magnum 330 4x4 model #a03cd32(aa)(ab)(ac) 330 magnum...

PARTS MANUAL PN 9917521 and MICROFICHE PN 9918976 3/03

MAGNUM 330 4X4Model #A03CD32(AA)(AB)(AC)

330 MAGNUM 4X4 HDSModel #A03CD32FB

Rev. 01

E 2002 Polaris Sales Inc.

TABLE OF CONTENTSMAGNUM3304X4A03CD32AAandMAGNUM3304X4A03CD32ABandMAGNUM3304X4A03CD32AC

and 330 MAGNUM 4X4 HDS A03CD32FB

Parts Manual

AA-ARM/STRUT MOUNTING C1. . . . . . . . . . . . . . . . . .AIR BOX B5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D7-8. . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR MOUNTING B3-4. . . . . . . . . . . . . . . . . .CLUTCH COVER C5. . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/BRAKE LINE A8. .CONTROLS - THROTTLE ASM./CABLE B12. . . . . . . .CRANKCASE D3. . . . . . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D5. . . . . . . . . . . . . . . . .CYLINDER D4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C2. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT B6-7. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C3-4. . . . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C6. . . . . . . . . . . . . . . . . . .ENGINE MOUNTING B1-2. . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM A14. . . . . . . . . . . . . . . . . . . . . . .

FFRONT BRAKE A11. . . . . . . . . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C8-9. . . . . . . . . . . . . . . . . . . . . . . . .FRONT PROP SHAFT B8-9. . . . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A7. . . . . . . .FRONT STRUT B10. . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT WHEEL B11. . . . . . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FFUEL TANK B3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GGEARCASE C11-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .GEAR SELECTOR C13. . . . . . . . . . . . . . . . . . . . . . . .

HHANDLEBAR B14. . . . . . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE and EXHAUST D6. . . . . . . . . . . . . . . . . . . . .

MMAGNETO D11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLING A13. . . . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP and OIL FILTER D10. . . . . . . . . . . . . . . . . .

RRACK MOUNTING, REAR A6. . . . . . . . . . . . . . . . . .REAR BRAKE A9-10. . . . . . . . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A3-4. . . . . . . . . . . . . . . . . . . . .REAR HOUSING C10. . . . . . . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C7. . . . . . . . . . . . . . . . . . . . . .RECOIL STARTER D9. . . . . . . . . . . . . . . . . . . . . . . .

SSHOCK MOUNTING D1. . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D12. . . . . . . . . . . . . . . . . . . . . . . .STEERING POST B13. . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/REAR/GEARCASE MOUNTING C14. . . . .

TTOOL KIT D14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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.

A3

REAR CAB and SEATMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

2423

2

7

3

6

910

14

13

15

16

17

37

12

19

20

21

32

5

29

39

40

1

38

35

114

36

18

3

31

33

30

8

26

22

34

25

6

27

2829


10

A4

REAR CAB and SEATMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.

Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7661645 10 Rivet (AA)(AB)(AC)2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-382

5433282-283A5432117-400

111

Cab, Rear, Silver (AA)(FB)Cab, Rear, Mossy Oak (AB)Cab, Rear, Camo Green Met (AC)

6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 2 Washer, Flat11 7512085 2 Screw12 5431786 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat16 7041370 1 Spring, Latch17 2682441-070

2682958-07058111045811105

1111

Seat, BlackCovering, Seat, BlackFoil, Seat Base, LargeFoil, Seat Base, Small

18 5412067 8 Bumper, Rubber19 7517375 2 Screw20 5431787 1 Cover, Tool Box21 5410896 1 Cap, Drain

22 ------ -- -- -- -- 1 Asm., Front Gearcase (See Front Hous-ing Pg. C8 and C9 for Details)

23 7552603 4 Washer, Spring Lock24 7512492 4 Screw25 5433435 1 Guard, Rock26 7556065 7 Washer27 7517386 9 Screw28 7558301 2 Washer, Flat29 7512232 21 Screw30 7542122 8 Nut, Nylok31 5412156 8 Grommet32 7517987 8 Screw33 1013899-067 1 Frame, Main34 5432221-070

5433219-0705434404-0705434405-070

1111

Footwell, LH, Black (AA)(AB)(AC)Footwell, RH, Black (AA)(AB)(AC)Guard, Mud, Footrest, LH (FB)Guard, Mud, Footrest, RH (FB

35 5811111 1 Foil, Foam, Rear Fender36 5811106 2 Foil, Rear Cab, Front37 7170007 1 Decal, 4 Stroke Carb/Filter38 5811087 1 Foil, Foam39 7670057 12 Nut, U-Type Speed40 5431796-070

5431797-0705434408-0705434409-070

1111

Guard, Mud, Rear, LH (AA)(AB)(AC)Guard, Mud, Rear, RH (AA)(AB)(AC)Guard, Mudflap, Rear, LH (FB)Guard, Mudflap, Rear, RH (FB)

5/03

A5

FRONT CABMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

7

8

9

10

14

22

16

32

13

2321

1817

2010

1

5

5

5

6

15

12

11

11

4

13

12

19

21




1 5811491 1 Foil, Side Panel, Gen IV, RH2 5812387 1 Foil, Side Panel, RH3 2632284-382

2632321-2832632284-4002632084-3172632633-3822632645-2832632633-400

1111111

Asm., Panel w/Foam, LH, Silver (AA)Asm., Panel w/Foam, LH, Mossy Oak (AB)Asm., Panel w/Foam, LH, Camo Gr (AC)Asm., Panel w/Foam, LH, Gunmetal (FB)Asm., Panel w/Foil, RH, Silver (AA)(FB)Asm., Panel w/Foil, RH, Mossy Oak (AB)Asm., Panel w/Foil, RH, Camo Gr (AC)

4 5811797 1 Foam, LH5 7512232 14 Screw6 5811801 1 Foam, Cab, Front7 5432088-382

5433290-2835432088-400

111

Cover, Front, Silver (AA)(FB)Cover, Front, Mossy Oak (AB)Cover, Front, Camo Green Met (AC)

8 7670085 2 Clip, Spring9 2632301-382

2632409-283

2632301-400

1

1

1

Cab, Front, Silver(Incl. Warning Decals)(AA)(FB)Cab, Front, Mossy Oak(Incl. Warning Decals)(AB)Cab, Front, Camo Green Met(Incl. Warning Decals)(AC)

10 7670057 12 Nut, Speed, U-Type11 5245394-067

5246021-06711

Shield, Splash, LHGuard, Splash, RH

12 7621509 3 Rivet, Plastic13 5811917 2 Shield, Deflector14 7670135

754724044

Nut, Speed (AA)(AB)Nut, Tinnerman, Push-On (FB)

15 7517312 2 Screw16 5431798-070

5431799-0705434406-0705434407-070

1111

Guard, Mud, Front, LH (AA)(AB)Guard, Mud, Front, RH (AA)(AB)Guard, Mudflap, Front, LH (FB)Guard, Mudflap, Front, RH (FB)

17 7541925 2 Nut, Nylok18 7555792 2 Washer19 5812138 1 Foam, LH20 7512085 2 Screw21 7542122 3 Nut, Nylok22 7512126 1 Screw23 7555931 2 Washer, Flat

5/03

A6

REAR RACK MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

4

3

1

2

6

10

9

8

11

5

7

1

7610

10


Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly.Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7517685 4 Screw2 7517983 2 Screw3 2670174-070 1 Asm., Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 7079927 2 Decal, Reflector, Red5 1013724-067 1 Support, Rear Rack

6 7512329 6 Bolt7 7558402 16 Washer, Flat8 5334092 2 Spacer9 5246394-067 2 Mount, Front, Rear Rack10 7542324 8 Nut, Nylok11 7512371 2 Screw

7/02

A7

FRONT RACK and BUMPER MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

12

13

14

1516

22

11

6

5

7

89

17

19

18

20

2

3

4

10

4

1

6

21




1 7517685 4 Screw2 2670180-070 1 Asm., Front Rack

(Incl. Ref. 3 and Warning Decal)3 7079926 2 Decal, Reflector, Amber4 7515399 8 Screw5 1014023-067 1 Support, Front Rack6 7542324 4 Nut, Nylok7 5432155-070 1 Bumper8 7515391 2 Screw9 7515390 2 Screw10 7555954 4 Washer11 1013744-067

1013746-06711

Support, Front Rack, LHSupport, Front Rack, RH

12 7512232 6 Screw

13 243101124310124030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

14 7512329 2 Bolt15 7558402 4 Washer, Flat16 5810467 1 Plug, Frame17 1013772-067 1 Guard, Brush18 7512097 6 Screw19 7670094 6 Nut, U-Type20 5433923

543392411

Shield, Radiator Side, LHShield, Radiator Side, RH

21 7547069 2 Nutsert22 5244729-067

5244730-06711

Extension, Frame, LHExtension, Frame, RH

7/02

A8

CONTROLS - MASTER CYLINDER/BRAKE LINEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

15

18

9

12

13

14

14

1617

3

1011

19

2

1

8

7

6

4

12

5




2010196 1 Asm., Master Cylinder1 5411297 1 Boot, Brake Line, Rubber2 5410988 2 Seal3 4110164 1 Switch4 2201834 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)5 7517899 2 Screw6 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)7 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)8 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)

9 1910565 1 Line, Brake10 7621462 1 Rivet11 7080539 1 Clamp, Nylon12 8360031-30 AR Conduit13 1910474 1 Line, Brake, Left Front w/Fittings14 7080138 8 Cable Tie15 7512024 2 Screw16 1910475 1 Line, Brake, Right Front Stainless

Steel17 7052292 1 Fitting, Cross18 1910470 1 Line, Brake, Pod, Stainless Steel19 1910499 1 Bolt, Banjo

7/02

A9

REAR BRAKEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

24

23

13

22

12

5

11

15

19

16

9

20

10

17

1211

2122

2813

16

78

2

3, 4

62

4

243,

2 2, 6

27

25

26

18 14

1 1 1, 1 1,

14

14

18

21


A10

REAR BRAKEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB


1910680 1 Asm., Caliper1 2201873 1 Kit, Anvil Body2 2201870 1 Kit, Slide Bolt3 2201872 1 Kit -Seal4 2201869 1 Kit, Piston and Seal5 2201732 1 Kit, Bracket6 2202414 1 Kit, Brake Pad7 7512084 6 Screw8 5434041 3 Clamp, Brake Line9 7542153 1 Nut, Flanged10 1930854 1 Reservoir, Brake, Rear11 7080003 2 Clamp, Hose12 1910675 1 Hose, Reservoir13 7515158 2 Screw14 7558301 3 Washer, Flat

15 1012753-067 1 Pivot, Mount, Brake, Rear16 7542122 2 Nut, Nylok17 7512240 3 Bolt18 7517386 2 Screw19 1014009-067 1 Rod, Brake20 7041750 1 Spring21 7555919 2 Washer22 5433189 2 Bushing, Pedal Pivot23 7661401 1 Pin, Cotter24 1910311 1 Master Cylinder, Foot25 5410988 6 Seal26 1910499 3 Bolt, Banjo27 1910516 1 Line, Foot Brake, Rear, Master Cyl.28 7042075 1 Spring

7/02

A11

FRONT BRAKEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

2 3

11

10

4

5

12

67

89




1910681 1 Asm., Brake Caliper, LH (Incl. 1-3,5-10)1910682 1 Asm., Brake Caliper, RH (Incl. 1-3,5-10)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5133407

51334081930642

111

Caliper, Brake, LHCaliper, Brake, RHKit, Front Brake Boot

4 5410494 1 Boot, Pin Seal5 5410495 1 Boot, Bushing

6 1930665 1 Kit, Piston and Seals (Incl. 7-9)7 5410779 1 Square Ring, Molded (.094)8 5410780 1 Square Ring, Molded (.103 x .134)9 5132294 1 Piston, Long10 1910411 1 Mount, Caliper11 2202412 1 Kit, Front Brake Pad12 7512365

75584027552901

444

ScrewWasherWasher, Lock

7/02

A12

DECALSMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1 2 63

7

1015

11

13

4

16 17

14

LH

RH

98

18

5

1

12




1 7170021 2 Decal, Warning, Front and Rear Rack2 7170664

717066571706707170671

1111

Decal, “4x4”, Side Panel, LH (AA)(AC)(FB)Decal, “4x4”, Side Panel, RH (AA)(AC)(FB)Decal, “4x4”, Side Panel, LH (AB)Decal, “4x4”, Side Panel, RH (AB)

3 7170660717066171706687170669

1111

Decal, Side Panel, LH (AA)(AC)(FB)Decal, Side Panel, RH(AA)(AC)(FB)Decal, ‘‘POLARIS”, Side Panel. LH (AB)Decal, ‘‘POLARIS”, Side Panel. RH(AB)

4 7078253 1 Decal, Age Warning, ATV5 7170025 1 Decal, Ignition (FB)6 7170658

71706667170746717065971706677170747

111111

Decal, “Magnum”,Tank Side, LH (AA)(AC)Decal, “Magnum”, Tank Side, LH (AB)Decal, “Magnum”, Tank Side, LH (FB)Decal, “Magnum”, Tank Side, RH (AA)(AC)Decal, “Magnum”,Tank Side, RH (AB)Decal, “Magnum”,Tank Side, RH (FB)

7 70797807079521

11

Decal, Warning, AWD Switch (AA)(AB)(AC)Decal, DHB, Low Range (FB)

8 7078465 1 Logo, Polaris Star9 7079916

707977311

Decal, “POLARIS” Front Cover (AA)(FB)Decal, “POLARIS”, Front Cover (AB)(AC)

10 7074220 1 Decal, “MacPherson Strut”11 7078577 1 Decal, Drain Recoil12 7079672 1 Decal, Foot Brake13 7079604 1 Decal, Warning, Override, AWD14 7079083 1 Decal, Warning, General, CPSC15 7079085 1 Decal, Discretionary Warning, ATV16 7077920 1 Decal, Passenger Warning17 7079087 1 Decal, Tire Pressure18 7079960

707995911

Decal, “POLARIS”, Rear (AA)(FB)Decal, “POLARIS”, Rear (AB)(AC)

7/02

A13

OIL COOLINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

12

1

11

9

2

8

10

6

18

16

3

19

54

13

17

15

7

7

14




1 5412039 2 Hose, Inlet2 7080851 1 Clamp, Hose3 7512084 1 Screw4 7080862 2 Clamp, Hose5 7542122 4 Nut, Nylok6 5245416-067 1 Bracket, Oil Cooler, Top7 7515133 4 Screw8 7517659 4 Screw9 2410157 1 Motor, Fan10 7670111 4 U-Clip

11 5433353 1 Shroud12 4010274 1 Thermister13 7558301 4 Washer, Flat14 7552801 4 Washer, Spring Lock15 7512240 4 Screw16 1240074 1 Cooler, Oil17 7080999 1 Cable Tie18 5411548 4 Mount, Rubber19 1013519 1 Asm., Bracket, Lower

11/02

A14

EXHAUST SYSTEMMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

7

11

3

1

8

2

4

10

6

9

13 14

15

10

16

12

9

5




1 7542324 2 Nut, Nylok2 7555716 2 Washer, Flat3 5410436 2 Washer, Rubber4 5412233 2 Dampener, Vibration5 5010192 2 Bushing6 7515316 2 Bolt, Carriage7 1261215-029 1 Silencer8 7512666 1 Bolt

9 7041804 4 Spring, Exhaust10 5243517 2 Seal, Exhaust11 1261222-029 1 Headpipe12 7041687 1 Spring, Exhaust13 7542301 2 Nut14 3110064 1 Mount, Torque Stop15 1260960-029 1 Manifold, Black16 3086237 1 Gasket, Exhaust

7/02

B1

ENGINE MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

29

17

26

8

20

5

12

2

28

13

14

1

27

2223

2425 15

79

19

30

6

18

11

27 27

28

28

28

21

4

16

4

10

3

4

4

4

4

4


B2

ENGINE MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB



1 8450003-1525 AR Line, Fuel2 7052075 1 Fitting, Tee3 1211750 1 Engine4 7547108 8 Nut, Flange Lock5 5243641-067 1 Bracket, Motor Mount6 7552901 2 Washer, Spring Lock7 7512232 1 Screw8 4010132 1 Cable, Ground Engine9 7512315 2 Bolt10 5412248 1 Mount, Rubber11 7555823 1 Washer, Flat12 5411721 1 Boot, Clutch Intake13 7080511 1 Clamp, Narrow Band14 8360009-600 AR Line, Fuel15 1013133-067 1 Mount, Engine, Rear

16 7517289 2 Screw17 3021119 1 Mount, Rubber, Rear18 7555815 2 Washer19 7515417 2 Screw20 5243288-067 1 Mount, Lower Front21 3021181 1 Mount, Rubber, Engine22 5430261 1 Bushing23 5210748 1 Washer, Flat24 7575202 1 Washer, Interlock25 7512566 1 Bolt26 4010095 1 Cable, Battery/Engine27 8450103 AR Hose, Fuel28 7080003 8 Clamp, Hose29 2530009 1 Filter30 7546601 2 Nut, Nylok

7/02

B3

FUEL TANK and CARBURETOR MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

5

25

1718

26

1312

1

2

3

14

11

4

2019

10

20

16

15

9

6824

23

8

10

19

22

21

27

28

7


B4

FUEL TANK and CARBURETOR MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB


1 5433687 1 Cap, Gas Tank (Includes Gasket)2 5812123 1 Gasket3 5811899 1 Seal, Foam4 8360009-600 AR Line, Fuel5 2520183 1 Asm., Fuel Tank (Incl. 17,18,25)6 7542105 1 Nut7 7552801 1 Washer, Split Lock8 7555859 5 Washer, Flat9 5245671-067 1 Bracket, Carburetor Support10 7547069 7 Nutsert11 7517505 1 Screw12 5432559 1 Knob, Fuel Valve13 5432733 1 Nut, Fuel Valve14 7052161 1 Valve, 3-Way15 7661637 2 Rivet

16 5240577-067 1 Bracket, Fuel Valve17 7052146 1 Fitting, Fuel Outlet, Main18 7052149 1 Fitting, Fuel Outlet, Reserve19 7080003 4 Clamp, Hose, Red20 8450103 AR Hose, Fuel21 3084205 2 Screw and Washer22 5245674-067 1 Mount, Carburetor23 3110050 1 Mount, Carburetor24 7512276 4 Screw25 5431053 1 Vent, Tank26 5222154

522215511

Bracket, Fuel Cover Mount, Rear, LHBracket, Fuel Cover Mount, Rear, RH

27 7558301 2 Washer28 7512277 2 Screw

7/02

B5

AIR BOXMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

26

1

2

3

4

6

7

8

91011

1213

15161718

1920

22

23

25

17

5

2114

24



1 7515180 1 Screw2 7558301 1 Washer, Flat3 5812023 1 Seal, Intake4 5433920 1 Duct, Inlet5 7517317 1 Screw6 5810317 1 Pad, Fuel Tank Bracket7 5433769 1 Cover, Air Box8 5811482 1 Seal, Air Box Cover9 5242044 6 Clip10 5432601 1 Collar, Carb Inlet11 7080699 1 Clamp, Hose12 5412101 1 Cap, Rubber13 5411866 1 Hose, Breather

14 7080694 2 Clamp, Hose, Spring15 7080511 1 Clamp, Narrow Band16 5411588 1 Boot, Carburetor17 7080413 2 Clamp, Narrow Band18 5433180 1 Duct, Carb Inlet19 5830128 1 Gasket, Carb Inlet20 5433768 1 Box, Air Intake, 4 Stroke21 7556091 2 Spacer22 5432377 1 Plug, Trap23 5812111 1 Foil, Air Box, RH24 8450059-100 AR Line25 7080650 1 Clamp, Hose26 1253372 1 Asm., Filter

7/02

B6

DRIVE SHAFTMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC

12

34

5



1380199 2 Asm., Drive Shaft1 7670092 2 Circlip2 1590358 2 Joint, CV

3 2201015 2 Kit, Boot (Incl. Clamps and Grease)4 1380186 2 Shaft5 3260104 2 Kit, Cross and Bearing

6/03

B7

DRIVE SHAFT330 MAGNUM 4X4 HDS A03CD32FB

1 23 4

5 67 8 9 10

11

1213



13802061380207

11

Asm., Drive Shaft, LHAsm., Drive Shaft, RH

1 1350063 2 CV-Joint2 1350062 2 Clamp, Large3 1350046 2 Grease4 3260114 2 Boot5 1350061 2 Clamp, Small6 1350057 2 Clamp, Small

7 1350058 2 Boot8 1350059 2 Grease9 1350060 2 Clamp, Large10 1350055 2 Joint, Plunging (Incl. 11)11 1350054 2 Ring, Spring12 2201972 2 Kit, Boot (Gear Side)(Incl. 6-9)13 2201630 2 Kit, Boot (Wheel Side)(Incl. 2-5)

7/02

B8

FRONT PROP SHAFTMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC

1 23

46

7

5E 2002 Polaris Sales Inc.



1380152 1 Asm., Prop Shaft (Incl. 1-4)1 3260133 1 Yoke, Gear Case, Front2 3260104 2 Kit, Cross and Bearing3 1380188 1 Shaft, Prop

4 3260131 1 Yoke5 7080424 1 Fitting, Lubrication6 5411092 1 O-Ring7 7661913 1 Pin, Spring

7/02

B9

FRONT PROP SHAFT330 MAGNUM 4X4 HDS A03CD32FB

1 23

4

65



1380181 1 Asm., Prop Shaft1 3260133 1 Yoke, Front Gearcase2 3260104 2 Kit, Cross and Bearing3 1380183 1 Shaft, Prop

4 3260131 1 Yoke, Prop Shaft5 5411092 1 O-Ring6 7080424 1 Fitting, Lubrication

7/02

B10

FRONT STRUTMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

2

3

4

5

6

7

8

910

1213

14

15

1617

18

19

20

21

22

10

10

18

11



1 7547104 2 Nut, Nylok2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7041375-067 2 Spring, Compression9 7515339 4 Bolt10 7558402 10 Washer, Flat11 5132301

513230211

Hubstrut, LHHubstrut, RH

12 3514342 2 Bearing, Hubstrut13 7710507 2 Ring, Retaining14 ------ -- -- -- -- 1 Asm., Front Brake Caliper, LH

(See Front Brake Pg. A11 for Details)15 7080306 2 Fitting, Lubrication16 7552901 4 Washer, Spring Lock17 7512365 4 Screw18 7542324 4 Nut, Nylok19 7080367 2 Clamp, Cable20 5211115 2 Washer21 7041761 2 Strut, Front22 5411608 2 Bumper

7/02

B11

FRONT WHEELMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

2 3

4

5

6

7

8

9

10

11

12



1 7512325 8 Bolt2 5244314 2 Disc, Brake3 7515513 8 Stud4 5133360 2 Hub5 1520563-385

1520563-06722

Rim, Front (AA)(AC)(FB)Rim, Front (AB)

6 5411709 2 Tire (24x8--12)

7 7547237 8 Nut, Flange8 7556004 1 Washer9 7542810 2 Nut, Slotted10 5411164 2 Cover, Dust11 7661401 2 Pin, Cotter12 1525017 2 Valve, Rim

7/02

B12

CONTROLS - THROTTLE ASM./CABLEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

3

1

8

5

4

2

6

7




1 5434113 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring4 7080967 1 Cable, Throttle5 2010205

2010204

1

1

Asm., Throttle Control(Incl.8)(AA)(AB)(AC)Asm., Throttle Control (Incl.8)(FB)

6 5245134 1 Bracket, Throttle Stop (FB)7 7517910 1 Screw (FB)8 2010191 1 Asm., Throttle Clamp

7/02

B13

STEERING POSTMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

31

4

2

5

8

10

6

9

7

2

5

6

1




1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1013920-067

1821110-06711

Post Steering (AA)(AB)(AC)Post, Steering (FB)

4 5246732 1 Bracket, Steering Post5 7512377 4 Bolt, Carriage

6 7556162 2 Bushing7 5222393 1 Flangette8 3514352 1 Bearing9 7547158 1 Nut10 7661633 1 Pin, Cotter

7/02

B14

HANDLEBARMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

7

2

9 10

12

13

15

16

21

24

23

5

25

6

8

20

25

22

1114

28

1817

19

3

26

4

A03CB32FB

7

27

1




1 40106714010818

11

Panel, Indicator (AA)(AB)(AC)Switch, Mode (FB)

2 7078465 1 Logo, Polaris Star (AA)(AB)(AC)3 7512024 2 Screw4 5432420 2 Cover, Screw5 7080922 1 Nut, Choke6 7081008 1 Cable, Choke7 5434643-070

5434642-07011

Panel, Instrument (AA)(AB)(AC)Panel, Instrument (FB)

8 75151897517224

44

Screw (AA)(AB)(AC)Screw (FB)

9 5246406-067 1 Bracket, Instrument Panel10 ------ -- -- -- -- 1 Asm., Master Cylinder

(See Control - Master Cyl./Brake LinePg. A8 for Details)

11 5433903 1 Spacer, Switch, LH12 4010422 1 Switch, Handlebar, Hi/Lo/Rev. Override13 5433834-070 2 Grip, Handlebar14 5432952 1 Plug, Hole15 7517625 1 Screw16 5334127-067

5246422-06711

Tube, Handlebar (AA)(AB)(AC)Tube, Handlebar (FB)

17 5132382 1 Cap, Hall Sensor (FB)

18 4010298 1 Sensor, Hall Effect (FB)19 7517658 1 Screw (FB)20 5631146

563114711

Block, Handlebar, PeggedBlock, Handlebar

21 7542122 4 Nut, Nylok22 7080631 1 Clip, Cable Retaining23 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B12, Ref. 5)24 2460841 1 Harness, Control Panel (FB)25 4010390

54319644010278

4010321

111

1

Switch, IgnitionCover, KeyBlank, Key, Series 2000, 6700, 6800NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

26 5433733 1 Nut, Ignition27 5412138 1 Mount, Rubber28 3280390 1 Asm., Instrument Cluster, KM (FB)

7/02

C1

A-ARM/STRUT MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

3

45

6

7

9

2

11

12

13

2414

15

17

1618

20

232221

2526

26 25

21

19

27

13

8

10E 2002 Polaris Sales Inc.



1 7542439 2 Nut, Nylok2 1820805 2 Asm., Tie Rod (Incl. 3-9)3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End5 7542711 2 Nut6 5020926 2 Tie Rod7 7547028 2 Nut, Jam, LH8 7517909 2 Bolt9 7061054 2 Rod End, LH10 5411920 1 Boot, Seal, Rod End11 7556099 4 Washer, Flat12 7547177 2 Nut13 7661203 4 Pin, Cotter14 7080927 2 Joint, Ball15 5211121 2 Bracket, Ball Joint16 7512284 4 Screw17 5410548 2 Boot, Rubber18 7542438 2 Nut, Castle

19 5431150-0705431149-0705433927-0705433928-070

1111

Shield, CV Joint, LH (AA)(AB)(AC)Shield, CV Joint, RH (AA)(AB)(AC)Shield, CV Joint, LH (FB)Shield, CV Joint, RH (FB)

20 7512084 4 Screw (FB uses Qty. 6)21 5434551 4 Bushing, A-Arm, Long22 5133806 2 Shaft, A-Arm23 2202282

2202283

2202274

2202275

1

1

1

1

Kit, A-Frame, LH(Incl. 13,21,22,25,26)(AA)(AB)(AC)Kit, A-Frame, RH (AA)(AB)(AC)(Incl. 13,21,22,25,26)Kit, A-Frame, LH (FB)(Incl. 13,21,22,25,26)Kit, A-Frame, RH (FB)(Incl. 13,21,22,25,26)

24 ------ -- -- -- -- -- 1 Hubstrut(See Front Strut Pg. B10, Ref. 11)

25 7512492 4 Screw26 7571611 4 Washer, Dish Lock27 7515415 2 Screw

7/02

C2

DRIVE CLUTCHMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

12 11

4

10

2 3 4

5

98

67

11

4

104

8

67 2

3

1

1

13 14 15 1617

9 12

A03CD32AA and A03CD32AB and A03CD32AC

A03CD32FB




1321976

1321706

1

1

Asm., Drive Clutch, ATV-06(Incl. All Less 6,11)(AA)(AB)(AC)Asm., Drive Clutch, Braking(Incl. All Less 6,11)(FB)

1 7518062 6 Screw2 5430945 6 Washer, Multilube3 1321457 3 Roller and Bushing4 5431936 6 Button, Clutch5 5210752

524298152107535210754

ARARARAR

Spacer (.020)(AA)(AB)(AC)Spacer (.025)(AA)(AB)(AC)Spacer (.032)(AA)(AB)(AC)Spacer (.050)(AA)(AB)(AC)

6 56313565630279

33

Weight, Shift, 20-40 (AA)(AB)(AC)Weight, Shift, 16 (FB)

7 7512266 3 Bolt, Shoulder8 7541906 3 Nut, FLEXLOC9 3576504

358571211

Bearing, Moveable (AA)(AB)(AC)Bearing (FB)

10 5020422 3 Pin, Roller11 7042202

704115711

Spring, Clutch (AA)(AB)(AC)Spring, Clutch (FB)

12 3576510 1 Cover, Bearing13 7556008 1 Washer (FB)14 1520231 1 Clutch, One Way Drive (FB)15 7556009 1 Washer (FB)16 5631119 1 Spacer (FB)17 7547130 1 Nut, Jam (FB)

7/02

C3

DRIVEN CLUTCHMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC

6

5

23

4

16

13

12

11

98

7

1

10

14

155




1 7556120 AR Bushing2 5220646 1 Washer, Domed3 7552901 1 Washer, Spring Lock4 7515382 1 Bolt5 1322337 1 Asm., Driven Clutch (Incl. 7-16)6 3211077 1 Belt, Drive7 5430766 3 Button, Ramp8 7511854 3 Bolt9 7710448 1 Ring, Retaining

10 5244116 1 Spacer11 5133701 1 Ramp, Stationary12 7041782 1 Spring, Clutch13 3576511 1 Bearing, Moveable (1 Inch)14 3576504 1 Bearing, Moveable (1/2 Inch)15 7556804 AR Washer (.030)16 7555898

7556076ARAR

Washer (.020)Washer (.025)

7/02

C4

DRIVEN CLUTCH330 MAGNUM 4X4 HDS A03CD32FB

1 2

34 5

67 8

9

1011

12

1314

15

16

17

2

18



1 7556120 AR Bushing2 1321973 1 Asm., Driven Clutch, Braking

(Incl.4-6,12-18)3 7556013 1 Washer4 7556010 1 Bushing5 7710461 1 Ring, Retaining6 5220646 1 Washer, Domed7 7552901 1 Washer, Spring Lock8 7515382 1 Bolt9 3211069 1 Belt, Drive

10 7517323 3 Screw11 1321977 3 Roller, Taper12 3585710 1 Bearing13 5211115 1 Washer14 3576511 1 Bearing, Moveable, 1 Inch15 7041635 1 Spring16 5132751 1 Ramp, Stationary17 5210753 2 Spacer18 7710448 1 Ring, Retaining

10/00

C5

CLUTCH COVERMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

4

8

910

14 13

15

192021

5

76

161

18

32

22

17

1

10

117

1211




1 7517386 3 Screw2 2632513

263211611

Foam, Clutch Air Inlet (AA)(AB)AC)Foam, Clutch Air Inlet (FB)

3 5433453 1 Plate, Backing (FB)4 2201676 1 Kit, Inner Clutch Cover5 5433363 1 Duct, Inlet6 7517599 5 Bolt and Washer7 7080909 1 Clamp, Narrow Band8 5521578 1 Seal, Clutch Cover9 5434255-070 1 Cover, Clutch, Outer10 7512094 9 Screw11 5410542 1 O-Ring12 5434264 1 Plug

13 7074782

7077666

1

1

Decal, “Automatic Transmission”(AA)(AB)(AC)Decal, “Automatic/EBS”, Clutch (FB)

14 7078689 1 Decal, Warning, Clutch Cover15 5411489 1 Boot, Duct16 7080707 2 Clamp, Narrow Band17 7558301 2 Washer, Flat18 5434213 1 Duct, Air Outlet19 ------ -- -- -- -- 3 Screw and Washer

(See Crankcase Pg. D3, Ref. 8)20 5242046 1 Bracket, Clutch Seal21 5410575 1 Seal, Cover Case22 5411795 1 Stopper, Inner Clutch Cover

7/02

C6

ELECTRICAL/TAILLIGHTMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

2

3 4

5

67

89 12

11

10

25

24

13

23

18 1920

21

2226

1110

34

33

32

30

29

1415

1617

2728

31




1 24610492461050

11

Harness, Main (AA)(AB)(AC)Harness, Main (FB)

2 2200593 1 Kit, Circuit Breaker, 20 AMP3 2410320 1 Asm., Taillight (Incl. 4-9)4 4032046 1 Lens, Taillight5 4032029 2 Screw, Taillight6 4030043 1 Bulb, Taillight7 4032045 1 Gasket, Taillight8 ------ -- -- -- -- 1 Backing, Taillight/Brake Light9 7670054 2 Nut, Speed10 7541925 4 Nut, Nylok11 7571602 4 Washer12 7512027 2 Screw13 5810290 3 Pad, Battery14 5810317 1 Pad, Fuel Tank (FB)15 4010310 1 Horn (FB)16 4010311 1 Switch, Horn (FB)17 7517386 1 Screw (FB)18 2202213 1 Kit, Battery Bolt

19 4010095 1 Cable, Battery/Engine20 7010032 2 Hook, Battery Strap21 5410424 1 Strap, Battery Holddown22 4010774 1 Battery23 5431769 1 Cover, Battery24 4010094 1 Cable, Battery/Solenoid25 4010093 1 Cable, Solenoid/Starter26 7512007 2 Bolt27 4010137

401035411

Limiter, RPM LR 44-3 (AA)(AB)(AC)Limiter, Speed (FB)

28 75120177512024

52

Screw (AA)(AB)(AC)Screw (FB)

29 40106844010697

11

Module, Control (AA)(AB)(AC)Module, Control (FB)

30 4020139 2 Clip, Rosebud31 7080965 2 Mount, Cable Tie32 7080138 5 Cable Tie33 4020149 2 Clip, Rosebud34 7670109 2 Clip, Routing

3/03

C7

REAR WHEEL DRIVEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

56

89

1

10

7

3

4

2



1 7661404 2 Pin, Cotter2 7547237 8 Nut, Flange3 5131649 1 Hub, Wheel, Rear4 7515513 8 Stud5 5411936 2 Tire, 24x11-126 1525017 2 Valve, Rim

7 1520564-3851520564-067

22

Rim, Rear, Silver (AA)(FB)(AC)Rim, Rear, Black (AB)

8 7555796 2 Washer, Cone9 7543005 2 Nut, Castle10 5411164 2 Cover, Dust, Hub

7/02

C8

FRONT HOUSINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC

12

34 5

67

89 10

1112

1314 15 16

17

19

2021

22

2324

25262728

29

3031

3233

3435

36

2228

13

6

18



1341344 1 Asm., Front Gearcase(Incl. 1-16,20-29,32-36)

3233950 1 Gearcase (Incl. 16,26,27)3233951 1 Asm., Drain Plug (Incl. 32,33)3233998 1 Asm., Cover Plate (Incl. 1,3,4)3233953 1 Asm., Race/Output Hub

(Incl. 7,14,15,34)3233954 1 Asm., Clutch (Incl. 9-13,35)3233956 1 Kit, Minor Repair (Incl. 2,20,21,28)3233949 1 Asm., Roll Cage (Incl. 11,35)

1 ------ -- -- -- -- 1 Cover, Output2 ------ -- -- -- -- 1 O-Ring3 ------ -- -- -- -- 1 Insert4 ---- -- -- -- -- -- 1 Coil5 3233925 1 Kit, Shim Set (Incl. Shims)6 3233926 2 Bearing, Roller Ball7 ---- -- -- -- -- -- 1 Hub, Race/Output, Male8 3233928 1 Pin, Dowel9 3233932 1 Bearing, Roller Ball10 3233933 1 Clutch Housing/Ring Gear11 ------ -- -- -- -- 1 Spring12 3233957 14 Kit, Roll13 3233934 2 Ring, Retaining14 ------ -- -- -- -- 1 Bushing

15 ------ -- -- -- -- 1 Hub, Race/Output, Female16 ------ -- -- -- -- 1 Bushing17 8450003-1525 AR Line, Fuel18 7670102 1 Clip19 7080307 1 Clamp, Hose20 ------ -- -- -- -- 1 O-Ring21 ------ -- -- -- -- 1 Seal22 3233955 11 Kit, Bolt23 3233947 1 Cover, Input24 3233945 1 Bearing, Roller Ball25 3233944 1 Shaft, Pinion, 11T26 ------ -- -- -- -- 1 Bushing27 ------ -- -- -- -- 1 Gearcase, LH28 ------ -- -- -- -- 2 Seal, Oil29 3233942 1 Plug, Oil Fill30 7552603 4 Washer, Spring Lock31 7512492 4 Screw32 ------ -- -- -- -- 1 Plug, Oil Drain33 ------ -- -- -- -- 1 Washer34 3233929 1 Bearing, Needle, Roller Thrust35 ------ -- -- -- -- 1 Roll Cage, Aluminum36 3233924 1 Plate Armature

7/02

C9

FRONT HOUSING330 MAGNUM 4X4 HDS A03CD32FB

2

3

4

5

6

7

8

9

1011

12 14

1819

13

1516

1715

79

15

1



1341351 1 Asm., Front Gearcase1 3233785 1 Seal, Triple Lip2 3233786 1 Cover, Gearcase3 3233588 1 O-Ring4 3233589 1 Bearing, Ball5 3233787 1 Pinion, 10T6 3233591 1 Bushing7 3233788 2 Seal8 3233789 1 Housing, Front Gearcase9 3233790 2 Bearing

10 3233791 1 Gear, 31T11 3233792 1 Differential12 3233554 1 Shim13 3233524 1 Tube, Vent14 3233794 1 Plug15 3233252 19 Screw16 3233793 1 Cover, Output, Front Housing17 3233529 2 Pipe, Knock18 3233777 1 Plug19 3233254 1 Washer

7/02

C10

REAR HOUSINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

14

6

3

1

13

21

5

4

2

1918

12

16

10

17 2220

15

724

8

7

1615

25

9

14

11 23




1341423 1 Asm., Gearcase, Rear(Incl. 1-8, 12-25)

1 3233585 2 Screw2 3233252 6 Screw3 3233753 1 Cover, Gearcase, Output4 3233529 1 Pipe, Knock5 3233587 1 O-Ring6 3233581 1 Shim7 3233268 2 Bearing, Ball8 3233965 1 Gear, Bevel, 31T9 7670102 3 Clip10 8450003-1525 AR Line, Vent11 7080307 1 Clamp,Hose12 3233524 1 Tube, Vent

13 3233970 1 Gearcase, Rear Housing14 3233711 2 Plug15 3233324 2 Washer16 3233878 2 Seal, Triple Lip17 3233577 1 Bearing, Plain18 3233969 1 Shaft, Pinion, 10T, Bevel19 3233714 1 Bearing, Ball20 3233699 1 Ring, Retaining21 3233968 1 Ring, Retaining22 3234003 1 Seal, Triple Lip23 3233963 1 Spring, Wave24 3233582 1 Button, Thrust25 3233583 1 Shim

7/02

C11

GEARCASEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

2

6869

19

64

12

54

8

3

36

67

37

2423

25

1

16

17

33

45

35

6

53

1110

6362

566665

9

18

5559

57

7

5250

26

15

39

47

45

51 4849

58

14

21

32

3130 29

34

28

43

4041

44

38

4227

46

3

13

20

22

6160

2423

33

33

29

313029

28

15

15

15

21

18

18

19

9


C12

GEARCASEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB



13413721341396

11

Asm., Gearcase, Main (AA)(AB)(AC)Asm., Gearcase (FB)

1 3233961 1 Nut, Lock2 3233906 1 Bellcrank3 3233826 8 Screw4 3233827 1 Cover5 3233829 1 Pawl, Detent6 3233869 1 O-Ring7 3233831 1 Shaft, Shift8 3233832 1 Gear, 31T9 3233788 2 Seal, Triple Lip10 3233324 1 Washer11 3233711 1 Plug, Oil Fill12 3233867 1 Gearcase, Main13 3233524 1 Tube, Vent14 3233910 1 Drum, Shift15 3233018 4 Bearing, Ball16 3233036 1 Chain, Silent17 3234028

323402911

Shaft, Input (AA)(AB)(AC)Shaft, Input (FB)

18 3233019 4 Bearing, Ball19 3233529 4 Pipe, Knock20 3233865 1 Cover, LH21 3233846 17 Screw, Tapping22 3233874 1 Seal, Dual Lip23 3233859 2 Pin, Dowel24 3233858 2 Fork, Shift25 3233860 1 Rail, Shift Shaft26 3233915 1 Plate27 3233916 1 Dog, Engagement28 3233849 2 Spring, Wave29 3233875 3 Dog, Engagement30 3233850 2 Ring, Retaining31 3233851 2 Washer32 3234027 1 Gear, 33T33 3233718 3 Bearing, Needle34 3233853 1 Shaft, Reverse35 3233854 1 Sprocket, 24T

36 3233855 1 Washer37 3233856

323391211

Gear, 30T (AA)(AB)(AC)Gear, 28T (FB)

38 32340143233971

11


39 32337093233764

11


40 3233608 4 Screw41 3233609 1 Cover, Bearing Center Drive42 3233106 1 Ring, Retaining43 3233357 1 Spacer44 3233607 1 Bearing, Ball45 3233606 1 Shaft, 10T46 3233777 1 Plug47 3233254 1 Washer48 3233781 1 Cover, Output, Front49 3233583 1 Shim50 3233582 1 Button, Thrust51 3233611 1 Shim52 3233625 1 Shaft, Output, Front53 3233622 1 Shaft, Output, Rear54 3233621 1 Gear, 31T55 3233784 1 Chain, Silent56 3233782 1 Sprocket, 22/18T57 3233783 1 Sprocket, 22/22T58 3233619 1 Washer, Thrust59 3233552 1 Bushing60 3234013 1 Clamp, Tie61 3233917 1 Lockout, Park62 3233548 1 O-Ring63 3233839 1 Gear, 16T64 3233838 1 Disc, Lockout65 3233909 1 Star, Detent66 3233076 1 O-Ring67 3233830 1 Spring, Compression68 3233835 1 Switch69 3233834 1 Ring, Retaining

7/02

C13

GEAR SELECTORMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

2

3

10

4

6

11

5

6

7

98

5




1 5412003 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector4 5433103 2 Mount, Gear Selector5 7515175 1 Screw6 7542122 2 Nut, Nylok

7 1821135 1 Asm., Linkage8 7542324 2 Nut, Nylok9 7555770 2 Washer10 1013315-067 1 Selector, Gear11 7515306 2 Bolt

7/02

C14

SWING ARM/REAR/GEARCASE MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1 2 34

5

67 8

9 1011 12

1415

16

18

1920

21

33

22

2324

25

262728

17

313234

7611

12

196

15

29

30

13

13




1 5412022 1 O-Ring2 5133360 1 Hub, Wheel, AWD3 7515513 4 Stud4 5244882 1 Disc, Brake5 ------ -- -- -- --

75154817552603

1

22

Asm., Brake Caliper(See Rear Brake Pg. A10 for Details)ScrewWasher, Spring Lock

6 7517604 3 Bolt7 7555721 3 Washer8 7547065 3 Nut, Nylon9 5133387 1 Nut, Jam10 5133388 1 Pivot, Threaded, LH11 3514399 2 Bearing, Tapered Roller Cone12 3514398 2 Bearing, Tapered Roller Cup13 5812447 2 Foam14 1541820 1 Asm., Swing Arm (Incl. 12)15 5412202 1 O-Ring16 1380202 1 Asm., Prop Shaft, Rear17 7661913 1 Pin, Spring

18 5133389 1 Pivot, Swing Arm, RH19 7553201 8 Washer, Split Lock20 7517585 8 Bolt21 5133626 1 Axle, Rear22 7517612 3 Screw23 5411531 1 O-Ring24 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See Rear

Housing Pg. C10 for Details)25 1012881

5242851-0675811716

111

Asm., Skid Plate, RearPlate, Skid, Rear HousingPad, Rubber

26 5132698 1 Collar, Rear Axle27 5411707 1 O-Ring28 7170910 1 Decal, Hitch29 5245050 2 Clamp, Brake Line, Rear30 7512017 2 Screw31 1013264-067 1 Tube, Axle, LH32 3514342 1 Bearing Hubstrut33 7710507 1 Ring, Retaining34 7512325 4 Bolt

7/02

D1

SHOCK MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

2

6

59

3

4

1

78

1




1 7542439 2 Nut, Nylok2 7515415 1 Screw3 5241147 1 Retainer, Shock4 7041849-067

7041815-06711

Spring, Compression (AA)(AB)(AC)Spring, Compression (FB)

5 7041964 1 Shock6 5630551 1 Cam, Adjuster7 5132021 1 Tube8 5433212 2 Bushing9 7515438 1 Screw

7/02

D2

TRANSMISSION MOUNTINGMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

1

2

45

10 9

88

910

6

2

16

7

11

12

2

2

3




-- -- -- -- -- -- -- 1 Asm., Gearcase(See Gearcase Pg. C12 for Details)

1 7515417 2 Screw2 7547108 6 Nut, Flange Lock3 8450003-100 AR Line, Vent4 7515398 2 Screw5 7542321 2 Nut, Flange6 7555976 3 Washer, Flat

7 5242819-067 1 Mount, Rear Transmission8 7517289 4 Screw9 7552603 4 Washer, Spring Lock10 7515522 4 Bolt11 5242820-067 1 Mount, Transmission12 ------ -- -- -- -- 1 Mount, Engine,Rear

(See Engine Mounting Pg. B2, Ref. 15)

7/02

D3

CRANKCASEMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

36

12

13

9

5

15

18

19

16

7

17

14

12

10

11

8

12

4




1 3083669 1 Bushing, Starter2 3086741 2 Pin, Dowel3 3087125 1 Asm., Crankcase

(Incl. 1-5,9,13,15,18,19)4 3087157 1 Plug, Blind5 3087116 2 Pin, Dowel6 3086395 1 Bearing, Ball7 3084838 2 Pin, Straight8 3084205 3 Screw and Washer9 3084839 1 Seal, Oil

10 3087128 1 Gauge, Oil11 3087065 1 O-Ring12 3087066 2 Union13 3087155 1 Plug14 3084849 1 Union, Oil Pump15 3087156 2 Bolt, Flange16 3086749 1 Plug17 3082956 1 Gasket18 3087117 8 Bolt, Flange19 3086399 1 Bolt, Flange

7/02

D4

CYLINDERMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

3

21

20

14

10

4

9 12

16

12

22

23

5

11 13

29

19

2425

26

27

15

18

17

10

12

1617

4

11

11

46 7

828




1 3087259 2 Cover, Valve2 3086414 2 O-Ring3 3087159 4 Bolt, Flange4 3087158 13 Bolt, Flange5 3086417 1 Plug, Cylinder Block6 3087033 1 Cover, Breather7 3085850 1 Pipe8 3087034 1 Gasket9 3084858 1 Seal, Intake Valve10 3084994 2 Guide, Valve11 3084798 3 Fin Damper A12 3084859 1 Seal, Exhaust Valve13 3086418 4 Bolt and Washer14 3087237 1 Asm., Cylinder Head

(Incl. 3,4,10-12,14,16)

15 3086421 1 Gasket, Exhaust16 3085326 2 Stud17 3080530 2 Washer18 3086787 2 Nut19 3084838 2 Pin, Straight20 3086407 1 Gasket, Cylinder21 3087236 1 Cylinder22 3087238 1 Gasket, Head23 3086416 1 Gasket, Cam24 3087050 1 Adapter25 3083166 1 Asm., Adapter Band (Incl. 26)26 3081497 1 Screw27 3086786 2 Bolt28 3086410 2 Pin, Straight29 3087160 2 Bolt, Flange

7/02

D5

CRANKSHAFT and PISTONMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

7

16

6

5

15

14

10

8

11

2

1

4

9

1312

5

146

4

8

3




1 308724430872453087246

111

Piston Ring Set (STD)Piston Ring Set (0.25 O/S)Piston Ring Set (0.50 O/S)

2 308724130872423087243

111

Piston Set (STD)(Incl. 3,4)Piston Set (0.25 O/S)(Incl. 3,4)Piston Set (0.50 O/S)(Incl. 3,4)

3 3086846 1 Pin, Piston4 3084167 2 Clip5 3087240 2 Bolt6 3087239 1 Asm., Connecting Rod (Incl. 5,15)7 3087119 1 Crankshaft, Complete (Incl. 16)8 3240168 2 Key, Woodruff

9 3086434308643530864363086437

1111

SpacerSpacerSpacerSpacer

10 3086492 1 Sprocket 111 3085528 1 Nut12 3086767 1 Washer13 3083905 1 Nut, Lock14 3086427

30867983086799

222

Bearing (STD)Bearing (0.05 U/S)(If built after 3/1/99)Bearing (0.25 U/S)(If built after 3/1/99)

15 3086426 2 Nut16 3085815 2 Bearing, Ball

7/02

D6

INTAKE and EXHAUSTMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

11

12

23

910

1314

8

76

4

2

16

24

2

15

27

1817

2526

28

1

31

76

8

5

222120

19




1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1,2)4 3087053 1 Shaft, Rocker5 3085836 1 Washer, Wave6 3084908 4 Collet, Valve7 3087203 2 Retainer, Spring8 3087248 2 Spring, Valve9 3086439 1 Lever, Release10 3086804 1 Spring, Return11 3087247 1 Camshaft (Incl. 9,10,12)12 3087254 1 Pin, Dowel13 3085778 1 Valve, Intake14 3086441 1 Valve, Exhaust

15 3086445 1 Guide, Chain16 3086444 1 Chain, Timing17 3086448 1 Gasket, Tensioner18 3086493 1 Tensioner19 3087132 1 Pin20 3087131 1 Spring21 3087130 1 Gasket22 3087129 1 Plug23 3083361 2 Bolt, Flange24 3086443 1 Sprocket 225 3087249 1 Washer26 3086449 1 Bolt, Flange27 3086446 1 Lever28 3084924 1 Bolt, Pivot

7/02

D7

CARBURETORMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

42

32

29

9

45

5

44

12

4

6

3637

33

31

123013

12

1415

21

19

26

1110

3

22

20

16

24

18

25

35

23

46

3940

87

41

34

28

27

17

43

38


D8

CARBURETORMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB



1 3130507 1 Ring2 3130508 1 E-Ring3 3130730 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131457 1 Jet, Needle7 3130541 2 Screw8 3130540 2 Washer, Spring9 3131128 1 Asm., Jet Block10 3130014 1 Washer11 3131458 1 Jet, Main (#122.5)12 3130515 2 Seal13 3130517 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 2 Screw

24 3131360 1 Valve, Needle25 3130533 1 O-Ring26 3131421 1 Jet, Pilot (#42.5)27 3131423 1 Screw, Adjust28 3130836 1 Spring29 3131460 1 Valve, Throttle (100)30 3130589 1 Spring31 3130514 1 Ring32 3130501 2 Screw33 3130513 1 Asm., Throttle Shaft34 3130543 1 Guide, Cable35 3130535 4 Screw36 3130511 1 Cover37 3130512 1 O-Ring38 3130199 1 Holder, Guide39 3130538 1 Spring40 3130593 1 Asm., Plunger41 3130625 1 Jet, Air (#160)42 3131456 1 Asm., Carburetor (Incl. 1-33,38-46)43 3084205 2 Screw and Washer44 3131129 1 Spring45 3131127 1 Asm., Cover46 3130592 4 Screw

4/03

D9

RECOIL STARTERMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM

4X4 HDS A03CD32FB

13

6

4

7

10

5

31 2

11

8

12

14

9

8

7



1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3086749 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3087150 9 Bolt, Flange13 3087163

308716411

Asm., Recoil (Incl. 1-6,9-11,13,14)Starter Case (Incl. 11)

14 3085083 1 Asm., Rope

7/02

D10

OIL PUMP and OIL FILTERMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

11

9

1

10

8

2

4

7

5

6

3




1 3086749 1 Plug2 3082956 1 Gasket3 3086455 1 Spring4 3086222 1 Valve, Relief5 3087256 1 Bolt, Flange6 3086454 1 Strainer, Oil

7 3084963 1 Filter, Oil8 3087255 5 Screw9 3086450 1 Cover, Oil Pump10 3086452 1 Rotor, Inner11 3086453 1 Rotor, Outer

7/02

D11

MAGNETOMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

7

4

6

1

2

10

8

3

5

9




1 30870363086484

11

Asm., Ignition CoilCoil, Ignition

2 3087037 1 Cap, Spark Plug3 3087257 1 Plug, Spark4 3084978 1 O-Ring5 3087252 1 Asm., Plate

6 3081657 5 Bolt and Washer7 3087251 1 Magneto Complete8 3087196 1 Switch, Magnetic9 3087258 2 Bolt, Flange10 3087253 1 CDI System

7/02

D12

STARTING MOTORMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

9

11

1

5

10

4

3

17

12

16

15

14

13

67

8

21

11




3084981 1 Motor, Starting (Incl. 1-5,7-11)1 3084982 1 Washer Set2 3085353 1 Armature3 3084406 1 Brush, Carbon4 3083649 2 Nut, Flange5 3084408 3 O-Ring6 3082038 2 Bolt and Washer7 3085034 1 Bracket, Rear8 3085033 1 Asm., Front Bracket (Incl. 9)

9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 5)11 3084405 2 Ring, Rubber12 3083737 1 Washer, Gear Shaft13 3084412 1 Clip14 3084411 1 Spring, Weight15 3084410 1 Spring, Return16 3084409 1 Clip17 3087030 1 Asm., Gear Shaft (Incl. 12-16)

7/00

D13

FUEL PUMPMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

4

1

3 2

2

4




3085275 1 Asm., Fuel Pump (Incl. 1-4)1 3084999 1 Screw and Washer2 3085000 2 Screw and Washer

3 3084591 4 Screw4 3084998 1 Diaphragm Gasket Set

11/98

D14

TOOL KITMAGNUM 330 4X4 A03CD32AA and MAGNUM 330 4X4 A03CD32AB and MAGNUM 330 4X4 A03CD32AC and 330 MAGNUM 4X4 HDS A03CD32FB

2

7

1

9

3

4

8

10

5

6




3086485 1 Kit, Tool (Incl. 2-7)1 2870725 1 Gauge, Tire Pressure2 3085001 1 Wrench, Open 8-10mm3 3085002 1 Wrench, Open 12-14mm4 3085567 1 Wrench, Box5 3085569 1 Puller, Spark Plug (Wrench Handle)6 3082657 1 Screwdriver

7 2682572 1 Pouch, Tool Kit8 2871515 1 Lube, U-Joint, 3 oz., Case9 9917492

9917520

9917524

11

1

Owner’s Manual, ’03 ATVSupplement, Owner’s Manual, ’03Magnum 330 4x4 (AA)(AB)Supplement, Owner’s Manual, ’03 330Magnum 4x4 HDS (FB)

10 2873647 1 Wrench, Torx7/02

PRINTED IN THE USA PARTS MANUAL PN 9917521 and MICROFICHE PN 9918976 3/03

Changed

pages

in9917521

12

34

56

78

910

1112

1314

Acover

toc

Bx

C D E F G

12

34

56

78

910

1112

1314

magnum 330 4x4 model #a03cd32(aa)(ab)(ac) 330 magnum...

Documents