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.
P ARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00
T ABLE OF CONTENTS
Magnum 325 4X4 A00CD32AA and Magnum 325 4X4 A 00CD32CA 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.........................
GEARCASE SELECTOR MOUNTING C13...........
HANDLEBAR B12............................
INTAKE an d EXHAUST D6.....................
MAGNETO D11..............................
MAIN GEARCASE C9.........................
MAIN GEARCASE C10........................
OIL COOLING (If built after 1/1/00) A12............
OIL COOLING (If built before 1/1/00) A11...........
OIL PUMP and OIL FILTER D8..................
PROP SHAFT B5............................
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........................
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
REAR BRAKE C5-6...........................
REAR CAB and SEAT A5-6.....................
REAR HOUSING C11..........................
REAR RACK MOUNTING A8...................
REAR WHEEL DRIVE C7......................
RECOIL STARTER D7........................
SHOCK MOUNTING D1.......................
STARTING MOTOR D12........................
STEERING POST B11.........................
SWING ARM/REAR GEARCASE MOUNTING C14.....
TOOL KIT E1...............................
TRANSMISSION MOUNTING D2.................
G
H
I
M
O
P
R
S
T
2000 MAGNUM 325 4x4 SPECIFICATIONS
BRAKES
Type - Front
Type - Rear
Type - Auxiliary
Type - Parking
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 Hi t c h
Tow Weight
DRIVE TRAIN
Type Shaft Ride System
DRIVE CLUTCH
Drive System Type
Center Distance (inches)
Clutch Offset (inches)
Clutch Weight (grams)
Spring Color
DRIVEN CLUTCH
Helix Angle
Outside Diameter (inches)
Spring Position
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)
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
TIRES&WHEELS
Tire Manufacturer
Tire Size - Front
Tire Size - Rear
Tire Size - Center
Tire Pressure - Front
Tire Pressure - Rear
Tire Pressure - Center
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.
Hydraulic Disc
Hydraulic Disc
Hydraulic Disc
3.75
400 (ml)
1.9
N/A
N/A
180
Standard
850
PVT
1/2
16 MH
Blue/Green
Compound
9.5
Black 2-2
588
N/A
7.25
620
49.75
PRD
Side Lever
7.46/1
5.12/1
3.3/1
3.7/1
3.1/1
N/A
N/A
N/A
Titan
24x8-12
24x11.5-10
N/A
N/A
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
90
30
10
65
46
81
34
46
4
3
Pilot Jet
Needle Jet
Cut Away
Pilot Screw
Jet Needle
Ignition
Ignition (Type & Deg. BTDC)
Spark Plug Gap (inches)
Spark Plug (Type)
Exhaust
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
Headlight - Front Hood (watts)
Headlight - Grill (watts)
Taillight (watts)
Brake Light (watts)
Indicator Bulb
Battery
Front Type -
Front Travel (inches)
Rear Type -
Rear Travel (inches)
Shock
Adjustment
ENGINE
4 Stroke, Single Cylinder
Air w/Fan Assisted Oil Cooler
1/BST31 (CV Type)
USFS Appr. Pending
GRAPHICS
ELECTRICAL
2 Single Beam/30 W
SUSPENSION
MacPherson Strut
Progressive Rate Swing Arm
2² Gas Charged Monotube
ES32PFE01
Wet Sump
78x68
325
9:2 Full Stroke
200
Standard
142.5
50
P-0 (829)
N/A
2
5F14-2
CDI
30@3500
.028
NGKBKR5E
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
N/A
12 V/8.26 W
12 V/26.9 W
12 V/1.0 W
12 V/14 AH
6.7
6.5
Cam
2000 ATV PUBLICATION NUMBERS
MODEL MODEL NO. OWNER’S
MANUAL
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
OWNER’S
MANUAL
SUPPLEMENT
PARTS
MANUAL
PARTS
MICROFICHE
ASSEMBLY
INSTRUCTIONS
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
E 2000 Polaris Sales Inc.
15
45
44
6
5
1
4
3
2
33
38
39
43
42
36
41
7
8
6
3
40
37
14
16
13
9
10
12
11
19
20
21
18
17
22
23
24
25
35
34
33
32
26
27
28
29
30
31
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
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
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
1
Seat, Sable Brown
1
Covering, Seat, Sable Brown
1
Foil, Seat Base, Large
1
Foil, Seat Base, Small
24 7621509 2 Rivet
25 5243829-067 1 Strap, Fuel Pump
26 -- -- -- -- -- -- -- 1 Asm., Front Gearcase (See Front Gear-
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
39 5811111 1 Foil, Foam, Rear Fender
40 5811 106 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
case Pg. C10 for Details)
11Footwell, LH, Black
Footwell, RH, Black
1
Guard, Mud, Rear, LH (AA)(AB)
1
Guard, Mud, Rear, RH (AA)(AB)
8
Washer,Flat(FA)(FB)
1
Kit - Mud Skirt, Full Set (FA)(FB)
2/00
A6
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
12
1
11
10
2
13
14
2
2
8
7
9
6
2
4
5
6
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2632084-195
2632284-195
2632101-195
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
1
Asm., Panel w/Foam, LH, E.B. Green
(If built before 3/20/00)
1
Asm., Panel w/Foam, LH, E.B. Green
(If built after 3/20/00)
1
Asm., Panel w/Foil, RH, E.B. Green
16
8 7661645 4 Rivet
9 5431798
5431799
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
11Guard, Mud, Front, LH
Guard, Mud, Front, RH
A7
10/00
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
1
2
3
2
4
5
6
7
8
10
6
9
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
10 7558402 2 Washer
11 5333332-067 4 Spacer
12 7515385 4 Screw
11
10
1040525-067
12
11Mount, Front, Rear Rack, LH
Mount, Front, Rear Rack, RH
2/00
A8
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
1
2
5
3
4
8
7
6
14
15
16
17
6
24
23
22
21
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517685 4 Screw
2 2670180 1 Asm., Front Rack
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
13 7517386 4 Screw
(Incl. Ref. 3 and Warning Decal)
1
Support, Front Rack, LH
(If built before 11/15/99)
1
Support, Front Rack, RH
(If built before 11/15/99)
1
Support, Front Rack, LH
(If built after 11/15/99)
1
Support, Front Rack, RH
(If built after 11/15/99)
13
12
4
18
19
20
14 2431011
2431012
4030059
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
24 5241398-067
5241399-067
5244623-067
5244624-067
1
Headlight, LH
1
Headlight, RH
2
Bulb, Replacement, 27W
11Shield, Radiator Side, LH
Shield, Radiator Side, RH
1
Extension, Frame, LH
(If built before 12/01/99)
1
Extension, Frame, RH
(If built before 12/01/99)
1
Extension, Frame, LH
(If built after 12/01/99)
1
Extension, Frame, RH
(If built after 12/01/99)
11
10
9
2/00
A9
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
10
6
5
4
7
8
RH
9
12
11
1
13
14
15
16
17
4
18
LH
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
8 7074220 1 Decal - “Macpherson Strut”
9 7078354 1 Decal - Discretionary Warning, ATV
11Logo, “45th Anniversary”
(If built before 1/01/00)
Logo, Polaris Star
(If built after 1/01/00)
10 7078577 1 Decal - Drain Recoil
11 7078015
7079007
7079008
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
1
Decal - “325” Front Cover (AA)(AB)
1
Decal - “325 4 Stroke HDS” (F A)
1
Decal - “325 4 Stroke HDS II” (FB)
A10
10/00
OIL COOLING (If built before 1/01/00)
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
18
4
9
10
7
8
17
16
11
12
1
22
2
3
4
4
5
21
4
15
1
2
3
4
5
6
20
19
4
14
4
15
4
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7547069 2 Nutsert
2 3110032 2 Mount, Rubber
3 5242924-067 2 Bracket, Cooling Fan
4 7542122 10 Nut, Nylok
5 7080474 2 Clamp, Hose
6 5411813 1 Hose, Cooler Inlet
7 7670111 4 U-Clip
8 5433353 1 Shroud, Fan
9 4010274 1 Thermister
10 7515158 4 Screw
11 1240064 1 Cooler, Oil
4
13
14
12 7052244 1 Valve, Drain
13 5242983-067 2 Mount, Oil Cooler
14 7558301 2 Washer, Flat
15 3110050 2 Mount, Carburetor
16 2410157 1 Motor, Fan
17 7517659 4 Screw
18 7080862 1 Clamp, Hose
19 7080866 1 Clamp, Hose
20 5411768 1 Hose, Oil Cooler Outlet, Flared
21 8450086-07 1 Tubing, Convoluted
22 7080869 1 P-Clamp
10
2/00
A11
OIL COOLING (If built after 1/01/00)
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
1
19
18
2
3
4
17
16
15
6
14
5
6
7
8
9
10
11
13
12
6
Ref. Part No. Qty. Description
1 7080474 2 Clamp, Hose
2 5411813 1 Hose, Inlet
3 7542122 4 Nut
4 5243783-067 1 Bracket, Top
5 7080869 1 Clamp, Rubber Coated
6 7515158 8 Screw
7 7517659 4 Screw
8 2410157 1 Motor, Fan
9 7670111 4 U-Clip
10 5433353 1 Shroud
Ref. Part No. Qty. Description
11 4010274 1 Thermister
12 7052244 1 Plug, Drain
13 1240064 1 Cooler, Oil to Air
14 3021186 4 Mount, Rubber
15 5244069-067 1 Bracket, Bottom
16 7080862 1 Clamp
17 7080866 1 Clamp, Hose
18 5411768 1 Hose, Outlet, Flared
19 8450086-07 AR Tubing, Convoluted
11/99
A12
EXHAUST SYSTEM
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
8
7
12
16
9
10
11
8
16
17
(If built after 7/01/99)
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542324 1 Nut, Nylok
2 7555716 1 Washer
3 5410436 1 Washer, Rubber
4 7555863 1 Washer (If built before 7/01/99)
5 5010192
5132295
6 5410241
5411790
7 7515316
7515339
7515394
8 1260977-029
1260961-029
11Bushing (If built before 7/01/99)
Bushing (If built after 7/01/99)
11Dampener, Vib. (If built before 7/01/99)
Dampener, Vib. (If built after 7/01/99)
1
Bolt, Carriage (If built before 7/01/99)
1
Bolt (If built after 7/01/99)
1
Screw, Carriage (If built after 8/12/99)
11Silencer (If built before 7/01/99)
Silencer (If built after 7/01/99)
12
13
14
13
9 7512666 1 Bolt
10 3110064 2 Mount, Torque Stop
11 7542301 2 Nut
12 7041804 4 Spring, Exhaust
13 7042029 2 Spring, Exhaust (If built before 7/01/99)
14 1260976-029
15 1260960-029 1 Manifold, Black
16 5243517 2 Seal, Exhaust
17 7041789 1 Spring, Exhaust (If built after 7/01/99)
14
13
1260987-029
10
11
(Only 1 used if built after 7/01/99)
11Headpipe (If built before 7/01/99)
Headpipe (If built after 7/01/99)
15
12
16
2/00
A13
FUEL TANK
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
24
4
6
5
7
8
9
10
11
22
21
19
18
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5430725 1 Cap, Gas Tank
2 5810144 1 Gasket, Fuel Cap
3 5811899 1 Seal, Foam
4 8360009-600 AR Line, Fuel
5 5431053 1 Vent, Tank
6 7517451 2 Bolt
7 7552801 2 Washer
8 7558301 2 Washer
9 5222154-067
5222155-067
10 5811796 1 Foam, Intake, Splash
11 5332457
5333936
23
21
20
20
17
11Bracket, Mounting, Rear, LH
Bracket, Mounting, Rear, RH
22Spacer (If built before 1/17/00)
Spacer (If built after 1/17/00)
13
16
15
14
12 7547069 4 Nutsert
13 5810317 2 Pad, Fuel Tank Bracket
14 7517505 1 Screw
15 5432559 1 Knob, Fuel V alve
16 5432733 1 Nut, Fuel Valve
17 7052161 1 Valve, 3-Way
18 7661637 2 Rivet
19 5240577-067 1 Bracket, Fuel Valve
20 8450040-600 AR Line, Fuel
21 7080003 4 Clamp, Hose, Red
22 7052149 1 Fitting, Fuel Outlet, Reserve
23 7052146 1 Fitting, Fuel Outlet, Main
24 2520183 1 Asm., Fuel Tank (Incl. 5,22,23)
12
2/00
A14
ENGINE MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
33
1
37
35
33
32
32 32
34
33
30
14
10
13
9
2
3
4
5
36
33
31
8
7
6
11
12
6
15
16
17
29
28
27
26
6
25
19
6
7
24
20
23
19
22
21
18
7
6
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
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 8450003-1525 AR Line, Fuel
2 7052075 1 Fitting, Tee
3 5243720-067 1 Bracket, Carburetor
4 3084205 2 Screw and Washer
5 3085823 1 Engine, Short Block NOTE: The
Short Block assembly contains a
crankcase assembly., cylinder & cylinder head assembly and a piston &
crankshaft assembly. Prior authorization is required for warranty consider-
ation.
6 7542403 4 Nut
7 7555806 2 Washer
8 5243641-067 1 Bracket, Motor Mount
9 7552901 2 Washer
10 7512315 2 Bolt
11 7512232 1 Screw
12 4010132 1 Cable, Ground Engine
13 7555823 1 Washer
14 3110068 1 Mount, Rubber Rear
15 5411721 1 Boot, Clutch Intake
16 7080511 1 Clamp, Narrow Band
17 8360009-600 AR Line, Fuel
18 1012960-067
1013133-067
19 7547108 4 Nut
20 7517289 2 Screw
21 3021119 1 Mount, Rubber, Rear
22 7555815 2 Washer
23 7515417 2 Screw
24 5243288-067 1 Mount, Lower Front
25 3021181 1 Mount, Rubber, Rear
26 5430261 1 Bushing
27 5210748 1 Washer
28 7575202 1 Washer
29 7512566 1 Bolt
30 4010095 1 Cable, Battery/Engine
31 7080482 1 T-Clip
32 8450040-600 AR Line, Fuel
33 7080003 8 Clamp, Hose
34 2530009 1 Filter
35 7546601 2 Nut, Nylok
36 3110079 2 Mount, Rubber
37 7517615 2 Screw
11Mount, Engine, Rear
(If built before 12/01/99)
Mount, Engine, Rear
(If built after 12/01/99)
2/00
B2
AIR BOX
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
1
26
2
3
4
5
6
7
25
8
12
24
9
23
10
11
12
13
14
20
22
21
18
17
19
9
16
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517541 4 Screw
2 5432859 1 Duct, Inlet
3 5411422 1 Gasket, Intake
4 5432868 1 Cover, Air Box
5 5811482 1 Seal, Cover
6 7515180 2 Screw
7 7558301 2 Washer
8 5433396 1 Cap, End
9 7080699 2 Clamp, Hose
10 5830128 1 Gasket, Duct
11 5433180 1 Duct, Carburetor Inlet
12 7080413 2 Clamp
13 5411588 1 Boot, Carb
14 7080511 1 Clamp
15 7080694 1 Clamp, Hose
16 5411746
5411848
17 5432774
5433678
18 5431863 2 Insulator
19 5811650 1 Foil, Air Box
20 5432377 1 Plug
21 8450059-150 AR Line, Fuel
22 7080650 1 Clamp, Hose
23 5243694 6 Clip
24 5432601 1 Collar, Carburetor Inlet
25 7080595 1 Filter, Air Intake
26 5811633 1 Filter, Precleaner Sleeve
ARARHose, Breather (If built before 7/26/99)
Hose, Breather (If built after 7/26/99)
11Box, Air (If built before 7/26/99)
Box, Air (If built after 7/26/99)
B3
2/00
CV JOINT - BTB
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
BTB
7
3
2
1
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
4
5
11
12
13
6
8
9
10
1 1380119 2 Asm., CV Housing w/Sleeve
2 5222299 1 Sleeve, Drive Shaft Seal
3 3260115 1 Clamp, CV Joint, Large
4 7670091 1 Circlip
5 5411106 1 Boot, CV Joint
6 1380094 1 Shaft Replacement (Incl. 4)
7 1380092 1 Cardan Replacement (Incl. 4,6,8,9)
8 2200771 1 Kit - Cross and Bearing
9 3260130 1 Yoke, Splined
10 7661913 1 Pin, Spring
11 7080627 1 Clamp, Small Band
12 2200773 1 Kit - Boot Replacement, CV Joint
(Incl. 3,5,11)
13 2200961 1 Kit - Drive Shaft w/Sleeve
11/98
B4
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
6
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3
4
5
1380138 1 Asm.,PropShaft(Incl.1-4)
1 3260133 1 Yoke, Gear Case, Front
2 3260104 2 Kit - Cross and Bearing
3 3260140 1 Shaft, Prop, Front
4 3260131 1 Yoke, Splined
5 5411092 1 O-Ring
6 7661913 1 Pin, Spring
11/98
B5
FRONT STRUT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
19
20
4
21
26
25
24
23
22
18
16
17
10
1
2
3
5
4
11
14
6
7
8
13
12
11
10
9
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411608 2 Bumper
2 7041761 2 Strut, Front
3 5 211115 2 Washer
4 7558402 6 Washer
5 7080573 2 Clamp, Rubber Coated
6 7542303 4 Nut
7 7517445 4 Screw
8 5810439 2 Retainer, Strut Casting Wire
9 -- -- -- -- -- -- -- 1 Asm., Front Brake Caliper, RH (See
Front Brake Pg. B8 for Details)
10 3554509 4 Bearing, Tapered Roller
11 3554507 4 Bearing, Tapered Roller Cup
12 5222193 2 Sleeve, Hubstrut Seal
13 7080306 2 Fitting, Lubrication
14 2410133 2 Coil, Magnetic
15 2201311
2201312
16 7041375-067 2 Spring, Coil
17 5243364 2 Retainer, Spring
18 5432871 2 Ball, Pivot, Bottom
19 7515339 4 Bolt
20 5132062 2 Spacer
21 -- -- -- -- -- -- -- 1 Kit - Drive Shaft w/Sleeve
22 3610028 2 Seal, Hubstrut
23 5432872 2 Ball, Pivot, Top
24 5810291 2 Spacer, Rubber
25 7555749 2 Washer
26 7547104 2 Nut
11Asm., Hubstrut, LH (32mm)
(Incl. 8,11-14,22)
Asm., Hubstrut, RH (32mm)
(Incl. 8,11-14,22)
(See CV Joint - BTB Pg. B4, Ref. 13)
2/00
B6
FRONT WHEEL
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
7
8
16
25
10
9
15
11 12
13
14
24
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512325 8 Bolt
2 5211869 2 Disc, Brake
3 3610019 2 Seal, Front Hub
4 5211148 2 Plate, Armature
5 1520281 2 Clutch, Front Hub, Elec./Mech.
6 3554506 4 Bearing, Tapered Roller Cone
7 3554507 4 Bearing, Tapered Roller Cup
8 7515523 8 Stud
9 1520243 2 Asm., Hub w/Bearing Race (Incl.3,7,8)
10 3250028 2 Cage, Roll
11 3250010 12 Roll
12 3250032 2 Spring, Garter
13 1321814 2 Spacer
7
6
17
23
14 3250030 2 Cam
15 7052045 2 Plug, Magnetic Drain
16 5411709 2 Tire (24x8-12)
17 7556004 2 Washer
18 7542810 2 Nut, Slotted
19 7661401 2 Pin, Cotter
20 5410470 2 O-Ring
21 5432611 2 Cap, Hub
22 7512027 6 Screw
23 7542459 8 Nut
24 1520269-117 2 Rim, Front
25 1525017 2 Val v e , R i m
18
19
20
21
22
11/98
B7
FRONT BRAKE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
12
2
1
10
3
4
5
11
6
7
9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1910271 1 Asm., Front Brake Caliper, LH
1910264 1 Asm., Front Brake Caliper, RH
1 7080352 1 Screw , Bleeder
2 7515489 1 Screw, Socket Set
3 5131115
5131116
1930642
4 1930665 1 Kit - Piston and Insulator Seal (Incl. 5-7)
5 5410779 1 Ring, Molded Square (.094)
(Incl. 1-7,9,10)
(Incl. 1-7,9,10)
1
Caliper,Brake,LH
1
Caliper,Brake,RH
1
Kit - Front Brake Boot
6 5410780 1 Ring, Molded Square (.103 x .134)
7 5132294 1 Piston, Brake, Long
8 2200465
2200901
2201149
9 1910265
1910412
10 5410495 1 Boot, Bushing
11 5410494 1 Boot, Pin Seal
12 -- -- -- -- -- -- -- 4 Screw (See Front Strut Pg. B6, Ref. 7)
1
Kit - Front Brake Pad, General Duty
1
Kit - Front Brake Pad, Severe Duty
1
Kit - Front Brake Pad, Soft Duty
11Mount, Caliper (If built before 7/09/99)
Mount, Caliper (If built after 7/09/99)
8
10/00
B8
CONTROLS - THROTTLE ASM./CABLE
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
1 5432721
5433806
2 5410193 1 O-Ring
3 5411439 1 O-Ring
11Cover, Throttle Control
(If built before 11/22/99)
Cover, Throttle Control
(If built after 11/22/99)
4 7080709
7080857
5 2010188 1 Asm., Throttle Control (Incl.1,3,6)
6 2010191 1 Asm., Throttle Clamp
11Cable, Throttle Control
(If built before 2/10/99)
Cable, Throttle Snap-In
(If built after 2/10/99)
2/00
B9
CONTROLS - MASTER CYLINDER/BRAKE LINE
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
22
24
25
28
27
26
23
22
15
16
20
14
17
21
19
18
13
12
5
6
11
7
8
9
10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2050078
2200809
1 1930797 2 Bolt, Cap
2 1930796 1 Cap, Reservoir
3 1930795 1 Diaphragm
4 2200808 1 Kit - Master Cylinder Clamp
5 1930799 1 Asm., Master Cylinder Piston
6 1930804 1 Rivet
7 2201034 1 Kit - Brake Lever w/Parking Latch
8 -- -- -- -- -- -- -- 1 Spring, Flat
9 2201090 1 Kit - Park Brake Lever (Incl. 6,8)
10 1930806 1 Nut
11 1930792 2 Bolt, Reservoir
12 1930805 1 Bolt, Lever
11Asm., Master Cylinder (Incl. 1-13)
Kit - Master Cylinder Reservoir
(Incl. 1-3,13)
(Incl. 6-9)
13 -- -- -- -- -- -- -- 1 Ring, Square, Reservoir
14 5411297 1 Boot, Rubber Brake Line
15 5410988 2 Seal
16 4110164 1 Switch
17 1910286 1 Line, Hand Brake, Front
18 7621462 1 Rivet
19 7080539 1 Clamp, Nylon
20 8360031-30 1 Conduit, Convoluted
21 1930752 1 Line, Brake, Left Front w/Fittings
22 7080138 8 Cable Tie
23 7512084 2 Screw
24 8360011-38 1 Tubing, Convoluted
25 1930753 1 Line, Brake, Right Front w/Fittings
26 7052237 1 Fitting, Cross
27 1930816 1 Line, Brake
28 1930674 1 Bolt, Banjo
B10
11/98
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
2
15
14
3
4
13
12
5
10
5433416
11
11Bushing, Steering (If built before 7/12/99)
Bushing,Steering (If built after 7/12/99)
6
6
5
7
5
8
9
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1843067 1 Asm., Steering Post (Incl. 12,13)
2 5431573
5433415
3 7080424 1 Fitting, Lubrication
4 7515321 2 Bolt
5 7555878 3 Washer
6 5410772 2 O-Ring
7 5431571 1 Spacer, Steering Post
8 7543203 1 Nut
11Bushing,Console (If built before 7/12/99)
Bushing,Console (If built after 7/12/99)
9 7661633 1 Pin, Cotter
10 5431570 1 Bushing, Steering, Lower
11 7661632 2 Rivet
12 5431574 1 Plug, Steering Grease
13 7080433 1 Fitting, Lubrication
14 5431572
15 5222999-067 1 Bracket, Steering Bushing, Upper
16 7542324 2 Nut, Nylok
2/00
B11
HANDLEBAR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
17
1
2
3
10
4
9
7
8
12
6
5
A00CD32FA and A00CD32FB
13
14
15
16
17
A00CD32FA and A00CD32FB
27
28
2
29
33
32
31
30
20
21
22
23
26
24
25
25
11
18
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5432247-070 1 Cover, Logo
2 5432420 2 Cover, Screw
3 5432246-070
5433183-070
4 7517216
7517224
5 5241397-067
5241698-067
11Panel, Instrument (AA)(CA)
Panel, Instrument (FA)(FB)
44Screw (AA)(CA)
Screw (FA)(FB)
11Bracket, Instrument Panel (AA)(CA)
Bracket, Accessory Panel (FA) (FB)
6 -- -- -- -- -- -- -- 1 Asm., Master Cylinder
(See Control - Master Cyl./Brake Line
Pg. B10 for Details)
7 7080726
2200188
11Cable, Choke w/Adjuster
Kit - Choke Lever
8 5432926 1 Spacer , Switch, LH
9 4010262 1 Switch, Handlebar, Hi/Lo/Rev. Override
10 5431030 2 Grip, Handlebar
11 5432952 1 Plug, Hole
12 7517625 1 Screw
13 5224715-067 1 Tube, Handlebar
14 5132382 1 Cap, Hall Sensor (FA)(FB)
15 4010298 1 Sensor, Hall Effect (FA)(FB)
16 7517658 1 Screw (FA)(FB)
17 5630629 4 Block, Handlebar
18 7542122 4 Nut, Nylok
19 7080631 1 Clip, Cable Retaining
20 -- -- -- -- -- -- -- 1 Asm., Throttle Control (See Controls -
Throttle Asm./Cable Pg. B9, Ref. 5)
21 2460715
2460841
11Harness, Control Panel (AA)(CA)
Harness, Control Panel (FA)(FB)
22 4040054 1 Indicator, Neutral/Reverse
23 4040053 1 Indicator, “Hot Temperature”
24 5430967
4010313
25 4110264
4010278
11Plug, Indicator Hole (AA)(CA)(FB)
Indicator, “P” Park (FA)
1
Switch, Ignition
1
Key, Blank, Series 2000, 6700, 6800.
NOTE: Spare key must be cut from ex-
isting key.
4010321
1
Key, Blank, Series 2200, 2300, 2700,
2800. NOTE: Spare key must be cut
from existing key.
5433733
5431964
1
Nut, Ignition
1
Cover, Key
26 7080229 1 Nut, Choke Slide
27 3280337
3280345
11Speedometer (FB)
Speedometer (FA)
28 7512024 2 Screw (FA)(FB)
29 3280201 1 Clamp (FA)(FB)
30 5630633 1 Block, Riser (FA)(FB)
31 7541933 2 Nut, Brass (FA)(FB)
32 7558212 2 Washer,Flat(FA)(FB)
33 7555868 2 Washer, Lock (FA)(FB)
19
10/00
B12
A-ARM/STRUT MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
1
4
2
3
5
6
7
8
9
10
20
30
26
28
29
22
23
16 5211121 2 Bracket, Ball Joint
17 7512284 4 Screw
18 5410548 2 Boot, Rubber
19 7542438 2 Nut, Castle
20 5431150
21 7517756 6 Screw
22 5433066 4 Bushing, A-Arm, Long
23 5020677 4 Bushing
24 5020681 2 Shaft, A-Arm
25 2201609
26 7080433 2 Fitting, Lubrication
27 -- -- -- -- -- -- -- -- 1 Asm., Heavy Hubstrut
28 7512492 4 Screw
29 7552603 4 Washer, Spring Lock
30 7517527 1 Bolt
31 7515415 1 Screw
27
5431149
2201610
15
18
19
14
11Shield, CV Joint, LH
Shield, CV Joint, RH
11Kit - A-Frame, LH
Kit - A-Frame, RH
(See Front Strut Pg. B6, Ref. 15)
16
31
29
28
24
23
22
21
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542403 2 Nut, FLEXLOC
2 5333367 1 Bushing
3 1820567
1820805
4 5411291 2 Boot, Seal, Rod End
5 7061034 2 Rod End
6 7542711 2 Nut
7 5020926 2 Tie Rod
8 7547028 2 Nut, LH
9 7061033
7061054
10 5411920 1 Boot, Seal, Rod End
11 7517674 2 Bolt (If Built after 8/16/99)
12 7555806
7556099
13 7546904 2 Nut
14 7661203 4 Pin, Cotter
15 7080927 2 Joint, Ball
22Asm., Tie Rod
(Incl. 4-9)(If Built before 8/16/99)
Asm., Tie Rod
(Incl. 4-9)(If Built after 8/16/99)
22Rod End, LH (If Built before 8/16/99)
Rod End, LH (If Built after 8/16/99)
44Washer, Flat (If Built before 8/16/99)
Washer, Flat (If Built after 8/16/99)
25
11
9
12
13
14
17
10/00
B13
DRIVE CLUTCH
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
4
3
1
2
13
12
5
11
5
10
14
7
6
9
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 5210752
5242981
5210753
5210754
AR
Spacer (.020)
AR
Spacer (.025)
AR
Spacer (.032)
AR
Spacer (.050)
7 5630279 3 Weight, Shift, 16
8 7512266 3 Bolt, Shoulder
9 7541906 3 Nut, FLEXLOC
10 3576504 1 Bearing, Moveable (1/2I)
11 5020422 3 Pin, Roller
12 7041157 1 Spring, Clutch
13 3576510 1 Cover, Bearing
14 1321632 1 Asm., Drive Clutch, ATV-08
(Incl. All Less 7,12)
B14
2/00
DRIVE CLUTCH
325 MAGNUM 4X4 A00CD32FA and 325 MAGNUM 4X4 A00CD32FB
5
18
12
3
16
17
14
13
6
7
5
9
8
10
12
11
4
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1520231 1 Clutch, One Way Drive
2 7556009 1 Washer
3 5131646 1 Spacer
4 7541906 3 Nut, FLEXLOC
5 5431936 6 Button, Clutch, Stemless
6 5020422 3 Pin, Roller
7 3585712 1 Bearing
8 7547130 1 Nut, Jam
9 3576510 1 Cover, Bearing
10 7552801 Washer, Spring Lock
11 7512176 6 Bolt
12 7041157 1 Spring, Clutch
13 1321457 3 Roller and Bushing
14 5430945 6 Washer, Multilube
15 7512266 3 Bolt, Shoulder
16 5630279 3 Weight, Shift, 16 MH
17 1321706 1 Asm., Drive Clutch, Braking
(Incl. All Less 12,7)
18 7556008 1 Washer
C1
2/00
DRIVEN CLUTCH
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
A00CD32AA
A00CD32CA
12
8
7
13
5
17
18
19
9
10
11
1
A00CD32FA
A00CD23FB
21
9
10
26
22
20
1
2
6
5
14
15
16
2
3
4
3
4
25
13
24
20
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7556120 AR Bushing
2 5220646 1 Washer, Domed
3 7552901 1 Washer, Spring Lock
4 7515382 1 Bolt
5 1321855 1 Asm., Driven Clutch, 3 Angle, Heavy
6 3211077 1 Belt, Drive
7 5430766 3 Button, Ramp
8 7511854 3 Bolt
9 7710448 1 Ring, Retaining
10 5210752 1 Spacer
11 5132344
5131447
12 7041782 1 Spring, Clutch
13 3576511 1 Bearing, Moveable (1”)
(Incl. 7-16)(AA)(CA)
11Ramp, Stationary (If built before 4/01/00)
Ramp, Stationary (If built after 4/01/00)
23
14 3576504 1 Bearing, Moveable (1/2”)
15 7556804 AR Washer (.030”)
16 7555898
7556076
17 7556013 1 Washer
18 7556010 1 Bushing
19 7710461 1 Ring, Retaining
20 1322184 1 Asm., Driven Clutch, Braking (Incl.
21 3211069 1 Belt, Drive
22 7517323 3 Screw
23 3585710 1 Bearing
24 521111 5 1 Washer
25 7041635 1 Spring
26 5131674 1 Ramp, Stationary
ARARWasher, Spacer (.020”)
Washer, Spacer (.025”)
2,9,10,13,18,19,23-26)(FA)(FB)
9/02
C2
CLUTCH COVER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
24
1
2
3
25
18
19
23
4
21
6
10
7
9
8
15
11
12
13
14
5
22
20
17
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512232 2 Screw
2 2632116 1 Foam, Clutch Air Inlet
3 5433453 1 Plate, Backing
4 2201520
2201676
5 5433363 1 Duct, Inlet, Down Tube
6 7517601
7517599
7 7080909 1 Clamp, Narrow Band
8 5521301 1 Seal, Clutch Cover
9 5432849
5433540
5433451-328
10 7670051 1 Clip, Clutch Cover
11 7512093
7512094
11Kit - Inner Clutch Cover (Incl. 8,11,15)
(If built before 1/03/00)
Kit - Clutch Cover, Inner
(If built after 1/03/00)
35Bolt and Washer (If built before
1/03/00)
Bolt and Washer (If built after 1/03/00)
1
Cover, Clutch, Outer
(If built before 2/13/99)
1
Cover, Clutch, Outer
(If built before 1/03/00)
1
Cover, Clutch, Outer
(If built after 1/03/00)
55Screw (If built before 1/03/00)
Screw (If built after 1/03/00)
12 7074946
7078689
13 7077377 1 Decal - Engine/Clutch Modification
14 7074782
7077666
15 7512094 9 Screw
16 5411489 1 Boot, Duct
17 7080761 2 Cable Tie
18 7558301 2 Washer, Flat
19 7517386 2 Screw
20 5433172
5433744
21 -- -- -- -- -- -- -- 3 Screw and Washer
22 5240409-067 1 Bracket, Retainer, Seal
23 5410575 1 Seal, Cover Case
24 5411795 1 Stopper, Inner Clutch Cover
25 5410489
5411901
11Decal - Clutch Cover
(If built before 10/04/99)
Decal - Warning, Clutch Cover
(If built after 10/04/99)
11Decal - “Automatic Transmission”
(AA)(AC)
Decal - “Automatic/EBS’ (FA)(FB)
11Duct, Air Outlet (If built before 11/05/99)
Duct, Air Outlet (If built after 11/05/99)
(See Crankcase Pg. D3, Ref. 6)
11Seal, Cover Case (If built before 1/03/00)
Seal, Clutch Cover (If built after 1/03/00)
2/00
C3
ELECTRICAL/TAILLIGHT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
15
16
17
33
38
36
1
34
35
37
4
3
2
10
11
12
31
32
11
5
6
7
8
9
13
12
30
29
28
14
27
25
26
19
20
21
22
23
24
18
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2460737
2460821
2460833
2460834
2 2200593 1 Kit - Circuit Breaker, 20 AMP
3 2201795 1 Kit - Circuit Breaker, 10 AMP
4 2432034 1 Asm., Taillight w/Brake Light (Incl.
5 4032046 1 Lens, Taillight
6 4032029 2 Screw, Taillight
7 4030043 1 Bulb, Taillight
8 4032045 1 Gasket, Taillight
9 4032064 1 Backing, Taillight/Brake Light
10 7670054 2 Nut, Speed
11 7541925 4 Nut, Nylok
12 7571602 4 Washer
13 7512027 2 Screw
14 5810290 3 Pad, Battery
15 4010311 1 Switch, Horn
16 4010310 1 Horn
17 7517386 1 Screw
1
Harness, Main Wire (AA)(CA)
(If built before 8/01/99)
1
Harness, Main Wire (AA)(CA)
(If built after 8/01/99)
1
Harness, Main Wire (FA)
1
Harness, Main Wire (FB)
5-10)
18 5810317 1 Pad
19 2200361 1 Kit - Battery Bolt, Short
20 4010095 1 Cable, Battery/Engine
21 7010032 2 Hook, Battery Strap
22 5410424 1 Strap, Battery Holddown
23 5432077 AR Tube, Battery Vent
24 4140006 1 Battery
25 7511876 2 Screw
26 4010354 1 Limiter, Speed (FA)(FB)
27 5431769 1 Cover, Battery
28 4010094 1 Cable, Battery/Solenoid
29 4010093 1 Cable, Solenoid/Starter
30 7512007 2 Bolt
31 5132214 1 Sink, Heat
32 4010249 1 Switch, Thermister LR-60
33 7512018 5 Screw
34 4060191 1 Rectifier, Regulator, LR 35
35 4010195 1 Limiter, RPM LR 83-3 (AA)(CA)
36 7512017 2 Screw
37 4020149 7 Clip, Rosebud
38 7670109 3 Clip, Routing
2/00
C4
REAR BRAKE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
2
3
4
1
7
6
5
7
5
15
19
13
16
17
18
9
8
14
10
11
12
13
18
17
5
24
28
27
26
24
25
29
27
22
21
30
23
19
20
21
22
9
19
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
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2201189
1910339
1930860
2 7515406 2 Screw
3 7555806 2 Washer
4 1910270
1910367
2201428
2201467
2201385
5 5410988 6 Seal
6 1910286 1 Line, Brake, Front Hand
7 1910288 1 Line, Brake, Rear Foot
8 7080573 1 Clamp
9 7517386 2 Screw
10 7080762 3 Clip, Brake Line
11 7661048 2 Rivet
12 7080816 1 T-Clip, Dual
1
Kit - Brake Pad (Incl. Spacer and Pin)
1
Pad, Spacer
1
Pin
1
Asm., Brake Caliper, Rear
(If built before 2/09/99)
1
Asm., Brake Caliper
(If built after 2/09/99)
1
Kit, Bleeder Replacement
1
Piston, Caliper, DH2P , Rear
1
Kit, Caliper Seal
13 1930674 3 Bolt, Banjo
14 7542403 2 Nut
15 7542153 1 Nut, Nylok
16 1930854 1 Reservoir, Brake, Rear
17 7080003 2 Clamp, Hose
18 1910331 1 Hose, Reservoir
19 7512240 3 Bolt
20 1012753-067 1 Pivot, Brake Mount, Rear
21 7542122 2 Nut, Nylok
22 7558301 2 Washer
23 1012752-067 1 Rod, Brake
24 7555919 2 Washer
25 7661401 1 Pin, Cotter
26 7556090 1 Washer
27 5433189 2 Bushing, Pedal Pivot
28 7515158 2 Screw
29 1910311 1 Master Cylinder, Foot
30 7041750 1 Spring, Torsion
9/02
C6
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
3
2
1
9
10
11
12
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
4 7512673 8 Bolt
5 7670081 8 Pushnut
6 5411710 2 Tire, 24x11.5-10
8
7
7 1525017 2 Val v e , R i m
8 1520183-117 2 Rim, Rear, Silver
9 7555745 2 Washer
10 7555796 2 Washer
11 7543005 2 Nut
12 5411164 2 Hub, Dust Cover
6
4
5
7/99
C7
FRONT HOUSING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
9
10
11
12
13
1
14
15
16
17
18
19
20
21
2
22
8
7
6
5
4
3
2
1
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
12
24
11
23
1341253 1 Asm., Front Gearcase (Incl. 1-24)
1 3233319 2 Seal, Oil
2 3233252 11 Screw
3 3233573 1 Cover, Gearcase
4 3233588 1 O-Ring
5 3233574 1 Nut
6 3233589 1 Bearing, Ball
7 3233590 1 Shaft, Input, Front Housing
8 3233591 1 Bushing
9 7080756 1 Clip
10 8450003-1525 AR Line, Vent
11 3233253 2 Plug, Drain
12 3233254 2 Washer
13 3233524 1 Tube, Vent
14 3233592 1 Housing, Front, Gearcase
15 3233593 1 Bushing
16 3233594 1 Gear, 37T, Bevel
17 3233595 1 Shaft, Output, Front
18 3233020 1 Bearing
19 3233554 1 Shim
20 3233596 1 O-Ring
21 3233597 1 Cover, Output, Front Housing
22 3233248 1 Seal
23 3233583 1 Shim
24 3233582 1 Button, Thrust
11/98
C8
MAIN GEARCASE
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
9
6
7
8
9
25
37
36
35
27
38
40
39
41
10
12
13
24
34
33
30
32
31
26
25
24
27
30
29
49
46
47
48
17
25
50
51
52
5
11
14
15
16
17
18
19
1
28
23
22
9
45
44
43
42
9
54
55
53
5
2
56
20
21
66
65
64
63
62
61
C9
60
59
58
4
5
57
1
MAIN GEARCASE
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
1341296
1341336
1 3233248
3233788
2 3233252 17 Screw
3 3233610
3233763
4 3233529 4 Pipe, Knock
5 3233019 4 Bearing, Ball
6 3233604
3233756
7 3233036 1 Chain, Silent
8 3233603
3233755
9 3233018 4 Bearing, Ball
10 3233055
3233961
11 3233054 2 Washer,Flat(FA)
12 3233153 2 Bellcrank
13 3233045 2 Ring, Retaining
14 3233040 2 Washer
15 8360009-600 AR Line, Vent
16 3233037 1 Tube, Vent
17 3233749 8 Screw
18 3233615 1 Switch, 3 Position (Qty. 2 for FA)
19 3233902
3233765
20 3233711 1 Plug
21 3233324 1 Washer
22 3233628 1 Washer
23 3233629
3233758
24 3233306 2 Ring, Retaining
25 3233619 3 Washer, Thrust
26 3233631
3233760
27 3233103 2 Bearing, Needle
28 3233602 1 Fork, Shift, H/R
29 3233598
3233761
30 3233012 2 Washer, Thrust
11Asm., Gearcase, Main
(Incl. all less 11)(AA)(CA)(FB)
Asm., Gearcase, Main
(Incl. 1-48,50-66)(FA)
33Seal (FA)
Seal (AA)(CA)(FB)
11Gearcase, LH (AA)(CA)(FB)
Cover, LH (FA)
11Shaft, Input, 31T (AA)(CA)(FB)
Shaft, Input, 31T (FA)
11Gear, 16T w/22T Spline (AA)(CA)(FB)
Gear, 14/19T (FA)
22Nut, FLEXLOC (FA)
Nut, Lock (AA)(CA)(FB)
11Gearcase, Main (AA)(CA)(FB)
Gearcase, RH (FA)
11Engagement Dog, Low (AA)(CA)(FB)
Engagement Dog, Low/Park (FA)
11Gear (AA)(CA)(FB)
Gear, 36T (FA)
11Shaft, Reverse (AA)(CA)(FB)
Shaft, Reverse (FA)
31 3233014 1 Bearing, Needle
32 3233599 1 Sprocket, 24T
33 3233029 1 Ring, Retaining
34 3233533 1 Engagement Dog, H/R, HLR
35 3233600 1 Gear, 30T
36 3233613 1 Spacer
37 3233708
3233762
38 3233309 1 Bracket, Interlock
39 3233032 1 Spring, Shifting, Interlock
40 3233308 2 Pin, Interlock
41 3233747 2 Screw
42 3233709
3233764
43 3233608 4 Screw (Qty. 8 for FA)
44 3233609 1 Cover, Bearing, Center
45 3233106 1 Ring, Retaining
46 3233607 1 Bearing, Ball
47 3233606 1 Shaft, 10T , Spiral Bevel
48 3233605
3233759
49 3233617 1 Switch, 2 Position (AA)(CA)(FB)
50 3233620 1 Sprocket, 12T w/18T Spline
51 3233621 1 Gear, Spiral, Bevel, 31T
52 3233622 1 Shaft, Rear Output
53 3233582 1 Button, Thrust
54 3233583 1 Shim
55 3233623
3233781
56 3233253
3233777
57 3233254 1 Washer
58 3233611 1 Shim
59 3233625 1 Shaft, Front Output
60 3233093 1 Sprocket, 12T
61 3233626 1 Chain, Roller
62 3233552 1 Bushing, Garlock
63 3233624 1 Shaft, Shift, Low
64 3233627 1 Shaft, Shift, H/R
65 3233548 2 O-Ring
66 3233618 2 Ring, Retaining
11Gear, Helical, 36T (AA)(CA)(FB)
Gear, Helical, 34T (FA)
11Gear, Helical, 48T (AA)(CA)(FB)
Gear, Helical, 50T (FA)
11Fork, Shift, Low (AA)(CA)(FB)
Fork, Shift, Low/Park (F A)
11Cover, Output (FA)
Cover, Output (AA)(CA)(FB)
11Plug, Drain (FA)
Plug, Drain (AA)(CA)(FB)
5/01
C10
REAR HOUSING
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
7
8
9
10
11
12
13
15
16
17
3
17
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341254
1341309
1341321
1 3233585 2 Screw
2 3233252 10 Screw
3 3233256 2 Seal
4 3233584
3233741
5 3233529 1 Pipe, Knock
6 3233587 1 O-Ring
7 3233581 1 Shim
8 3233268 2 Bearing, Ball
9 3233580 1 Shaft, Rear Axle
10 3233579
3233740
11 7670102 3 Clip
12 8450003-1525 AR Line, Vent
1
Asm., Gearcase, Rear (Incl. 1-10,
14-26) (If built before 2-21-99)
1
Asm., Gearcase, Rear (Incl. 1-10,
14-26) (If built before 7-01-99)
1
Asm., Gearcase, Rear (Incl. 1-10,
14-26) (If built after 7-01-99)
11Cover, Gearcase, Output
(For Gearcase 1341254 and 1341309)
Cover, Gearcase, Output
(For Gearcase 1341321)
(For Gearcase 1341254 and 1341309)
11Gear, Bevel, 31T, Rear
(For Gearcase 1341254 and 1341309)
Gear, Bevel, 31T, Rear
(For Gearcase 1341321)
14
8
18
13 7080307 1 Clamp,Hose
14 3233524 1 Tube, Vent
15 3233586
3233739
16 3233711 2 Plug
17 3233324 2 Washer
18 3233577 1 Bushing
19 3233576
3233707
3233738
20 3233575
3233714
21 3233588 1 O-Ring
22 3233319 1 Seal, Oil
23 3233573 1 Gearcase, Cover, Input
24 3233574 1 Nut, Lock
25 3233582 1 Button, Thrust
26 3233583 1 Shim
19
20
25
24
26
23
21
22
2
11Gearcase, Rear Housing
(For Gearcase 1341254 and 1341309)
Gearcase, Rear Housing
(For Gearcase 1341321)
1
Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341254)
1
Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341309)
1
Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341321)
11Bearing, Ball
(For Gearcase 1341254 and 1341309)
Bearing, Ball
(For Gearcase 1341321)
2/00
C11
GEAR SELECTOR
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
10
16
7
11
8
15
9
10
11
12
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341271
1341337
1 3233195
3233767
2 7512024 1 Screw
3 3233649 4 Screw
4 3233131 1 Strap, Wire
5 3233648 1 Cover, Gear Selector Boot
6 3233658
3233766
11Asm., Gear Selector
(Incl. 1-16)(AA)(CA)(FB)
Asm., Gear Selector (Incl. 1-16)(FA)
11Asm., Knob (AA)(CA)(FB)
Asm., Knob (FA)
11Handle, Gear Selector (AA)(CA)(FB)
Handle, Gear Selector (FA)
7 3233646 1 Sphere, Plastic
8 3233754 1 Pin, Groove
9 3233644 1 Pin, Dowel
10 3233642 2 Spring, Detent
11 3233060 2 Bullet, Detent
12 3233076 2 O-Ring
13 3233639 1 Slide, Low (AA)(CA)(FB)
14 3233640 1 Slide, High/Reverse (FA use Qty. 2)
15 3233641 1 Body, Gear Selector
16 3233643 1 Spring, Centering
14
13
9/00
C12
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
3
2
13
4
6
5
2
6
2
12
7
11
8
9
9
10
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7061013 2 Rod End, LH
2 7546707 4 Nut, FLEXLOC
3 7546702 2 Nut, LH
4 5020974 1 Rod, Low
5 7546701 2 Nut
6 7061014 2 Rod End, RH
7 1012822-067 1 Bracket, Shifter
8 7512130 2 Screw
9 7542122 4 Nut, Nylok
10 7555827 2 Washer
11 7512126 2 Bolt
12 7517386 4 Screw
13 5020973 1 Rod, High, Rev
C13
10/00
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
9
11
32
31
10
5
20
30
12
14
13
15
6
75
8
28
29
24
25
23
16
22
17
20
18
21
19
15
14
13
12
10
11
9
38
1
2
4
3
36
37
35
34
33
26
27
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5132152 1 Hub, Brake Disc
2 -- -- -- -- -- -- -- 1 Asm., Rear Brake Caliper
3 3513523 2 Bearing, Ball
4 5411653 1 Shield, Brake Line, Rear
5 7517604 3 Bolt
6 7512084 2 Screw
7 7555721 3 Washer
8 7542703 3 Nut, FLEXLOC
9 5411532 2 Cap, Swing Arm Pivot
10 5131863 2 Nut
11 5131864 2 Pivot, Threaded
12 3610072 2 Seal, Swing Arm Pivot
13 3554506 2 Bearing, Tapered Roller Cone
14 3554507 2 Bearing, Tapered Roller Cup
15 5411602 2 Seal, Swing Arm Pivot
16 1541323 1 Asm., Swing Arm (Incl. 14,15)
17 5132201
7080433
18 5411092 1 O-Ring
19 1380137 1 Asm., Prop Shaft, Rear
20 7553201 8 Washer
(See Rear Brake Pg C6, Ref. 4)
11Coupling, Prop Shaft, Greased
Fitting, Lubricating
21 7517585 8 Bolt
22 5131862 1 Axle, Rear
23 7710482 1 Ring, Retaining
24 7517612 3 Screw
25 1012881
5242851-067
5811716
26 -- -- -- -- -- -- -- 1 Asm., Gearcase, Rear (See Rear
27 5411531 1 O-Ring
28 5131930 1 Collar, Rear Axle
29 5411707 1 O-Ring
30 7072533 1 Decal - Hitch
31 7661913 1 Pin
32 1012740-067 1 Tube, Axle, LH
33 7515481 3 Screw
34 7710471 1 Ring, Retaining
35 5132075 1 Spacer , Bearing
36 3610071 1 Seal, Axle, Rear
37 5211849 1 Disc, Brake
38 5411092 1 O-Ring
1
Asm., Skid Plate
1
Plate, Rear Housing Skid,
1
Pad, Rubber
Housing Pg. C11 for Details)
4/00
C14
SHOCK 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
5
6
11
1
10
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 7515415 1 Screw
4 5132022 1 Tube (If built before 6/21/99)
5 5241147 1 Retainer, Shock
6 7041777-067
7041849-067
7041815-067
1
Spring
(For 7041774)(If built before 6/21/99)
1
Spring
(For 7041890)(If built after 6/21/99)
1
Spring (FA)(FB)
9
7
8
7 7041774
7041890
8 5630921
5630551
9 5132021 1 Tube
10 5433212 2 Bushing
11 7515438 1 Screw
11Shock (If built before 6/21/99)
Shock (If built after 6/21/99)
11Cam, Adjuster
(For 7041774)(If built before 6/21/99)
Cam, Adjuster
(For 7041890)(If built after 6/21/99)
2/00
D1
TRANSMISSION MOUNTING
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
5
8
9
7
11
2
4
5
1
6
7
8
9
2
10
2
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
-- -- -- -- -- -- -- 1 Asm., Main Gearcase (See Main
Gearcase Pg. C10 for Details)
1 7515417 2 Screw
2 7547108 6 Nut
3 7515398 2 Screw
4 7542321 2 Nut
5 7555976 3 Washer
6 5242819-067 1 Mount, Rear Transmission
7 7517289 4 Screw
8 7552603 4 Washer
9 7515522 4 Bolt
10 5242820-067 1 Mount, Transmission
11 -- -- -- -- -- -- -- 1 Mount, Engine,Rear
(See Engine Mounting Pg. B2, Ref.
18)
D2
11/98
CRANKCASE
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
6
5
7
8
22
3
2
1
21
20
19
18
4
9
10
11
12
13
14
15
16
17
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083669 1 Bushing, Starter
2 3080103 2 Pin, Dowel
3 3086394
3086793
4 3086395 1 Bearing, Ball
5 3084840 2 Pin, Dowel
6 3084205 3 Screw and Washer
7 3084839 1 Seal, Oil
8 3085850 1 Pipe
9 3086404
3086794
10 3086405 1 O-Ring
11Asm., Crankcase (Incl. 1-5,7,8,12,
18,21,22)(If built before 3/1/99)
Asm., Crankcase (Incl. 1-5,7,8,12,
18,21,22)(If built after 3/1/99)
11Gauge, Oil (If built before 3/1/99)
Gauge, Oil (If built after 3/1/99)
11 3084838 2 Pin, Straight
12 3086397 1 Plug
13 3084842 1 Union
14 3086400 1 Gasket, Oil Cooler
15 3086403 1 Union
16 3086402 1 Adapter, Oil Cooler (Incl. 13,15)
17 3086401 1 Connector, Oil Cooler
18 3084841 8 Bolt, Flange
19 3083453 1 Plug
20 3082956 1 Gasket
21 3086398 2 Bolt, Flange
22 3086399 1 Bolt, Flange
3/99
D3
CYLINDER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
24
23
25
22
27
9
20
1
26
21
2
3
4
6
6
9
7
8
10
8
14
5
1
2
11
14
9
15
16
12
13
15
17
19
4
18
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3086413 2 Cover, Valve
2 3086414 2 O-Ring
3 3086412 4 Bolt, Flange
4 3084874 6 Bolt, Flange
5 3086417 1 Plug, Cylinder Block
6 3086410 2 Pin, Straight
7 3084858 1 Seal, Intake Valve
8 3084994 2 Guide, Valve
9 3084798 3 Fin Damper A
10 3084859 1 Seal, Exhaust Valve
11 3086418 4 Bolt and Washer
12 3086408
3086796
13 3086421 1 Gasket, Exhaust
14 3085326 2 Stud
11Asm., Cylinder Head (Incl. 3,4,6-10,
12,14,26)(If built before 3/1/99)
Asm., Cylinder Head (Incl. 3,4,6-10,
12,14,26)(If built after 3/1/99)
15 3080530 2 Washer
16 3080285 2 Nut
17 3084838 2 Pin, Straight
18 3086407 1 Gasket, Cylinder
19 3086406
3086795
20 3086415 1 Gasket, Head
21 3086416 1 Gasket, Cam
22 3086420 1 Adapter
23 3083166 1 Asm., Adapter Band (Incl. 24)
24 3081497 1 Screw
25 3081330 2 Bolt
26 3086491 1 Cover, Rocker (If built before 3/1/99
27 3086419 2 Bolt, Flange
11Cylinder (If built before 3/1/99)
Cylinder (If built after 3/1/99)
only)
3/99
D4
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
1
13
12
2
3
4
5
6
7
8
8
9
10
11
14
4
5
14
16
6
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3085774
3085775
3085776
2 3086431
3086432
3086433
3086800
3086801
3086802
3 3086846 1 Pin, Piston
4 3084167 2 Clip
5 3086425 2 Bolt
6 3086424 1 Asm., Connecting Rod (Incl. 5,15)
7 3086422
3086423
3086797
1
Piston Ring Set (STD)
1
Piston Ring Set (0.25 O/S)
1
Piston Ring Set (0.50 O/S)
1
Piston Set (STD)(Incl. 3,4)
1
Piston Set (0.25 O/S)(Incl. 3,4)
1
Piston Set (0.50 O/S)(Incl. 3,4)(If built
before 3/1/99 use above Set)
1
Piston Set (STD)(Incl. 3,4)(If built after
3/1/99 use Set below)
1
Piston Set (0.25 O/S)(Incl. 3,4)
1
Piston Set (0.50 O/S)(Incl. 3,4)
1
Crankshaft, Complete (Incl. 16)
1
Crankshaft (If built before 3/1/99)
1
Crankshaft (If built after 3/1/99)
8 3240168 2 Key, Woodruff
9 3086434
3086435
3086436
3086437
10 3086492 1 Sprocket 1
11 3085528 1 Nut
12 3083904 1 Washer
13 3083905 1 Nut
14 3086427
3086798
3086799
15 3086426 2 Nut
16 3085815 2 Bearing, Ball
1
Spacer
1
Spacer
1
Spacer
1
Spacer
2
Bearing (STD)
2
Bearing (0.05 U/S)(If built after 3/1/99)
2
Bearing (0.25 U/S)(If built after 3/1/99)
D5
8/00
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
22
21
20
19
18
17
16
1
6
7
8
3
2
5
6
7
8
10
9
4
1
2
11
12
23
24
15
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084911 2 Screw, Adjusting
2 3084912 2 Nut
3 3084910 2 Asm., Rocker Arm (Incl. 1,2)
4 3086442 1 Shaft, Rocker
5 3085836 1 Washer
6 3084908 4 Collet, Valve
7 3084907 2 Retainer, Spring
8 3084906 2 Spring, Valve
9 3086439 1 Lever, Release
10 3086440
3086804
11 3086438
3086803
11Spring, Return (If built before 3/1/99)
Spring, Return (If built after 3/1/99)
11Camshaft (Incl. 9,10,12)(If built before
3/1/99)
Camshaft (Incl. 9,10,12)(If built after
3/1/99)
14
12 3084899 1 Pin, Dowel
13 3085778 1 Valve, Intake
14 3086441 1 Valve, Exhaust
15 3086445 1 Guide, Chain
16 3086444 1 Chain, Timing
17 3086448 1 Gasket, Tensioner
18 3086493 1 Tensioner
19 3083361 2 Bolt, Flange
20 3086443 1 Sprocket 2
21 3083663 1 Washer
22 3086449 1 Bolt, Flange
23 3086446 1 Lever
24 3084924 1 Bolt, Pivot
13
7/99
D6
RECOIL STARTER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
5
4
3
1
7
8
2
6
9
15
11
12
14
8
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084822 1 Reel
2 3083463 1 Spring, Return
3 3083378 1 Ratchet
4 3083379 1 Spring, Friction
5 3084744 1 Plate, Friction
6 3085266 1 Bolt and Washer
7 3083453 2 Plug
8 3082956 2 Gasket
13
9 3083669 1 Bushing, Starter
10 3083185 1 Spring, Spiral
11 3084750 1 Bushing
12 3084933 1 Gasket, Recoil
13 3084877 9 Bolt, Flange
14 3085856
3085943
15 3085083 1 Rope
10
11Asm., Recoil (Incl. 1-6,9-11,14,15)
Starter Case (Incl. 11)
11/9 8
D7
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
1
2
3
4
5
6
11
10
9
8
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083453 1 Plug
2 3082956 1 Gasket
3 3086455 1 Spring
4 3086222 1 Valve, Relief
5 3083568 1 Bolt, Flange
6 3086454
3087015
11Strainer, Oil
Strainer, Oil (For Engine Serial Numbers 35878-39057 Only)
7 3084963 1 Filter, Oil
8 3086451
3086805
9 3086450 1 Cover, Oil Pump
10 3086452 1 Rotor, Inner
11 3086453 1 Rotor, Outer
55Screw (If built before 3/1/99)
Screw (If built after 3/1/99)
7/00
D8
CARBURETOR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
1
3
4
5
6
9
10
11
15
14
16
2
13
52
51
50
7
8
46
29
30
31
12
49
25
47
48
26
27
28
24
43
45
34
33
35
32
44
12
42
36
41
37
40
39
38
17
18
19
D9
23
22
21
20
CARBURETOR
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 3130507 1 Ring
2 3130508 1 E-Ring
3 3130730 1 Needle, Jet
4 3130752 1 Ring
5 3130732 1 Diaphragm
6 3131130 1 Jet, Needle (P-0M)
7 3130541 2 Screw
8 3130540 2 Washer, Spring
9 3131128 1 Asm., Jet Block
10 3130014 1 Washer
11 3130566
3130567
12 3130515 2 Seal
13 3130517 1 Packing
14 3130518 1 E-Ring
15 3130519 1 Cap
16 3130361 1 Pin, Float
17 3130594 1 Plate
18 3130532 1 O-Ring
19 3130520 4 Screw
20 3130590 1 Asm., Float Body
21 3130521 1 Screw
22 3130529 1 Asm., Float
23 3130591 2 Screw
24 3130531 1 Valve, Needle (1.5)
25 3130533 1 O-Ring
26 3131132 1 Jet, Pilot (#50)
27 3130522 1 O-Ring
11Jet, Main (#142.5)(If built before
3/1/99)
Jet, Main (#145)(If built after 3/1/99)
28 3130523 1 Washer
29 3130525 1 Spring
30 3131131 1 Adjuster
31 3130905 1 Plug (If built before 3/1/99 only)
32 3130546 1 Screw, Adjust
33 3130545 1 Ring
34 3130544 1 Spring
35 3131126 1 Valve, Throttle (120)
36 3130589 1 Spring
37 3130514 1 Ring
38 3130501 2 Screw
39 3130513 1 Asm., Throttle Shaft
40 3130543 1 Guide, Cable
41 3130535 4 Screw
42 3130511 1 Cover
43 3130512 1 O-Ring
44 3130199 1 Holder, Guide
45 3130538 1 Spring
46 3130593 1 Asm., Plunger
47 3131133 1 Jet, Air (#175)
48 3131125
3131147
49 3084205 2 Screw and Washer
50 3131129 1 Spring
51 3131127 1 Asm., Cover
52 3130592 4 Screw
11Asm., Carburetor (Incl. 1-39,44-52)
(If built before 3/1/99)
Asm., Carburetor (Incl. 1-39,44-52)
(If built after 3/1/99)
3/99
D10
MAGNETO
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
10
9
13
12
11
6
4
14
8
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3086483
3086484
3086807
2 3086463 1 Cap, Spark Plug
3 3084997 1 Plug, Spark
4 3084978 1 O-Ring
5 3086460 1 Bearing, Dry
6 3086458 1 Asm., Plate (Incl. 5,8)(Incl. 9 if built
1
Asm., Ignition Coil (Incl. 1,2)
1
Ignition Coil (If built before 3/1/99)
1
Ignition Coil (If built after 3/1/99)
before 3/1/99 only)
7 3081657 5 Bolt and Washer
8 3084973 1 Seal, Oil
9 3081256 1 Screw and Washer
10 3086464 1 CDI System
11 3083073 2 Nut
12 3080077 2 Washer, Spring
13 3085521 1 Switch, Magnetic
14 3086457 1 Flywheel w/Ring Gear
7
6
(If built before 3/1/99 only)
D11
5
6/99
STARTING MOTOR
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
1
8
5
6
7
11
11
12
10
9
15
16
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3084981 1 Motor, Starting (Incl. 1-5,7-11)
1 3084982 1 Washer Set
2 3085353 1 Armature
3 3084406 1 Brush, Carbon
4 3083649 2 Nut, Flange
5 3084408 3 O-Ring
6 3082038 2 Bolt and Washer
7 3085034 1 Bracket, Rear
8 3085033 1 Asm.,FrontBracket(Incl.9)
14
9 3240114 1 O-Ring
10 3084983 2 Asm., Set Bolt (Incl. 5)
11 3084405 2 Ring, Rubber
12 3083737 1 Washer, Gear Shaft
13 3084412 1 Clip
14 3084411 1 Spring, Weight
15 3084410 1 Spring, Return
16 3084409 1 Clip
17 3085394 1 Asm., Gear Shaft (Incl. 12-16)
13
17
11/9 8
D12
FUEL PUMP
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
3
2
1
2
4
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 Washer
3 3084591 4 Screw
4 3084998 1 Diaphragm Gasket Set
11/9 8
D13
BREATHER BOX
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
5
1
17
18
7
23
22
21
16
13
15
14
14
19
20
13
12
7
8
5
9
5
10
11
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3085850 1 Pipe
2 3086481 3 Bolt, Flange
3 3086486
3086808
3086487
4 3085525 1 Pipe, Air Breather
5 3084085 4 Clamp
6 3086476 1 Pipe 1, Rubber
7 3083568 4 Bolt, Flange (Use 3 if built after
8 3086495 1 Pipe 1
9 3086478 1 Pipe 3, Rubber
10 3086482 1 Bolt, Banjo
1
Asm., Breather Box (Incl. 4,16-20,
21-23)(If built before 3/1/99)
1
Asm., Breather Box (Incl. 4,16-20,
21-23)(If built after 3/1/99)
1
Box, Breather (Incl. 1,4,16)
3/1/99)
11 3082719 2 Gasket
12 3086496 1 Pipe 2
13 3083418 2 Clamp, Hose
14 3084823 3 Band, Wire (Use 2 if built after 3/1/99)
15 3086809 1 Pipe 2, Rubber
16 3083798 1 Pipe, Pulse
17 3086470 1 Gasket, Breather Plate
18 3086468 1 Plate, Breather
19 3086494 1 Bracket 1
20 3083361 1 Bolt, Flange
21 3081180 4 Screw
22 3086467 1 Plate, Breather Box
23 3086469 1 Gasket, Plate
D14
3/99
TOOL KIT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
1
8
2
3
9
4
5
6
7
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
10
11
3086485 1 Kit - Tool (Incl. 2-7)
1 2870725 1 Gauge, Tire Pressure
2 3085001 1 Wrench, Open 8-10mm
3 3085002 1 Wrench, Open 12-14mm
4 3085567 1 Wrench, Box
5 3085569 1 Puller, Spark Plug (Wrench Handle)
6 3082657 1 Screwdriver
7 2682572 1 Pouch, Tool Kit
8 2871515 1 Lube, U-Joint, 3 oz., Case
9 9915299
9914939
10 2871095-067 1 Wrench, Spanner, Cam
11 2460442 1 Pigtail, Power
11Owner’s Manual, ‘00 ATV
Supplement, Owner’s Manual, ’00
Magnum 325 4x4
E1
2/00
PRINTED IN THE USA PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Changed pages in 9914940
A cover toc
B
C x x
D
E
F
G
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