 6 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1380138 1 Asm., Prop Shaft (Incl. 1-4) 1 3260133 1 Yoke, Gear Case, Front 2 3260104 2 Kit...

Page 20 - FRONT STRUT

B6 FRONT STRUT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 2 3 5 6 7 8 9 10 11 12 14 15 13 16 17 18 20 4 19 21 22 23 24 25 26 10 11 4 1 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5411608 2 Bumper 2 70...

Page 21 - FRONT WHEEL

B7 FRONT WHEEL MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 10 11 12 14 1 2 3 4 5 7 9 8 15 16 25 24 7 17 18 20 21 23 13 6 6 22 19 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512325 8 Bolt 2 5211869 2 D...

Page 22 - FRONT BRAKE

B8 FRONT BRAKE 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 8 9 11 10 12 4 5 6 7 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1910271 1 Asm., Front Brake Caliper, LH (Incl. 1-7,9,10) 1910264 1 Asm., ...

Page 25 - STEERING POST

B11 STEERING POST MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 1 16 15 14 2 3 4 13 9 12 5 6 10 5 5 8 11 6 7 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1843067 1 Asm., Steering Post (Incl. 12,13) 2 5431...

Page 26 - HANDLEBAR

B12 HANDLEBAR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 3 1 2 5 6 9 10 12 13 18 21 20 22 26 25 24 7 4 23 17 17 25 19 8 11 27 15 14 16 28 33 32 31 30 29 A00CD32FA and A00CD32FB A00CD32FA and A00CD32FB 2 Ref. Part No. Qty...

Page 28 - DRIVE CLUTCH

B14 DRIVE CLUTCH MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA 14 1 2 13 12 5 11 3 4 5 6 10 9 7 8 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512176 6 Bolt 2 7552801 6 Washer 3 5430945 6 Washer, Multilube 4 1321457 3 Roller and Bushing 5 5431936 6 Button, Clutch 6 521075...

Page 30 - DRIVEN CLUTCH

C2 DRIVEN CLUTCH MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 6 5 2 3 4 16 14 13 12 11 9 8 7 5 1 15 10 1 3 4 13 10 9 2 17 18 19 20 20 A00CD32AA A00CD32CA A00CD32FA A00CD23FB 21 22 23 24 25 26 Ref. Part No. Qty. Description...

Page 31 - CLUTCH COVER

C3 CLUTCH COVER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 4 25 8 9 11 12 13 14 10 16 21 22 23 5 7 15 6 17 19 20 1 3 2 24 18 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512232 2 Screw 2 2632116 1 Foa...

Page 33 - REAR BRAKE

C5 REAR BRAKE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 29 3 25 11 24 9 28 8 7 10 12 27 18 1 6 5 17 13 20 23 2 4 30 16 19 5 7 13 5 18 17 24 27 22 15 26 19 19 22 9 21 21 14

Page 35 - REAR WHEEL DRIVE

C7 REAR WHEEL DRIVE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 6 7 10 11 1 12 4 8 2 3 5 9 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7661404 2 Pin, Cotter 2 7542714 8 Nut 3 5131777 2 Hub, Wheel, Rear...

Page 36 - FRONT HOUSING

C8 FRONT HOUSING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 2 1 3 4 5 6 7 8 12 22 13 18 19 16 20 21 24 23 2 11 15 17 10 14 1 11 12 9 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341253 1 Asm., Front Gea...

Page 37 - MAIN GEARCASE

C9 MAIN GEARCASE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 44 50 5 49 53 10 11 18 52 12 13 14 16 15 61 62 59 63 56 57 22 24 27 30 31 47 35 8 7 19 64 32 33 34 2 55 5 66 17 60 54 4 9 17 51 4 1 21 20 26 25 23 48 6 28 37 29...

Page 39 - REAR HOUSING

C11 REAR HOUSING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 9 16 7 4 1 15 21 6 5 23 2 20 19 14 3 12 18 22 24 17 8 25 10 8 3 17 2 26 11 16 13 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341254 1341309 1...

Page 40 - GEAR SELECTOR

C12 GEAR SELECTOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 2 4 3 5 7 8 6 11 16 10 15 1 13 14 9 12 10 11 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1341271 1341337 1 1 Asm., Gear Selector (Incl. 1-16)...

Page 41 - GEARCASE SELECTOR MOUNTING

C13 GEARCASE SELECTOR MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 1 2 11 9 12 4 3 5 7 13 2 2 6 6 2 9 10 8 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7061013 2 Rod End, LH 2 7546707 4 Nut, FLE...

Page 42 - SWING ARM/REAR GEARCASE MOUNTING

C14 SWING ARM/REAR GEARCASE MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 12 28 33 11 21 17 22 29 38 25 23 34 15 9 27 11 37 9 10 10 15 20 7 5 5 31 35 8 32 1 16 26 19 2 3 13 14 36 12 13 14 30 24 6 4 20 18 Ref. Part ...

Page 43 - SHOCK MOUNTING

D1 SHOCK MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 3 8 4 7 11 5 6 1 9 2 10 1 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7542439 2 Nut, Nylok 2 5433213 2 Bushing (If built before 6/21/99) 3 ...

Page 44 - TRANSMISSION MOUNTING

D2 TRANSMISSION MOUNTING 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 4 9 8 7 7 8 9 5 2 1 5 6 10 11 2 2 Ref. Part No. Qty. Description Ref. Part No. Qty. Description -- -- -- -- -- -- -- 1 Asm., Main Gearcase (See Ma...

Page 45 - CRANKCASE

D3 CRANKCASE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 3 4 1 2 12 7 5 8 18 21 22 19 11 20 14 17 16 15 13 9 10 6 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3083669 1 Bushing, Starter 2 3080103 2 Pin,...

Page 46 - CYLINDER

D4 CYLINDER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 3 19 18 12 8 26 6 4 7 10 14 1 2 20 21 5 9 11 27 17 22 23 24 25 13 16 15 6 8 1 2 14 15 4 9 9 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3086413 2...

Page 47 - CRANKSHAFT and PISTON

D5 CRANKSHAFT and PISTON MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 7 16 6 5 15 14 10 8 11 2 1 4 9 13 12 5 14 6 4 8 3 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3085774 3085775 3085776 1 1 1 Piston R...

Page 48 - INTAKE and EXHAUST

D6 INTAKE and EXHAUST MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 11 12 19 9 10 13 14 8 7 6 4 2 16 20 2 15 23 18 17 21 22 24 1 3 1 7 6 8 5 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084911 2 Screw, A...

Page 49 - RECOIL STARTER

D7 RECOIL STARTER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 14 6 4 7 10 5 3 1 2 11 8 12 13 15 9 8 7 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3084822 1 Reel 2 3083463 1 Spring, Return 3 3083378 1 R...

Page 50 - OIL PUMP and OIL FILTER

D8 OIL PUMP and OIL FILTER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 11 9 1 10 8 2 4 7 5 6 3 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3083453 1 Plug 2 3082956 1 Gasket 3 3086455 1 Spring 4 3086222...

Page 51 - CARBURETOR

D9 CARBURETOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 48 38 35 9 51 5 50 1 2 4 6 42 43 39 37 12 36 13 12 14 15 21 19 27 30 29 26 11 10 3 22 20 16 24 18 25 41 23 52 45 46 8 7 47 40 34 33 32 28 17 49 44 31

Page 53 - MAGNETO

D11 MAGNETO MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 14 4 7 1 2 10 13 3 9 11 12 6 6 5 8 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3086483 3086484 3086807 1 1 1 Asm., Ignition Coil (Incl. 1,2) Igni...

Page 54 - STARTING MOTOR

D12 STARTING MOTOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 9 11 1 5 10 4 3 17 12 16 15 14 13 6 7 8 2 1 11 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 3084981 1 Motor, Starting (Incl. 1-5,7-11) 1 3084...

Page 55 - FUEL PUMP

D13 FUEL PUMP MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 4 1 3 2 2 4 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 3085275 1 Asm., Fuel Pump (Incl. 1-4) 1 3084999 1 Screw and Washer 2 3085000 2 Screw and ...

Page 56 - BREATHER BOX

D14 BREATHER BOX MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 3 22 18 16 4 10 23 17 19 21 20 1 8 12 6 5 9 15 2 11 5 5 5 7 7 14 14 13 13 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 3085850 1 Pipe 2 30864...

Page 57 - TOOL KIT

E1 TOOL KIT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 2 7 1 9 3 4 11 8 10 5 6 Ref. Part No. Qty. Description Ref. Part No. Qty. Description 3086485 1 Kit - Tool (Incl. 2-7) 1 2870725 1 Gauge, Tire Pressure 2 3085001 1 W...

Page 59 - cover

C h anged p ages in 9914940 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A cover toc B C x x D E F G 1 2 3 4 5 6 7 8 9 10 11 12 13 14