magnum 330 4x4 model #a05cd32aa model #a05cd32ab model...

PARTS MANUAL PN 9919490 and MICROFICHE PN 9919491 7/04

E 2004 Polaris Sales Inc.

MAGNUM 330 4X4Model #A05CD32AAModel #A05CD32ABModel #A05CD32AC

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TABLE OF CONTENTSMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Parts Manual

AA-ARM B14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR BOX B6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D1-2. . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR MOUNTING B3-4. . . . . . . . . . . . . . . . . .CLUTCH COVER C3. . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/BRAKE LINE A8. .CONTROLS - THROTTLE ASM./CABLE B11. . . . . . . .CRANKCASE C14. . . . . . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D4. . . . . . . . . . . . . . . . .CYLINDER D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C1. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT, FRONT B7. . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C2. . . . . . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C4. . . . . . . . . . . . . . . . . . .ENGINE MOUNTING B1-2. . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM B5. . . . . . . . . . . . . . . . . . . . . . .

FFRONT BRAKE A10. . . . . . . . . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C6. . . . . . . . . . . . . . . . . . . . . . . . .FRONT PROP SHAFT B8. . . . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A7. . . . . . . .FRONT STORAGE BOX A9. . . . . . . . . . . . . . . . . . . .FUEL PUMP D10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C10. . . . . . . . . . . . . . . . . . . . . . . .

GGEARCASE C7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE C8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HHANDLEBAR B13. . . . . . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE and EXHAUST D5. . . . . . . . . . . . . . . . . . . . .

MMAGNETO D8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OOIL COOLING A14. . . . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP and OIL FILTER D7. . . . . . . . . . . . . . . . . .

RRACK MOUNTING, REAR A6. . . . . . . . . . . . . . . . . .REAR BRAKE A11-12. . . . . . . . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A3-4. . . . . . . . . . . . . . . . . . . . .REAR HOUSING C9. . . . . . . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C5. . . . . . . . . . . . . . . . . . . . . .RECOIL STARTER D6. . . . . . . . . . . . . . . . . . . . . . . .

SSHOCK MOUNTING C12. . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D9. . . . . . . . . . . . . . . . . . . . . . . .STEERING POST B12. . . . . . . . . . . . . . . . . . . . . . . . .STRUT MOUNTING B14. . . . . . . . . . . . . . . . . . . . . . . .STRUT, FRONT B9. . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/REAR/GEARCASE MOUNTING C11. . . . .

TTOOL KIT D11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING C13. . . . . . . . . . . . . . . . .

WWHEEL, FRONT B10. . . . . . . . . . . . . . . . . . . . . . . . . .

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 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2524

2

7

3

6

910

15

14

16

1718

38

13

19

20

32

5

35

40

41

1

39

36

114

37 3

31

33

30

8

27

23

34

26

6

28

29


10 28

21

22

12

A4

REAR CAB and SEATMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description

1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-382

5432117-4005435164-455

111

Cab, Rear, Silver Vapor Metallic (AA)Cab, Rear, Camo Green Metallic (AB)Cab, Rear, New Break Up (AC)

6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 14 Washer, Flat11 7512085 2 Screw12 7556034 2 Washer13 5431786 1 Box, Tool14 7621403 2 Rivet15 5211033 2 Bracket, Lever Retainer16 1040387 1 Latch, Seat17 7041370 1 Spring, Latch18 2683222-070

2682958-07011

Asm., Seat, BlackCovering, Seat, Black

19 7517375 2 Screw20 5431787 1 Cover, Tool Box21 7515199 3 Screw

22 1040447-067 1 Box, Battery23 ------ -- -- -- -- 1 Asm., Front Gearcase

(See Front Housing Pg. C6 for Details)24 7552603 4 Washer, Spring Lock25 7512492 4 Screw26 5435005 1 Guard, Rock27 7556065 7 Washer28 7517386 9 Screw29 7558301 2 Washer, Flat30 7542122 8 Nut, Nylok31 5412156 8 Grommet32 7517987 8 Screw33 1014293-067 1 Frame, Main34 5432221-070

5433219-07011

Footwell, LH, BlackFootwell, RH, Black

35 7512232 21 Screw36 5811111 1 Foil, Rear Fender37 5811322 1 Foil, Tape38 7170007 1 Decal, 4 Stroke Carburetor/Filter39 5811087 1 Foil40 7670057 12 Nut, U-Type Speed41 5431796-070

5431797-07011

Guard, Mud, Rear, LHGuard, Mud, Rear, RH

7/04

A5

FRONT CABMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

7

8

9

13

22

15

32

2321

171620

9

1

5

5

6

14

11

10

10

4

11

18

21


12

19


1 5811491 1 Foil, Side Panel, RH2 5812484 1 Foil, Side Panel, RH3 2632284-177

2632848-455

2632633-382

2632849-455

1

1

1

1

Asm., Panel w/Foam, LH, Black Metallic(AA)(AB)Asm., Panel w/Foam, LH, New Break Up(AC)Asm., Panel w/Foil, RH, Silver Vapor Me-tallic (AA)(AB)Asm., Panel w/Foil, RH, New Break Up(AC)

4 5811797 1 Foam, Panel, Side, LH5 7512232 10 Screw6 5811801 1 Foam, Cab, Front7 5435110-382

5435110-4005435166-455

111

Cover, Front, Silver Vapor Metallic (AA)Cover, Front, Camo Green Metallic (AB)Cover, Front, New Break Up (AC)

8 2632981-382

2632981-400

2632982-455

1

1

1

Asm., Cab, Foam, Front, Silver Vapor Me-tallic (Incl. Warning Decals)(AA)Asm., Cab, Foam, Front, Camo GreenMetallic (Incl. Warning Decals)(AB)Asm., Cab, Front, New Break Up(Incl. Warning Decals)(AC)

9 7670057 12 Nut, Speed, U-Type10 5245394-067

5246021-06711

Shield, Splash, LHGuard, Splash, RH

11 7621509 2 Rivet12 7515158 2 Screw13 7670135 4 Nut, Speed14 7517312 2 Screw15 5431798-070

5431799-07011

Guard, Mud, Front, LHGuard, Mud, Front, RH

16 7541925 2 Nut, Nylok17 7555792 2 Washer18 5812138 1 Foam, Panel, LH19 7556034 2 Washer20 7512085 2 Screw21 7542122 3 Nut, Nylok22 7512126 1 Bolt23 7558221 2 Washer, Flat

7/04

A6

REAR RACK MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4

3

1

2

8

12

11

10

13

7

9

9

812

12


5

6


1 7518280 2 Screw2 7517983 2 Screw3 2670174-070 1 Asm., Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 7079927 2 Decal, Reflector, Red5 7517312 2 Screw6 7555859 2 Washer, Flat

7 1013724-067 1 Support, Rear Rack8 7512329 6 Bolt9 7558402 16 Washer, Flat10 5334092 2 Spacer11 5246394-067 2 Mount, Front, Rear Rack12 7542324 8 Nut, Nylok13 7512371 2 Bolt

7/03

A7

FRONT RACK and BUMPER MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

6

15

16

3

14

2

7

5

9

8

10

1112

13

4

7

4

7

6

7

4

4

15

167


1

2

4

5


1 7512232 6 Screw2 1013744-067

1013746-06711

Support, Front Rack, LHSupport, Front Rack, RH

3 5810467 1 Plug, Frame4 7515399 6 Screw5 1014099-067

1014101-06711

Mount, Rack, LHMount, Rack, RH

6 243101124310124030061

112

Asm., Headlight, Side, LHAsm., Headlight, Side, RHBulb, Headlamp, 30W

7 7542324 4 Nut, Nylok

8 7517977 4 Screw9 5432155-070 1 Bumper10 1013772-067 1 Guard, Brush11 7670094 6 Nut, U-Type12 7512097 6 Screw13 5433923

543392411

Shield, Radiator Side, LHShield, Radiator Side, RH

14 5244729-0675244730-067

11

Extension, Frame, LHExtension, Frame, RH

15 7512329 2 Bolt16 7558402 2 Washer, Flat

10/03

A8

CONTROLS - MASTER CYLINDER/BRAKE LINEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

29

34

25

28

30

3233

18

2627

35

17

24

22

21

19

31

20


23


2010238 1 Asm., Master Cylinder, LH17 5410988 2 Seal18 4110164 1 Switch19 2202725 1 Kit, Master Cylinder Cap

(Incl. Cap, Screws, Sight, Gasket)20 7517899 2 Screw21 2201836 1 Kit, Master Cylinder Park Brake Lever

(Incl. Lever, Spring)22 2201833 1 Kit, Master Cylinder Clamp

(Incl. Clamp, Screws)23 2202410 1 Kit, Piston

(Incl. Piston, Seals, Boot, Spring)24 2201835 1 Kit, Master Cylinder Lever

(Incl. Pin, Lever, Clip)

25 1910565 1 Line, Brake, JB to Rear26 7621462 1 Rivet27 7080539 1 Clamp, Nylon28 1910838 1 Line, Brake, Left Front29 7512024 2 Screw30 7080138 4 Cable Tie31 8360031-34 1 Conduit32 1910839 1 Line, Brake, Right Front33 7052292 1 Fitting, Cross34 1910470 1 Line, Brake, Pod35 1910499 1 Bolt, Banjo

7/04

A9

FRONT STORAGE BOXMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4

6

7

1

12

3

19

5

8

9

11

16 1017

2

18

15

13

14

4

7

5

5



1 1253528 1 Asm., Front Cover (Incl. 2-5,8,17)2 7518216 6 Screw3 7081101 6 Ring, Tie Down4 5334257 2 Latch, Wire5 7512076 6 Screw6 5521641 1 Seal, Front Compartment7 7081125

708114511

Latch, 1/4 Turn, RHLatch, 1/4 Turn, LH

8 7542324 6 Nut, Nylok9 7515399 6 Screw

10 7555958 4 Washer, Flat11 5133825 2 Pin, Hinge, Front12 5435073-070 1 Base, Front Box w/Decals13 7541925 2 Nut, Nylok14 7555792 2 Washer15 7512007 2 Bolt16 5412352 3 Plug, Compartment17 5246928 2 Channel, Lid18 7512024 2 Screw19 7081124 2 Cable, Lid, Front

7/03

A10

FRONT BRAKEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

12 3

456

7 8

9

10

11


Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current

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

19108411910842

11

Asm., Brake Caliper, LH (Incl. 1-7,9,10)Asm., Brake Caliper, RH (Incl. 1-7,9,10)

1 7515489 1 Screw, Socket Set2 5134639

51346401930642

111

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

3 5410494 1 Boot, Pin Seal4 1930665 1 Kit, Piston and Seal (Incl. 5-7)

5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long8 2202412 1 Kit, Front Brake Pad9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder

7/04

A11

REAR BRAKEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

25

24

14

23

13

5

12

16

20

17

21

11

18

1312

2223

29

14

17

910

2

3, 4

62

4

243,

2 2, 6

28

26

27

19 15

1 1 1, 1 1,

15

15

19

22


19

7

8

30

A12

REAR BRAKEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC


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, Bracket Pad, Rear Axle6 2202414 1 Kit, Brake Pad Assembly7 7512018 1 Screw8 7080573 1 Clamp, Rubber Coated9 7512084 6 Screw10 5434041 3 Clamp, Brake Line11 1930854 1 Asm., Reservoir, Brake, Rear12 7080003 2 Clamp, Hose13 1910675 1 Hose, Reservoir14 7515158 2 Screw15 7558301 3 Washer, Flat

16 1012753-067 1 Pivot, Mount, Brake, Rear17 7542122 2 Nut, Nylok18 7512240 2 Bolt19 7517386 3 Screw20 1014009-067 1 Rod, Brake21 7041750 1 Spring, Torsion, Brake22 7555919 2 Washer23 5433189 2 Bushing, Pedal Pivot24 7661401 1 Pin, Cotter25 1910791 1 Asm., Brake, Master Cylinder, Foot26 5410988 6 Seal27 1910499 3 Bolt, Banjo28 1910516 1 Line, Brake, Foot, Master Cylinder to

Rear29 7042075 1 Spring30 7670126 1 Clip, Retaining

7/04

A13

DECALSMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2 385 7

12

24

1417

6

2021

25 LH

RH

109

23

16

E 2004 Polaris Sales Inc.11

14

18

151319

22


1 54354247173013

11

Badge, 50 Years (If built before 7/05/04)Urocal, 50th Anniversary(If built after 7/05/04)

2 7172572 2 Decal, Warning, Front and Rear Rack3 7172579

71725807172533

7172534

111

1

Decal, “AWD”, Side Panel, Lower, LH (AC)Decal, “AWD”, Side Panel, Lower, RH (AC)Decal, “AWD”, Side Panel, Lower, LH(AA)(AB)Decal, “AWD”, Side Panel, Lower, RH(AA)(AB)

4 7171495 1 Decal, Arrow, ATP Container, RH5 7172531

717253211

Decal, Side Panel, Upper, LH (AA)(AB)Decal, Side Panel, Upper, RH (AA)(AB)

6 7172559 1 Decal, Age Warning, 16, ATV7 7079780 1 Decal, Warning, AWD Switch8 7172576

7172529

71725777172530

11

11

Decal, “Magnum 330”,Tank Side, LH (AC)Decal, “Magnum 330”,Tank Side, LH(AA)(AB)Decal, “Magnum 330”, Tank Side, RH (AC)Decal, “Magnum 330”, Tank Side, RH(AA)(AB)

9 7078465 1 Logo, Polaris Star

10 707991670797737171879

111

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

11 7172569 1 Decal, Warning, Front Rack, 90 lbs12 7074220 1 Decal, “MacPherson Strut”13 7171473 1 Decal, Reflector, Amber, RH14 7172562 1 Decal, Drain Recoil15 7171472 1 Decal, Reflector, Amber, LH16 7079672 1 Decal, Foot Brake17 7172564 1 Decal, Warning, Override, AWD18 7171494 1 Decal, Arrow, ATP Container, LH19 7172578 2 Decal, Side Panel, Upper (AC)20 7172566 1 Decal, Passenger Warning21 7172571 1 Decal, Tire Pressure22 7079927 2 Decal, Reflector, Red23 7079960

70799597172066

111

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

24 7172561 1 Decal, Discretionary Warning, Drum Shift25 7172560 1 Decal, Warning, General, CPSC

8/04

A14

OIL COOLINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

14

1

13

11

3

10

12

6

9

17

2

8

7

15

18

16

4

4

5 E 2004 Polaris Sales Inc.


1 5412355 2 Hose, Cooler, Threaded 90 Degree2 7512084 1 Screw3 7080851 1 Clamp, Hose4 7515133 4 Bolt5 7547069 2 Nutsert6 5245416-067 1 Bracket, Oil Cooler, Top7 7542122 4 Nut, Nylok8 5248139

754213012

Bracket, Lower Oil CoolerNut, Rivet

9 7555932 4 Washer, Nylon

10 7517659 4 Screw11 2410534 1 Asm., Motor, Fan12 7670111 4 U-Clip13 5433353 1 Shroud, Fan14 4010934 1 Thermister15 7558301 4 Washer, Flat16 7512240

751216344

Bolt (If built before 2/21/04)Bolt (If built after 2/21/04)

17 1240191 1 Cooler, Oil18 7080999 1 Cable Tie

7/04

B1

ENGINE MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

28

17

26

8

20

5

12

2

13

14

1

27

2223

2425 15

79

19

31

6

18

11

2729

21

4

16

4

10

3

4

4

4

4

4


29

29

30

B2

ENGINE MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC



1 8450003-1525 AR Line, Fuel2 7052075 1 Fitting, Tee3 1202789 1 Engine, ES320PFE1034 7547108 8 Nut, Flange Lock5 5247341 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, Rear16 7517289 2 Screw

17 3021119 1 Mount, Rubber, Rear18 7555815 2 Washer19 7515417 2 Screw20 5247342 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 2530009 1 Filter29 7080003 8 Clamp, Hose30 8450040-150 AR Line, Fuel31 7546601 2 Nut, Nylok

7/04

B3

FUEL TANK and CARBURETOR MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

5

8

19 18

7

1615

3

2 9

14

4

13

12

1024

23

22

13

21

20

6

1

11


1918

18

19

17

26

25

B4

FUEL TANK and CARBURETOR MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC



1 2520409 1 Asm., Tank, Fuel2 5812123 1 Gasket3 2873626 1 Kit, Fuel Gauge4 8360009-600 AR Hose, Vent5 5431053 1 Vent, Tank6 7512277 2 Bolt7 7558301 2 Washer, Flat8 5222154

522215511

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

9 5811899 1 Seal, Foam10 7542105 1 Nut, Hex11 7552801 1 Washer, Spring Lock12 5245671-067 1 Bracket, Carburetor Support13 7547069 5 Nutsert

14 7517505 1 Screw15 5432559 1 Knob, Fuel Valve16 5432733 1 Nut, Fuel Valve17 7052161 1 Valve, 3-Way18 7080003 8 Clamp, Hose19 8450103 AR Line, Fuel20 3084205 2 Asm., Screw and Washer21 5245674-067 1 Mount, Carburetor22 3110050 1 Mount, Carburetor23 7512276 2 Bolt24 7555859 3 Washer, Flat25 7515136 2 Screw26 7052364 1 Fitting, Fuel, Duel Outlet

7/04

B5

EXHAUST SYSTEMMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

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 Silencer, Black8 7512666 1 Bolt

9 7041804 4 Spring, Exhaust10 5243517 2 Seal, Exhaust11 1261222-029 1 Headpipe, Black12 7041687 1 Spring, Exhaust13 7542301 2 Nut14 3110064 1 Mount, Torque Stop15 1260960-029 1 Manifold, Black16 3086237 1 Gasket, Exhaust

7/04

B6

AIR BOXMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

26

1

2

3

4

6

7

8

91011

1213

15161718

1920

22

23

25

17

5

2114

24

E 2004 Polaris Sales Inc.6



1 7518306 1 Screw2 7558301 1 Washer, Flat3 5812023 1 Seal, Airbox, Intake4 5433920 1 Duct, Inlet, Airbox Cover5 7517317 2 Screw6 5810317 2 Pad7 5433769 1 Cover, Air Box8 5811482 1 Seal, Air Box Cover9 5242044 6 Clip, Air Box10 5432601 1 Collar, Carburetor Inlet11 7080699 1 Clamp, Hose12 5433396 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, Carburetor Inlet19 5830128 1 Gasket, Carburetor Inlet20 5435758 1 Box, Air Intake, 4 Stroke21 7556091 2 Spacer22 5435299 1 Plug, Trap23 5812111 1 Foil, Air Box, RH24 8450059-100 AR Line, Fuel25 7080650 1 Clamp, Hose26 1253372 1 Asm., Filter

7/04

B7

FRONT DRIVE SHAFTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2 43

1


35

6



1332288 2 Asm., Drive Shaft, Front1 7670092 2 Circlip2 1590395 2 Joint (CV, Inner)3 7710557 2 Circlip

4 2202826 2 Kit, Boot(Inner)(Incl. Clamps and Grease)

5 2201015 1 Kit, Boot(Outer)(Incl. Clamps and Grease)

6 1590396 1 Joint, CV (Outer)3/04

B8

FRONT PROP SHAFTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 23

46

7

5E 2004 Polaris Sales Inc.



1380229 1 Asm., Front Prop Shaft (Incl. 1-4)1 3260133 1 Yoke, Gear Case, Front2 2202015 2 Kit, Cross and Bearing3 1380188 1 Shaft, Prop

4 3260131 1 Yoke, Propshaft, Transmission5 7080424 1 Fitting, Lubrication6 5411092 1 O-Ring7 7661913 1 Pin, Spring

7/03

B9

FRONT STRUTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1234

5

6

7

8

10

1112

13

15

14

171618

1920

21

22

9



1 7547104 2 Nut2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7042312-385

7042312-06722

Spring, Compression, Silver (AA)Spring, Compression, Black (AB)(AC)

9 5411608 2 Bumper10 7518340 4 Bolt, Flange11 5134154

513415511

Support, Hubstrut, LHSupport, Hubstrut, RH

12 3514342 2 Bearing, Hubstrut13 7710507 2 Ring, Retaining14 7080306 2 Fitting, Lubrication w/Ball15 ------ -- -- -- -- 1 Asm., Brake Caliper

(See Front Brake Pg. A10 for Details)16 7558402 4 Washer, Flat17 7552901 4 Washer, Spring Lock18 7512365 4 Screw, Cap19 7542343 4 Nut, Flange20 7080367 2 Clamp, Cable21 5211115 2 Washer22 7041761 2 Strut, Front

7/04

B10

FRONT WHEELMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

12

3

4

9

11

10

56

8

7

12



1 7512325 8 Bolt2 5244314 2 Disc, Brake, Front3 7515513 8 Stud4 5134310 2 Hub, Wheel, AWD5 7556004 2 Washer6 7542810 2 Nut, Slotted7 7661401 2 Pin, Cotter

8 5411164 2 Hub, Dust Cover9 1520269-486

1520269-06722

Rim, Front, Silver (AA)Rim, Front, Black (AB)(AC)

10 7547237 8 Nut, Flange11 5411709 2 Tire, Front, 24x8-1212 1525017 2 Valve, Rim

7/04

B11

CONTROLS - THROTTLE ASM./CABLEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

3

1

6

5

4

2




1 5434113 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7081181 1 Cable, Throttle5 2010230 1 Asm., Throttle Control (Incl.6)6 2010191 1 Asm., Throttle Clamp

7/04

B12

STEERING POSTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

31

4

2

5

8

10

6

9

7

2

5

6

1


11



1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1822630-067 1 Post Steering4 5246732 1 Bracket, Upper Steering Bushing5 7517428 4 Bolt, Carriage6 7556162 2 Bushing

7 5222393 1 Flangette8 3514352 1 Bearing9 7547158 1 Nut, Slotted Hex10 7661633 1 Pin, Cotter11 7558402 2 Washer, Flat

7/04

B13

HANDLEBARMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

5

1

7 8

10

11

13

14

19

20

3

21

4

6

18

21

912

24

1615

17

2

22

23




1 7078465 1 Logo, Polaris Star2 7518176 2 Screw3 7080922 1 Nut, Choke4 7081176 1 Cable, Choke5 5435256-070 1 Panel, Instrument6 7515189 4 Screw7 5248182 1 Bracket, Instrument Panel8 ------ -- -- -- -- 1 Asm., Master Cylinder

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

9 5433903 1 Spacer, Switch, LH10 4010592 1 Switch, Handlebar, Hi/Lo/Off11 5433834-070 2 Grip, Handlebar12 5432952 1 Plug, Hole13 7517625 1 Screw, Set14 5334127-067 1 Tube, Handlebar15 5132382 1 Cap, Hall Sensor

16 4010298 1 Sensor, Hall Effect17 7517658 1 Screw18 5631517

563151611

Block, Handlebar, PeggedBlock, Handlebar

19 7542122 4 Nut, Nylok20 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B11, Ref. 5)21 4011002

543196440102784010321

1111

Switch, IgnitionCover, KeyBlank, Key, Series 2000, 6700, 6800Blank, 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.

22 5433733 1 Nut, Ignition23 5412138 1 Mount, Rubber24 3280450 1 Cluster, Instrument

7/04

B14

A-ARM/STRUT MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

28

18

1716

15

1413

20

10

11

6

24

1

2

3

4

5

8

23

21

22 2526

2625

22

7

19

6

9

12

27

27



1 7080927 2 Joint, Ball2 5211121 2 Bracket, Ball Joint3 5410548 2 Boot, Rubber4 7512284 4 Bolt, Socket5 7542438 2 Nut, Castle6 7661203 4 Pin, Cotter7 5435028-070

5435029-07011

Shield, CV Joint, Black, LHShield, CV Joint, Black, RH

8 7512084 6 Screw9 7517909 2 Bolt10 7556099 4 Washer11 7547177 2 Nut, Lock12 5411920 1 Boot, Seal, Rod End13 7061054 2 Rod, End, LH14 7547028 2 Nut, Jam, LH15 5020926 2 Rod, Tie

16 7542711 2 Nut, Jam17 7061034 2 Rod End, RH18 5411291 2 Boot, Seal, Rod End19 7515415 2 Screw20 1820805 2 Asm., Tie Rod (Incl. 13-18)21 5133806 2 Shaft, A-Arm22 5434551 4 Bushing, A-Arm, Long23 2202280

220228111

Kit, A-Frame, LH (Incl. 6,21,22,25,26)Kit, A-Frame, RH (Incl. 6,21,22,25,26)

24 ------ -- -- -- -- 1 Support, Hubstrut(See Front Strut Pg. B9, Ref. 11)

25 7512492 4 Screw26 7552603 4 Washer, Spring Lock27 7555832 2 Washer28 7542439 2 Nut, Nylok

7/04

C1

DRIVE CLUTCHMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

12 11

4

10

2 3 4

5

98

67

1




1321976 1 Asm., Drive Clutch, Wide(Incl. All Less 6,11)

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

524298152107535210754

ARARARAR

Spacer, .020Spacer, .025Spacer, .032Spacer, .050

6 5630279 3 Weight, Shift, 167 7512266 3 Bolt, Shoulder8 7541906 3 Nut, FLEXLOC9 3576504 1 Bearing, Moveable10 5020422 3 Pin, Roller11 7041157 1 Spring, Clutch12 3576510 1 Cover, Bearing

7/04

C2

DRIVEN CLUTCHMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

6

5

23

4

16

13

12

11

98

7

1

10

14

15




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 Inch14 3576504 1 Bearing, Moveable, 1/2 Inch15 7556804 AR Washer, .03016 7555898

7556076ARAR

Washer, .020Washer, .025

7/03

C3

CLUTCH COVERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

3

7

89

13 12

14

181920

4

65

151

17

2

21

16

1

9

116

1110




1 7517386 3 Screw2 2632513 1 Asm., Foam, Clutch Air Inlet3 2201956 1 Kit, Inner Clutch Cover4 5433363 1 Duct, Inlet5 7517599 5 Asm., Bolt and Washer6 7080909 1 Clamp, Narrow Band7 5521578 1 Seal, Outer, Clutch Cover8 5434255-070 1 Cover, Clutch, Outer9 7512094 9 Screw10 5410542 1 O-Ring11 5434264 1 Plug, Drain

12 7172746 1 Decal, “Automatic Transmission”13 7172563 1 Decal, Warning, Clutch Cover14 5411489 1 Boot, Duct15 7080707 2 Clamp, Narrow Band16 7558301 2 Washer, Flat17 5434213 1 Duct, Air Outlet18 ------ -- -- -- -- 3 Asm., Screw and Washer

(See Crankcase Pg. C14, Ref. 8)19 5242046 1 Bracket, Clutch Seal20 5410575 1 Seal, Cover Case21 5411795 1 Stopper, Inner Clutch Cover

7/04

C4

ELECTRICAL/TAILLIGHTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3 4

5

67

89 12

11

21

20

13

19

14 1516

17

1822

11

25

28

27

26

23


24

10



1 2410500 1 Harness, Main2 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 7518287 2 Nut, Flange11 7571602 4 Washer12 7512027 2 Screw13 5810290 3 Pad, Battery14 2202213 1 Kit, Battery Bolt

15 4010095 1 Cable, Battery/Engine16 7010032 2 Hook, Battery Strap17 5412499 1 Strap, Battery Holddown18 4010774 1 Battery19 5431769 1 Cover, Battery20 4010094 1 Cable, Battery/Solenoid21 4010093 1 Cable, Solenoid/Starter22 7512007 2 Bolt23 4011088 1 Module, Electronic Control24 7512024 2 Screw (AA)25 7541925 2 Nut, Nylok26 4020139 2 Clip, Rosebud27 7080138 9 Cable Tie28 7670109 2 Clip, Routing

7/04

C5

REAR WHEEL DRIVEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

56

89

1

10

7

3

4

2




1 7661404 2 Pin, Cotter2 7547237 8 Nut, Flange3 5131649 1 Hub, Wheel, Rear (RH Side)4 7515513 8 Stud5 5411936 2 Tire, 24x11-126 1525017 2 Valve, Rim

7 1520564-3851520457-067

22

Rim, Rear (AA)Rim, Rear (AB)(AC)

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

7/04

C6

FRONT HOUSINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

13

56

78

910

11

1214

1516

1718

19

2021

22

25

14

6

23

13

13

7


2

1

3 4

24



1341497 1 Asm., Front Gearcase3233955 1 Kit, Bolt

1 3234163 1 Screw, Set2 3234159 1 Asm., Cover Plate

(Incl. Output Cover, Insert and Coil)3 3234164 1 Button, Thrust4 3234165 1 Plate, Thrust5 3234161 1 Shim, Armature Plate6 3233926 2 Bearing, Roller Ball7 3233953 1 Asm., Race/Output Hub (Incl. 22)8 3233928 1 Pin, Dowel9 3234166 1 Clutch Housing/Ring Gear10 3234167

------ -- -- -- --

1

1

Asm., Roll Cage(Incl. Spring and Roll Cage)Spring

11 3233957 14 Kit, Roll

12 3234169 1 Bushing13 3233956 1 Kit, Minor Repair

(Incl. O-Rings and Seals)14 3233918 11 Bolt15 3233947 1 Cover, Input16 3234112 1 Bearing, Roller Ball17 3233944 1 Shaft, Pinion, 11T18 ------ -- -- -- -- 1 Bushing19 ------ -- -- -- -- 1 Gearcase, LH20 3233942 1 Plug, Oil Fill21 3233951 1 Asm., Drain Plug

(Incl. Plug and Washer)22 3233929 1 Bearing, Needle, Roller Thrust23 3234168 1 Asm., Clutch (Incl. 9-11)24 3234162 1 Ring, Retaining, Internal25 3234160 1 Plate Armature

7/03

C7

GEARCASEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

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


C8

GEARCASEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC



1341372 1 Asm., Gearcase, Shaft1 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 Bearing16 3233036 1 Chain, Silent17 3234028 1 Shaft, Input18 3233019 4 Bearing, Ball19 3233529 4 Pipe, Knock20 3233865 1 Cover, Main, LH21 3233846 17 Screw22 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, Reverse

35 3233854 1 Sprocket, 24T36 3233855 1 Washer37 3233856 1 Gear, 30T38 3234014 1 Gear, 36T39 3233709 1 Gear, 48T40 3233608 4 Screw41 3233609 1 Cover, Bearing42 3233106 1 Ring, Snap43 3233357 1 Spacer44 3233607 1 Bearing, Ball45 3233606 1 Shaft, 10T46 3233777 1 Plug, Hex Flange47 3233254 1 Washer, Plug48 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

7/04

C9

REAR HOUSINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

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, Output, Rear Housing4 3233529 1 Pipe, Knock5 3233587 1 O-Ring6 3233581 1 Shim7 3233268 2 Bearing, Ball8 3233965 1 Gear, 31T9 7670102 3 Clip10 8450003-1525 AR Line, Fuel11 7080307 1 Clamp,Hose12 3233524 1 Tube, Vent

13 3233970 1 Gearcase, Rear Housing14 3233711 2 Plug, Oil Fill15 3233324 2 Washer16 3233878 2 Seal, Triple Lip17 3233577 1 Bushing18 3233969 1 Shaft, Pinion, 10T19 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

C10

GEAR SELECTORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

9

4

6

10

5

6

7

8

5




1 5412003 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector Shift4 5435042 2 Mount, Gear Selector5 7515175 2 Screw

6 7542122 2 Nut, Nylok7 1821135 1 Asm., Linkage Rod8 7542324 2 Nut, Nylok9 1013315-067 1 Selector, Gear10 7518342 2 Bolt

7/04

C11

SWING ARM/REAR/GEARCASE MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

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 5411531 1 O-Ring2 5134211 1 Hub, Wheel, AWD3 7515513 4 Stud4 5244882 1 Disc, Brake, Rear5 ------ -- -- -- --

75154817552603

1

22

Asm., Brake Caliper(See Rear Brake Pg. A12 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 5134212 1 Axle, Rear22 7517612 3 Screw23 5411531 1 O-Ring24 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See Rear

Housing Pg. C9 for Details)25 1012881

5242851-0675811716

111

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

26 5132698 1 Collar, Axle Lock27 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

7/04

C12

SHOCK MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

6

59

3

4

1

78

1




1 7542439 2 Nut, Nylok2 7515415 1 Screw3 5241147 1 Retainer, Shock4 7041849-385

7041849-06711

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

5 7041964 1 Shock, Rear Axle6 5630551 1 Cam, Adjusting, Spring7 5132021 1 Tube8 5433212 2 Bushing9 7515438 1 Screw

7/04

C13

TRANSMISSION MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

8 9

14 13

1212

1314

10

2

110

11

15

16

2

2

7


3

6

5

4



-- -- -- -- -- -- -- 1 Asm., Gearcase(See Gearcase Pg. C8 for Details)

1 7515417 2 Screw2 7547108 6 Nut, Flange Lock3 7052075 1 Fitting, T4 7080693 1 Clamp, Hose5 7512024 1 Screw6 7080307 1 Clamp, Hose7 8450003-1525 AR Line, Vent8 7512377 2 Bolt, Carriage

9 7542321 2 Nut, Flange10 7555976 3 Washer, Flat11 5247343 1 Mount, Rear Transmission12 7517289 4 Screw13 7552603 4 Washer, Spring Lock14 7515522 4 Bolt15 5242820-067 1 Mount, Transmission16 ------ -- -- -- -- 1 Mount, Engine,Rear

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

7/03

C14

CRANKCASEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

36

12

13

9

5

15

18

19

16

7

17

14

12

10

11

8

12

4




1 3083669 1 Bushing, Starter2 3080103 2 Pin, Dowel3 3087125 1 Asm., Crankcase

(Incl. 1-6,9,13,15,18,19)4 3087157 1 Asm., Plug, Blind5 3087116 2 Pin, Dowel6 3086395 1 Bearing, Ball7 3087266 2 Knock, Pipe8 3084205 3 Asm., Screw and Washer9 3084839 1 Seal, Oil

10 3087128 1 Gauge, Oil11 3087065 1 O-Ring12 3087066 2 Union13 3087155 1 Plug14 3084849 1 Union15 3087156 2 Bolt, Flange16 3086749 1 Plug17 3082956 1 Gasket18 3087117 8 Bolt, Flange19 3086399 1 Bolt, Flange

7/04

D1

CARBURETORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

41

32

29

9

44

5

43

12

4

6

36

33

31

1230

1312

1415

21

19

26

1110

3

22

20

16

24

18

25

35

23

45

3839

8

7

40

34

28

27

17

42

37


D2

CARBURETORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.


1 3130507 1 Ring2 3130508 1 E-Ring3 3131554 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Asm., Diaphragm6 3131588 1 Jet, Needle7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3131458 1 Jet, Main, #122.512 3130515 2 Seal13 ------ -- -- -- -- 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 3130526 1 Jet, Pilot, #42.527 3131423 1 Screw, Adjust28 3130836 1 Spring29 3130502 1 Valve, Throttle, 10030 3130589 1 Spring31 3130514 1 Ring32 3130501 2 Screw33 3130513 1 Asm., Throttle Shaft34 3130543 1 Guide, Cable35 3130535 4 Screw36 3130511 1 Cover37 3130199 1 Holder, Guide38 3130538 1 Spring39 3131228 1 Asm., Plunger40 3130625 1 Jet, Air, Pilot, #16041 3131590 1 Asm., Carburetor

(Incl. 1-33,36-41,43-45)42 3084205 2 Asm., Screw and Washer43 3131129 1 Spring44 3130503 1 Asm., Cover45 3130924 4 Screw

7/04

D3

CYLINDERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

3

21

20

14

10

4

9 12

16

12

22

27

5

11 13

29

19

2324

25

26

15

18

17

10

12

1617

4

11

11

4

6 7

828




1 3087259 2 Cover, Valve2 3086414 2 O-Ring3 3087159 4 Bolt, Flange4 3084874 13 Bolt, Flange5 3089272 1 Asm., Plug6 3089271 1 Asm., Cover, Breather (Incl. 7)7 3085850 1 Asm., Pipe8 3087034 1 Gasket, Breather Cover9 3084858 1 Seal, Intake Valve10 3084994 2 Guide, Valve11 3084798 3 Fin, Damper A12 3084859 1 Seal, Exhaust Valve13 3086418 4 Asm., Bolt and Washer14 3089270 1 Asm., Cylinder Head

(Incl. 9,10,12,14,16,28)

15 3086421 1 Gasket, Exhaust16 3085326 2 Stud17 3080530 2 Washer, Spring Lock18 3086787 2 Nut19 3087266 2 Knock, Pipe20 3086407 1 Gasket, Cylinder21 3087236 1 Unit, Cylinder22 3087238 1 Gasket, Head23 3087050 1 Asm., Adapter24 3083166 1 Asm., Adapter Band (Incl. 25)25 3081497 1 Asm., Screw and Washer26 3081330 2 Bolt, Socket, Head27 3086416 1 Gasket, Cam28 3087275 2 Knock, Pipe29 3087160 2 Bolt, Flange

7/04

D4

CRANKSHAFT and PISTONMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

7

16

6

5

14

15

10

8

11

2

1

4

9

1312

5

15

6

4

8

3




1 308724430872453087246

111

Set, Piston, Ring, StandardSet, Piston, Ring, .010 Inch/.25MM O/SSet, Piston, Ring, .020 Inch/.50MM O/S

2 308724130872423087243

111

Set, Piston, Standard (Incl. 4)Set, Piston, .010 Inch/.25MM O/S (Incl. 4)Set, Piston, .020 Inch/.50MM O/S (Incl. 4)

3 3086846 1 Pin, Piston4 3084167 2 Clip, Piston Pin5 3087240 2 Bolt, Connecting Rod6 3087239 1 Asm., Connecting Rod (Incl. 5,14)7 3087051 1 Asm., Crankshaft (Incl. 16)8 3240168 2 Key, Woodruff

9 3086434308643530864363086437

1111

Spacer, .4Spacer, .6Spacer, .8Spacer, 1.0

10 3086492 1 Sprocket 111 3085528 1 Nut, Slit12 3086767 1 Washer13 3083905 1 Nut, Lock14 3086426 2 Nut15 3086427

30867983086799

222

Bearing, StandardBearing, 0.05Bearing, 0.25

16 3085815 2 Bearing, Ball7/04

D5

INTAKE and EXHAUSTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

11

12

23

9 10

13

14

8

76

4

2

16

24

2

15

27

1817

2526

28

1

31

76

8

5

21

22

2019




1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1-3)4 3087053 1 Shaft, Rocker5 3085836 1 Washer, Wave6 3084908 4 Collet, Valve7 3087203 2 Retainer, Spring, Valve8 3087248 2 Spring, Valve9 3086439 1 Asm., Lever, Release10 3086804 1 Spring, Return11 3087247 1 Asm., Camshaft (Incl. 9-12)12 3084899 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 Asm., Tensioner (Incl. 18-22)19 3087132 1 Pin20 3087131 1 Spring, Tensioner21 3087129 1 Plug22 3087130 1 Gasket, Plug23 3083361 2 Bolt, Flange24 3086443 1 Sprocket 225 3087249 1 Washer26 3086449 1 Bolt, Flange27 3086446 1 Asm., Lever28 3084924 1 Asm., Bolt, Pivot, Lever

7/04

D6

RECOIL STARTERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

13

6

4

7

10

5

312

11

8

12

14

9

8

7




1 3084822 1 Asm., Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Asm., 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)Asm., Starter Case (Incl. 11)

14 3085083 1 Asm., Rope

1/03

D7

OIL PUMP and OIL FILTERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

11

9

1

10

8

2

4

7

5

6

3




1 3086749 1 Plug2 3082956 1 Gasket3 3086455 1 Spring, Relief Valve4 3086222 1 Valve, Oil Relief5 3087256 1 Bolt, Flange6 3086454 1 Unit, Strainer, Oil

7 3084963 1 Asm., Filter, Oil8 3087255 5 Screw, Counter Sunk9 3086450 1 Cover, Oil Pump10 3086452 1 Rotor, Inner11 3086453 1 Rotor, Outer

1/03

D8

MAGNETOMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

7

4

6

1

2

8 3

5




1 3087036 1 Asm., Ignition Coil (Incl. 2)2 3087037 1 Cap, Spark Plug3 3070172 1 Plug, Spark4 3084978 1 O-Ring

5 3089275 1 Asm., Stator Plate6 3081657 5 Asm., Bolt and Washer7 3087251 1 Flywheel w/Wiring Gear8 3088209 1 Asm., CDI System

7/04

D9

STARTING MOTORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

9

11

1

5

10

4

3

12

16

15

14

13

67

8

21


5



3084981 1 Asm., Motor, Starting (Incl. 1-5,7-11)3087030 1 Asm., Gear Shaft (Incl. 13-16)

1 3084982 1 Set, Washer2 3085353 1 Asm., Armature3 3088169 1 Set, Brush, Carbon4 3083649 2 Nut, Flange5 3084408 3 O-Ring6 3082038 2 Asm., Bolt and Washer7 3085034 1 Asm., Cover, Rear

8 3085033 1 Asm., Front Bracket (Incl. 9)9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 5)11 3084405 2 Ring, Rubber12 7555908 1 Washer13 3084412 1 Clip14 3084411 1 Spring, Weight15 3084410 1 Spring, Return16 3084409 1 Clip

7/04

D10

FUEL PUMPMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4

1

3 2

2

4




3085275 1 Asm., Fuel Pump (Incl. All)1 3084999 1 Asm., Screw and Washer2 3085356 2 Asm., Screw and Washer

3 3084591 4 Asm., Screw and Washer4 3084998 1 Diaphragm, Gasket Set

1/03

D11

TOOL KITMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

7

1

9

3

4

8

10

5

6


11



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 ------ -- -- -- -- 1 Wrench, Plug5 3085569 1 Puller, Spark Plug (Wrench Handle)

6 3082657 1 Screwdriver7 2682572 1 Pouch, Tool Kit8 2871515 1 Lube, U-Joint, 3 oz., Case9 9919487 1 Owner’s Manual, ‘05 Magnum 2x4/4x410 2873647 1 Wrench, Torx11 2874743 1 Wrench, Open End, 1/2 x 9/16

7/04

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PRINTED IN THE USA PARTS MANUAL PN 9919490 and MICROFICHE PN 9919491 7/04

magnum 330 4x4 model #a05cd32aa model #a05cd32ab model...

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