magnum325 2x4 model #a00cb32aa model …pi54.com/corp/manuals/parts/9914935r03.pdfmagnum325 2x4...

MAGNUM 325 2X4Model #A00CB32AAModel #A00CB32CA325 MAGNUM 2X4 HDSModel #A00CB32FA

Rev. 03

PARTS MANUAL PN 9914935 and MICROFICHE PN 9916574 3/00E 2000 Polaris Sales Inc.

TABLE OF CONTENTSMagnum 325 2x4 A00CB32AA and Magnum 325 2x4 A00CB32CA and 325 MAGNUM 2X4 HDS A0032CBFA

Parts Manual

AA-ARM/STRUT MOUNTING B7. . . . . . . . . . . . .AIR BOX B3. . . . . . . . . . . . . . . . . . . . . . . . . . .

BBREATHER BOX D10. . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D3-4. . . . . . . . . . . . . . . . . . . . . .CLUTCH COVER B14. . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER

CYLINDER/BRAKE LINE B9. . . . . . . . . . .CONTROLS - THROTTLE ASM./CABLE B6. . .CRANKCASE C13. . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D1. . . . . . . . . . . . .CYLINDER C14. . . . . . . . . . . . . . . . . . . . . . . . . .

DDECALS A10. . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH B12. . . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH B13. . . . . . . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C1. . . . . . . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . . . . . . .EXHAUST SYSTEM B1. . . . . . . . . . . . . . . . . . .

FFRONT BRAKE B5. . . . . . . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A9. . .FRONT WHEEL B4. . . . . . . . . . . . . . . . . . . . . .FUEL PUMP D9. . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B2. . . . . . . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR C8. . . . . . . . . . . . . . . . . . . .

GGEARCASE SELECTOR MOUNTING C9. . . . . .

HHANDLEBAR B11. . . . . . . . . . . . . . . . . . . . . . . .

IINTAKE and EXHAUST D2. . . . . . . . . . . . . . . .

MMAGNETO D7. . . . . . . . . . . . . . . . . . . . . . . . . .MAIN GEARCASE C5. . . . . . . . . . . . . . . . . . . .MAIN GEARCASE C6. . . . . . . . . . . . . . . . . . .

OOIL COOLING (If built after 1/1/00) A12. . . . . . . .OIL COOLING (If built before 1/1/00) A11. . . . . .OIL PUMP and OIL FILTER D6. . . . . . . . . . . . .

RREAR BRAKE C3-4. . . . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A5-6. . . . . . . . . . . . . . . . .REAR HOUSING C7. . . . . . . . . . . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . . . . . . .REAR WHEEL DRIVE C2. . . . . . . . . . . . . . . . .RECOIL STARTER D5. . . . . . . . . . . . . . . . . . . .

SSHOCK MOUNTING C11. . . . . . . . . . . . . . . . . . .STARTING MOTOR D8. . . . . . . . . . . . . . . . . . .STEERING POST B10. . . . . . . . . . . . . . . . . . . . .STRUT B8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/REAR GEARCASE MOUNTING C10

TTOOL KIT D11. . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING C12. . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

2000 MAGNUM 325 2x4 SPECIFICATIONSBRAKES

Type - FrontType - RearType - AuxiliaryType - Parking

Hydraulic DiscHydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIESFuel Tank (gallon)Gearcase Oil (ounces)Engine Oil (quarts) 0W40Engine Counter BalanceOil (quarts) InjectorRack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

3.75400 (ml)

1.9N/AN/A9018030

Standard850

DRIVE TRAINType Shaft Ride System

DRIVE CLUTCHDrive System TypeCenter Distance (inches)Clutch Offset (inches)Clutch Weight (grams)Spring Color

PVT101/216

Blue/Green

DRIVEN CLUTCHHelix AngleOutside Diameter (inches)Spring Position

Compound9.5

Black 2-2

DIMENSIONAL FEATURES

Approx. Turning Radius (inches)Box, Tool Volume (Cu. Inches)Box Dimensions (inches)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (dry)Wheel Base (inches)Width (inches)

65588N/A7.25468134574

49.7546

GEARCASETrans. Number and TypeShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

PRDSide Lever

7.46/15.12/13.3/1N/A3.1/1N/AN/AN/A

TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Titan24x8-12

24x11.5-10N/A43

N/A

ENGINEEngine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCoolingAlternator Output (watts)Elec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayPilot ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

ES32PFE01/04/054 Stroke, Single Cylinder

Wet Sump78x683259:2

Air w/fan assisted oil cooler200

Standard1/BST31 (CV Type)

142.550

P-0(829)N/A2

5F14-2CDI

[email protected]

NGKBKR5EUSFS Appr. Pending

GRAPHICSBumper Caps/Polyprop.Cargo Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverHandlebar CoverHeadlight/Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

N/AN/A

Bonnie BlueBonnie Blue

BlackBlack

Bonnie BlueBlackBlackBlackBlack

AluminumSteel GrayBonnie BlueBonnie BlueBonnie Blue

N/AN/A

ELECTRICALHeadlight - Handlebar(watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillight (watts)Brake Light (watts)Indicator BulbBattery

N/AN/A

2 Single Beam 30 W12 V/8.26 W12 V/26.9 W12 V/1.0 W12 V/14 AH

SUSPENSIONFront Type -

Front Travel (inches)Rear Type -

Rear Travel (inches)ShockAdjustment

MacPherson Strut6.7

Progressive Rate Swing Arm6.5

2� Gas Charged MonotubeCam

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.

2000 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUAL

SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Magnum 325 2X4 A00CB32AAA00CB32CA

9915299 9914934 9914935 9916574 9914937

325 Magnum 2X4 HDS A00CB32FA 9915299 9914934 9914935 9916574 9914937

A5

REAR CAB and SEATMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

2

7

3

6

910

14

13

15

16

17

3938

12

19

20

21

33

5

28

41

42

1

40

36

114

37

18

3

32

34

31

8

27

35

26

6

2322

28

29

2425

30

E 2000 Polaris Sales Inc.

A6

REAR CAB and SEATMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

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

1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 6 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-157 1 Cab, Rear, Bonnie Blue6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 4 Washer11 7512085 2 Screw12 5431786 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat16 7041370 1 Spring, Latch17 2682441-132

2681747-13258111045811105

1111

Seat, Steel GrayCovering, Seat, Steel GrayFoil, Seat Base, LargeFoil, Seat Base, Small

18 5410414 8 Bumper, Rubber19 7517599 2 Bolt and Washer20 5431787 1 Cover, Tool Box21 5410896 1 Cap, Drain22 5243188-067 1 Guard, Clutch

23 7661638 4 Rivet24 7621509 2 Rivet25 5243829-067 1 Strap, Fuel Pump26 5433435 1 Guard, Rock27 7556065 7 Washer28 7512232 21 Screw29 7558301 2 Washer30 7517386 9 Screw31 7542122 8 Nut32 5411548 8 Mount, Rubber33 7517264 8 Screw34 1012764-067 1 Frame, Main35 5432221-070

5433219-07011

Footwell, LH, BlackFootwell, RH, Black

36 5811111 1 Foil, Foam, Rear Fender37 5811106 2 Foil, Rear Cab, Front38 7073761 1 Decal - Carb Information39 7078396 1 Decal - Filter Element40 5811087 1 Foil, Foam41 7670057 12 Nut, U-Type Speed42 5431796

543179728732137555913

1118

Guard, Mud, Rear, LH (AA)(CA)Guard, Mud, Rear, RH (AA)(CA)Kit - Mudskirt, Full Set(FA)Washer, Flat (FA)

2/00

A7

FRONT CABMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

3

4

5

6

78

9

1516

2

1314

1110

126

1

2

2

2


1 2632084-157

2632284-157

2632101-157

1

1

1

Asm., Panel w/Foam, LH(If built before 3/27/00)Asm., Panel w/Foam, LH(If built after 3/27/00)Asm., Panel w/Foil, RH

2 7512232 12 Screw3 5432088-157 1 Cover, Front, Bonnie Blue4 7670085 2 Clip, Spring5 2632144-157 1 Cab, Front, Bonnie Blue6 7670057 10 Nut, U-Type Speed7 7670068 2 Nut, Push-on

8 7661645 4 Rivet9 5431798

543179911

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

10 7541925 2 Nut, Nylok11 7555792 2 Washer12 7512085 2 Screw13 7555931 2 Washer14 7542122 2 Nut, Nylok15 7621509 4 Rivet16 5811917 2 Shield, Deflector

3/00

A8

REAR RACK MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

4

3

1

2

8

6

9

11

1210

10

6

5

7

2


1 7517685 2 Screw2 7517686 4 Screw3 2670174 1 Asm., Rack, Rear

(Incl. Ref. 4 and Warning Decal)4 2670070 2 Reflector, Red5 1040490-067 1 Support, Rear Rack6 7542324 8 Nut, Nylok

7 7670096 2 Nut, Chimney8 7512329 4 Bolt9 1040524-067

1040525-06711

Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH

10 7558402 2 Washer11 5333332-067 4 Spacer12 7515385 4 Screw

2/00

A9

FRONT RACK and BUMPER MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

15

7

8

9

1011

4

12

13

6

20

17

1821

23

19

3

5

2

22

18 14

4

4

4

16

1

22

2425

262728

29


1 2670071 2 Reflector, Amber2 2670180 1 Asm., Front Rack

(Incl. Reflector & Decal)3 7517685 4 Screw4 7515399 12 Screw5 1040565 1 Mount, Front Rack6 1040471-067 1 Support, Front Rack, LH7 5432299-070 1 Panel, Grill8 7517396 4 Screw9 5431774-070 1 Bumper, Front10 7515182 8 Screw11 1040461-067 1 Bumper Mount12 7512130 2 Screw13 7542122 2 Nut, Nylok14 1040472-067 1 Support, Front Rack, RH15 1040554-067

1040555-06711

Support, Front Rack, LHSupport, Front Rack, RH

16 7517386 4 Screw17 7515382 2 Bolt18 7558402 4 Washer19 2431011

24310124030061

112

Headlight, 30/30 Watt, LHHeadlight, 30/30 Watt, RHBulb, 30/30 Watt Replacement

20 5241399-0675241398-067

11

Extension, Frame, RHExtension, Frame, LH

21 5810467 1 Plug, Frame22 7542324 4 Nut, Nylok23 1013018-067 1 Brushguard24 7670112 4 Nut, U-Type25 5243594-067 1 Grill, Front Bumper26 7542101 4 Nut27 7512252 4 Screw28 5433438

543343911

Shroud, LHShroud, RH

29 7517561 4 Screw

2/00

A10

DECALSMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1 2 3 54

8

9

4

10 11 12

15

13

14

16LH

RH

76

1


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution, 4W3 7078193 1 Decal - “2x4”, RH4 7077780 2 Decal - ‘‘POLARIS” Side Panel5 7078013 1 Decal - Tank Side, RH6 7078315

7078465

1

1

Logo, “45th Anniversary”(If built before 1/01/00)Logo, Polaris Star (If built after1/01/00)

7 70780157079007

11

Decal - “325 Four Stroke” (AA)(CA)Decal - “325 Four Stroke”, HDS (FA)

8 7078354 1 Decal - Discretionary Warning, ATV9 7078577 1 Decal - Drain Recoil10 7079218 1 Decal - Override Switch, 2WD11 7078012 1 Decal - Tank Side, LH12 7078253 1 Decal - Age Warning, ATV13 7077920 1 Decal - Passenger Warning14 7073069 1 Decal - Tire Pressure15 7078192 1 Decal - “2x4”, LH16 7077919 1 Decal - Warning, General, CPSC

10/00

A11

OIL COOLING (If built before 1/01/00)MAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

14

2

15

3

13

9

10

17

7

11

21

16

20

68

4

4

4

4

4

4

44

2

18

15

3

19

5

22

12

5

10

14

4

11


1 7547069 2 Nutsert2 3110032 2 Mount, Rubber3 5242924-067 2 Bracket, Cooling Fan4 7542122 10 Nut, Nylok5 7080474 2 Clamp, Hose6 5411813 1 Hose, Cooler Inlet7 7670111 4 U-Clip8 5433353 1 Shroud, Fan9 4010274 1 Thermister10 7515158 4 Screw11 1240064 1 Cooler, Oil

12 7052244 1 Valve, Drain13 5242983-067 2 Mount, Oil Cooler14 7558301 2 Washer, Flat15 3110050 2 Mount, Carburetor16 2410157 1 Motor, Fan17 7517659 4 Screw18 7080862 1 Clamp, Hose19 7080866 1 Clamp, Hose20 5411768 1 Hose, Oil Cooler Outlet, Flared21 8450086-07 1 Tubing, Convoluted22 7080869 1 P-Clamp

2/00

A12

OIL COOLING (If built after 1/01/00)MAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

11

2

10

8

1716

5

12

7

9

4

14

13

6

15

1

3

18

6

6

19


1 7080474 2 Clamp, Hose2 5411813 1 Hose, Inlet3 7542122 4 Nut, Nylok4 5243783-067 1 Bracket, Top5 7080869 1 P-Clamp6 7515158 8 Screw7 7517659 4 Screw8 2410157 1 Motor, Fan9 7670111 4 U-Clip10 5433353 1 Shroud

11 4010274 1 Thermister12 7052244 1 Valve, Drain13 1240064 1 Cooler, Oil to Air14 3021186 4 Mount, Rubber15 5244069-067

1013302

1

1

Bracket, Lower(If built before 1/24/00)Bracket, Lower (If built after 1/24/00)

16 7080862 1 Clamp, Hose17 7080866 1 Clamp, Hose18 5411768 1 Hose, Outlet, Flared19 8450086-07 AR Tubing, Convoluted

2/00

A13

ENGINE MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

34

21

30

12

24

8

15

2

33

16

17

1

32

2627

2829 18

4

36

3

38

1110

23

6

35

9

7

22

13

67

32 32

33

33

33

67

6

6

7

25

6

37

31

20

19

145

A14

ENGINE MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA


1 8450003-1525 AR Line, Fuel2 7052075 1 Fitting, Tee3 5243720-067 1 Bracket, Carburetor4 3084205 2 Screw and Washer5 3085823 1 Engine, Short Block NOTE: The

Short Block assembly contains acrankcase asm., cylinder & cylinderhead assembly and a piston & crank-shaft assembly. Prior authorization isrequired for warranty consideration.

6 7542403 4 Nut7 7555806 2 Washer8 5243641-067 1 Bracket, Motor Mount9 7552901 2 Washer10 7512315 2 Bolt11 7512232 1 Screw12 4010132 1 Cable, Ground Engine13 7555823 1 Washer14 3110068 1 Mount, Engine, Rear15 5411721 1 Boot, Clutch Intake16 7080511 1 Clamp, Narrow Band17 8360009-100 AR Line, Fuel18 1012960-067

1013133-067

1

1

Mount, Engine, Rear(If built before 12/01/99)Mount, Engine, Rear(If built after 12/01/99)

19 7542459 1 Nut20 7517289 1 Screw21 3021119 1 Mount, Rubber22 7555815 2 Washer23 7515417 2 Screw24 5243288-067 1 Mount, Lower Front25 3021181 2 Mount, Rubber26 5430261 1 Bushing27 5210748 1 Washer28 7575202 1 Washer29 7512566 1 Bolt30 4010095 1 Cable, Battery/Engine31 7080482 1 T-Clip32 8450040-600 AR Line, Fuel33 7080003 8 Clamp, Hose34 2530009 1 Filter35 7546601 2 Nut, Nylok36 3110079 2 Mount, Rubber37 7552604 2 Washer38 7517615 2 Screw

3/00

B1

EXHAUST SYSTEMMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

13

8

14

3

1

10

9

2

11

6

4

16

5

7

12

12

12

13

1110

15

1617

(If built after 7/01/99)

816

14

13


1 7542324 1 Nut, Nylok2 7555716 1 Washer, Flat3 5410436 1 Washer, Rubber4 7555863 1 Washer (If built before 7/01/99)5 5010192

513229511

Bushing (If built before 7/01/99)Bushing (If built after 7/01/99)

6 54102415411790

11

Dampener, Vib. (If built before7/01/99)Dampener, Vib. (If built after 7/01/99)

7 751531675153397515394

111

Bolt, Carriage (If built before 7/01/99)Bolt (If built after 7/01/99)Screw, Carriage (If built after 8/12/99)

8 1260977-0291260961-029

11

Silencer (If built before 7/01/99)Silencer (If built after 7/01/99)

9 7512666 1 Bolt10 3110064 2 Mount, Torque Stop11 7542301 2 Nut12 7041804 4 Spring, Exhaust13 7042029 2 Spring, Exhaust (If built before

7/01/99)(Only 1 used if built after 7/01/99)

14 1260976-0291260987-029

11

Headpipe (If built before 7/01/99)Headpipe (If built after 7/01/99)

15 1260960-029 1 Manifold, Black16 5243517 2 Seal, Exhaust17 7041789 1 Spring, Exhaust (If built after 7/01/99)

2/00

B2

FUEL TANKMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

24

5

22 23

9

16

15

1

11

2

13

3

17

21

14

7

4

20

8

6

21

12

2019

18

10


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Fuel Cap3 5811899 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7517451 2 Bolt7 7552801 2 Washer8 7558301 2 Washer9 5222154-067

5222155-06711

Bracket, Mounting, Rear, LHBracket, Mounting, Rear, RH

10 5811796 1 Foam, Intake, Splash11 5332457

533393622

Spacer (If built before 1/17/00)Spacer (If built after 1/17/00)

12 7547069 4 Nutsert13 5810317 2 Pad, Fuel Tank Bracket14 7517505 1 Screw15 5432559 1 Knob, Fuel Valve16 5432733 1 Nut, Fuel Valve17 7052161 1 Valve, 3-Way18 7661637 2 Rivet19 5240577-067 1 Bracket, Fuel Valve20 8450040-600 AR Line, Fuel21 7080003 4 Clamp, Hose, Red22 7052149 1 Fitting, Fuel Outlet, Reserve23 7052146 1 Fitting, Fuel Outlet, Main24 2520183 1 Asm., Fuel Tank (Incl. 5,22,23)

2/00

B3

AIR BOXMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

20

23

11

24

10

13

6

2

17

5

25

22

21

4

12

15

14

7

8

12

16

26

19

3

1

18

9

8


1 7517541 4 Screw2 5432859 1 Duct, Inlet3 5411422 1 Gasket, Intake4 5432868 1 Cover, Air Box5 5811482 1 Seal, Cover6 7515180 2 Screw7 7558301 2 Washer8 7080699 2 Clamp9 5433396 1 Cap, End10 5830128 1 Gasket, Duct11 5433180 1 Duct, Carburetor Inlet12 7080413 2 Clamp13 5411588 1 Boot, Carb14 7080511 1 Clamp

15 7080694 1 Clamp, Hose16 5411746

541184811

Hose, Breather (If built before 7/26/99)Hose, Breather (If built after 7/26/99)

17 54327745433678

11

Box, Air (If built before 7/26/99)Box, Air, Intake (If built after 7/26/99)

18 5431863 2 Insulator19 5811650 1 Foil, Air Box20 5432377 1 Plug21 8450059-150 AR Line, Fuel22 7080650 1 Clamp, Hose23 5243694 6 Clip24 5432601 1 Collar, Carburetor Inlet25 7080595 1 Filter, Air Intake26 5811633 1 Filter, Precleaner Sleeve

2/00

B4

FRONT WHEELMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

23 4

5 6

7

8

93

11

12

1314

15

16

17

10


1 ------ -- -- -- -- 1 Support, Strut & Spindle(See Strut Pg. B8, Ref. 16)

2 3610020 2 Seal, Front Hub3 3513519 4 Bearing, Ball4 5211869 2 Disc, Brake5 5130940 2 Hub, Wheel6 5411709 2 Tire (24x8-12)7 1520269-117 2 Rim, Front8 1525017 2 Valve, Rim

9 5010256 2 Spacer, Hub, Front10 7555721 2 Washer11 7542712 2 Nut12 7661407 2 Pin, Cotter13 5431018 2 Cap, Hub14 5410470 2 O-Ring15 7542459 8 Nut16 7515523 8 Stud17 7512325 8 Bolt

11/98

B5

FRONT BRAKEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

2 3

89

11

10

12

4

5 6 7


1910444 1 Asm., Front Brake Caliper, LH(Incl. 1-7,9,10)

1910445 1 Asm., Front Brake Caliper, RH(Incl. 1-7,9,10)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5131115

51311161930642

111

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

4 1930665 1 Kit - Piston and Insulator Seal (Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)

6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Caliper8 2200465

22009012201149

111

Kit - Front Brake Pad, General DutyKit - Front Brake Pad, Severe DutyKit - Front Brake Pad, Soft Duty

9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 7517445 4 Screw

10/00

B6

CONTROLS - THROTTLE ASM./CABLEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

3

1

6

5

4

2


1 5432721

5433806

1

1

Cover, Throttle Control(If built before 11/22/99)Cover, Throttle Control(If built after 11/22/99)

2 5410193 1 O-Ring3 5411439 1 O-Ring

4 7080709

7080857

1

1

Cable, Throttle Control(If built before 2/10/99)Cable, Throttle Control(If built after 2/10/99)

5 2010178 1 Asm., Throttle Control (Incl.1,3,6)6 2010191 1 Asm., Throttle Clamp

2/00

B7

A-ARM/STRUT MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

34

5

6

7

8

11

13

14

20

1915

18

161724

23

25

22

21

27 26

28

12

14

2726

22

21

2

12 8

9

10


1 7542403 2 Nut, FLEXLOC2 5333367 2 Bushing3 5411291 2 Boot, Seal, Rod End4 7061034 2 Rod End, RH5 7542711 2 Nut6 5020927 2 Tie Rod7 7547028 2 Nut, LH8 7061033

706105422

Rod End, LH (If built before 8/16/99)Rod End, LH (If built after 8/16/99)

9 5411920 2 Boot, Seal10 7517674 2 Bolt11 1820566

1820806

2

2

Asm., Tie Rod (Incl. 3-8)(If built before 8/16/99)Asm., Tie Rod (Incl. 3-8)(If built after 8/16/99)

12 75558067556099

42

Washer (If built before 8/16/99)Washer, Flat (If built after 8/16/99)

13 7546904 2 Nut

14 7661203 4 Cotter Pin15 5240717 2 Bracket, Ball Joint16 7512284 4 Bolt17 7542438 2 Nut, Castle18 5410548 2 Boot, Rubber19 7080673 2 Ball Joint20 ------ -- -- -- -- 1 Asm., Hubstrut

(See Strut Pg. B8, Ref. 16)21 5433066 2 Bushing, A-Arm, Long22 5020677 2 Bushing23 7080433 2 Fitting, Lubrication24 2201601

220160211

Kit, A-Frame, LH (Incl. 21-23,26,27)Kit, A-Frame, RH (Incl. 21-23,26,27)

25 5020681 2 Shaft, A-Arm26 7512492 4 Bolt27 7552603 4 Washer, Spring Lock28 7517527 2 Bolt

2/00

B8

STRUTMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

123

4

5

6

7

8 9

10

11

12

13

14

16

1315

17


1 7547104 2 Nut2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Pivot, Ball, Top5 5432871 2 Pivot, Ball, Bottom6 5132062 2 Spacer7 5243364 2 Retainer, Spring8 7041375-067 2 Spring, Coil9 5411608 2 Bumper

10 7041761 2 Strut, Front11 7080573 2 Clamp, Rubber Coated12 7542303 4 Nut, FLEXLOC13 7558402 6 Washer14 7080306 2 Fitting, Lubrication15 7515339 4 Bolt16 5131039

513104011

Support, Strut & Spindle, LHSupport, Strut & Spindle, RH

17 5211115 2 Washer, Spring Retainer

2/00

B9

CONTROLS - MASTER CYLINDER/BRAKE LINEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

2

3

5

10

6

4

12

1

11

13

21

24

17

20

2316

1819

25

15

14

9

8

7

22


2050078

2200809

1

1

Asm., Master Cylinder(Incl. 1-13)Kit - Master Cylinder Reservoir(Incl. 1-3,13)

1 1930797 2 Bolt, Cap2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm4 2200808 1 Kit - Master Cylinder Clamp5 1930799 1 Asm., Master Cylinder Piston6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever w/Parking Latch

(Incl. 6-9)8 ------ -- -- -- -- 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8)10 1930806 1 Nut11 1930792 2 Bolt

12 1930805 1 Bolt13 ------ -- -- -- -- 1 Ring, Square, Reservoir14 5411297 1 Boot, Rubber Brake Line15 5410988 2 Seal16 4110164 1 Switch17 1910286 1 Line, Hand Brake, Front18 7621462 1 Rivet19 7080539 1 Clamp, Nylon20 1930752 1 Line, Brake, Left Front w/Fittings21 7512084 2 Screw22 1930753 1 Line, Brake, Right Front w/Fittings23 7052237 1 Fitting, Cross24 1930816 1 Line, Brake25 1930674 1 Bolt, Banjo

11/98

B10

STEERING POSTMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

16

1514

2

3

4

13

9

125

6

10

5

5

8

11

6

7


1 1820729 1 Asm., Steering Post (Incl. 12,13)2 5431573

5433415

1

1

Bushing, Console Steering(If built before 7/12/99)Bushing, Console Steering(If built after 7/12/99)

3 7080424 1 Fitting, Lubrication4 7515321 2 Bolt5 7555878 3 Washer6 5410772 2 O-Ring7 5431571 1 Spacer, Steering Post

8 7543203 1 Nut9 7661633 1 Pin, Cotter10 5431570 1 Bushing, Steering, Lower11 7661632 2 Rivet12 5431574 1 Plug, Steering Grease13 7080433 1 Fitting, Lubrication14 5431572 1 Bushing, Console Steering15 5222999-067 1 Bracket, Steering Bushing, Upper16 7542324 2 Nut, Nylok

2/00

B11

HANDLEBARMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

3

12

5

6

9

10

12

13

18

21

20

22

2725

24

74

23

17

17

25

19

8 11

28

1514

16

29

3433

32

31

30

A00CB32FA

A00CB32FA

26

2


1 5432247-070 1 Cover, Logo (AA)(CA)2 5432420 2 Cover, Screw3 5432246-070

5433183-07011

Panel, Instrument (AA)(CA)Panel, Instrument (FA)

4 75172167517224

44

Screw (AA)(CA)Screw (FA)

5 5241397-0675241698-067

11

Bracket, Instrument Panel (AA)(CA)Bracket, Accessory Panel (FA)

6 ------ -- -- -- -- 1 Asm., Master Cylinder(See Control - Master Cyl./Brake LinePg. B9 for Details)

7 70807262200188

11

Cable, Choke w/AdjusterKit - Choke Lever

8 5432926 1 Spacer, Switch, LH9 4010262 1 Switch, Handlebar, Hi/Lo/Rev. Override10 5431030 2 Grip, Handlebar11 5432952 1 Plug, Hole12 7517625 1 Screw13 5224715-067 1 Tube, Handlebar14 5132382 1 Cap, Hall Sensor (FA)15 4010298 1 Sensor, Hall Effect (FA)16 7517658 1 Screw (FA)17 5630629 4 Block, Handlebar18 7542122 4 Nut, Nylok

19 7080631 1 Clip, Cable Retaining20 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B6, Ref. 5)21 2460715

246084111

Harness, Control Panel (AA)(CA)Harness, Control Panel (FA)

22 4040054 1 Indicator, Neutral/Reverse23 4040053 1 Indicator, “Hot Temperature”24 5430967 1 Plug, Indicator Hole25 4110264

4010278

4010321

5431964

11

1

1

Switch, IgnitionBlank, Key, Series 2000,6700,6800.NOTE: Spare key must be cut fromexisting key.Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Spare key must be cutfrom existing key.Cover, Key

26 5433733 1 Nut, Ignition27 7080229 1 Nut, Choke Slide28 3280337 1 Speedometer (FA)29 7512024 2 Screw (FA)30 3280201 1 Clamp (FA)31 5630633 1 Block, Riser (FA)32 7541933 2 Nut (FA)33 7558212 2 Washer, Flat (FA)34 7555868 2 Washer, Lock (FA)

10/00

B12

DRIVE CLUTCHMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

14

1 23 4

7

13

5 67

8

12

11

910


1 7512176 6 Bolt2 7552801 6 Washer3 3576510 1 Cover, Bearing4 7041157 1 Spring, Clutch,5 5430945 6 Washer, Multilube6 1321457 3 Roller and Bushing7 5431936 6 Button, Guide8 5210752

524298152107535210754

ARARARAR

Spacer (.020)Spacer (.025)Spacer (.032)Spacer (.050)

9 5630279 3 Weight, Shift, 1610 7512266 3 Bolt, Shoulder11 7541906 3 Nut, FLEXLOC12 3576504 1 Bearing, Moveable, 1/2I13 5020422 3 Pin, Roller14 1321632 1 Asm., Drive Clutch, ATV-08

(Incl. All Less 4,9)

2/00

B13

DRIVEN CLUTCHMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

2

3

45

6

7

10

11

12

13

1516

17

3

1

9

14

8


1 7556120 AR Bushing2 3211077

321106911

Belt, Drive (AA)(CA)Belt, Drive (FA)

3 1321874 1 Asm., Driven Clutch, 3 Angle (Incl. 7-17)4 5220646 1 Washer, Domed5 7552901 1 Washer6 7515382 1 Bolt7 7555898 AR Washer (.020 mm)8 7556076 AR Washer (.025mm)

9 7556804 AR Washer (.03mm)

10 3576504 1 Bearing, Moveable (1/2�)11 3576511 1 Bearing, Moveable (1I)12 7041782 1 Spring13 5132344 1 Ramp, Stationary14 5244116 1 Spacer15 7710448 1 Ring, Retaining16 7511854 3 Bolt17 5430766 3 Button, Ramp

10/00

B14

CLUTCH COVERMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

4

25

8

911

12

13

14

10

16

212223

57

15

6

17

19

20

1

32

24

18


1 7512232 2 Screw2 2632116 1 Foam, Clutch Airlet3 5433453 1 Plate, Backing4 2201520

2201676

1

1

Kit - Inner Clutch Cover (Incl. 8,11,15)(If built before 1/03/00)Kit - Clutch, Inner(If built after 1/03/00)

5 5433363 1 Duct, Inlet, Down Tube6 7517601

751759935

Bolt and Washer (If built before 1/03/00)Bolt and Washer (If built after 1/03/00)

7 7080909 1 Clamp, Narrow Band8 5521301 1 Seal, Clutch Cover9 5432849

5433540

5433451-328

1

1

1

Cover, Clutch, Outer(If built before 2/13/99)Cover, Clutch, Outer(If built before 1/03/00)Cover, Clutch, Outer(If built after 1/03/00)

10 7670051 1 Clip, Clutch Cover11 7512093

751209455

Screw (If built before 1/03/00)Screw (If built after 1/03/00)

12 7074946

7078689

1

1

Decal - Clutch Cover(If built before 10/04/99)Decal - Clutch Cover, Warning(If built after 10/04/99)

13 7077377 1 Decal - Engine/Clutch Modification14 7074782

7077666

1

1

Decal - “Automatic Transmission”(AA)(CA)Decal - “Automatic/EBS”, Clutch (FA)

15 7512094 9 Screw16 5411489 1 Boot, Duct17 7080761 2 Cable Tie18 7558301 2 Washer, Flat19 7517386 2 Screw20 5433172

543374411

Duct, Air Outlet (If built before 11/05/99)Duct, Air Outlet (If built after 11/05/99)

21 ------ -- -- -- -- 3 Screw and Washer(See Crankcase Pg. C13, Ref. 6)

22 5240409-067 1 Bracket, Retainer, Seal23 5410575 1 Seal, Cover Case24 5411795 1 Stopper, Inner Clutch Cover25 5410489

541190111

Seal, Cover Case (If built before 1/03/00)Seal, Clutch Cover (If built after 1/03/00)

3/00

C1

ELECTRICAL/TAILLIGHTMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

2

4 5

6

78

910 13

12

11

28

27

14

26

20 2122

23

24

2529

1211

37

36

33

30

32

34

35

31

3

1617

18

19

15


1 24607372460884

11

Harness, Main Wire (AA)(CA)Harness, Main Wire (FA)

2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2201795 1 Kit - Circuit Breaker, 10 AMP4 2432034 1 Asm., Taillight w/Brake Light (Incl. 5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw, Taillight7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight/Brake Light10 7670054 2 Nut, Speed11 7541925 4 Nut, Nylok12 7571602 4 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 2460837 1 Harness, Adaptor, Horn (FA)16 4010311 1 Switch, Horn (FA)17 4010310 1 Horn (FA)18 7517386 1 Screw (FA)

19 5810317 1 Pad20 2200361 1 Kit - Battery Bolt, Short21 4010095 1 Cable, Battery/Engine22 7010032 2 Hook, Battery Strap23 5410424 1 Strap, Battery Holddown24 5432077 AR Tube, Battery Vent25 4140006 1 Battery26 5431769 1 Cover, Battery27 4010094 1 Cable, Battery/Solenoid28 4010093 1 Cable, Solenoid/Starter29 7512007 2 Bolt30 5132214 1 Sink, Heat31 4010249 1 Switch, Thermister LR-6032 7512018 5 Screw33 4060191 1 Rectifier, Regulator, LR 3534 4010137 1 Limiter, RPM LR 44-3 (AA)(CA)35 7512017 2 Screw36 4020149 7 Clip, Rosebud37 7670109 3 Clip, Routing

3/00

C2

REAR WHEEL DRIVEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

67

1011

1

12

4

8

2

3

5

9


1 7661404 2 Pin, Cotter2 7542714 8 Nut3 5131777 2 Hub, Wheel, Rear4 7512673 8 Bolt5 7670081 8 Pushnut6 5411710 2 Tire, 24x11.5-10

7 1525017 2 Valve, Rim8 1520183-117 2 Rim, Rear, Silver9 7555745 2 Washer10 7555796 2 Washer11 7543005 2 Nut12 5411164 2 Hub, Dust Cover

6/99

C3

REAR BRAKEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

29

3

25

11

24

9

28

8

7

10

12

27

18

1

65

17

13

20

23

2

4

30

16

19

5

7

13

5

1817

2427

22

15

26

19

19

22

9

21

21

14

C4

REAR BRAKEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA


1 220118919103391930860

111

Kit - Brake Pads (Incl. Spacer and Pin)SpacerPin

2 7515406 2 Screw3 7555806 2 Washer4 1910367

220142822014672201385

1 Asm., CaliperKit, Bleeder ReplacementPiston, Caliper, DH2P, RearKit, Caliper Seal

5 5410988 6 Seal6 ------ -- -- -- -- 1 Line, Hand Brake, Front

(See Controls-Master Cylinder/BrakeLine Pg. B9, Ref 17)

7 1910288 1 Line, Foot Brake, Rear8 7080573 1 Clamp9 7517386 2 Screw10 7080762 3 Clip, Brake Line11 7661048 2 Rivet12 7080816 1 T-Clip, Dual13 1930674 3 Bolt, Banjo

14 7542403 2 Nut

15 7542153 1 Nut, Nylok16 1930854 1 Reservoir, Brake, Rear17 7080003 2 Clamp, Hose18 1910331 1 Hose, Reservoir19 7512240 3 Bolt20 1012753-067 1 Pivot, Brake Mount, Rear21 7542122 2 Nut, Nylok22 7558301 2 Washer23 1012752-067 1 Rod, Brake24 7555919 2 Washer25 7661401 1 Pin, Cotter26 7556090 1 Washer27 5433189 2 Bushing, Pedal Pivot28 7515158 2 Screw29 1910311 1 Master Cylinder, Foot30 7041750 1 Spring, Torsion

9/02

C5

MAIN GEARCASEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

40

36

29

67

14

30

89

10

12

11

19

35

24

25

44

46

48

51

52

37

56

4

3

15

21

53

54

55

26

27

1

34

13

28

23

5

13

31

23

17

18

16

47

32

45

43

2

49

58

50

17

2611

5

5

51

32

46

48

5

38

39

33

41

6261

60

59

22

20

42

57

32

20

C6

MAIN GEARCASEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA


1341278 1 Asm., Gearcase, Main (Incl. all)1 3233019 3 Bearing, Ball2 3233604 1 Shaft, Input, 31T3 3233036 1 Chain, Silent4 3233603 1 Gear, 16T w/22T Spline5 3233018 4 Bearing, Ball6 3233961 2 Nut, FLEXLOC7 3233054 2 Washer, Flat8 3233153 2 Bellcrank9 3233045 2 Ring, Retaining10 3233040 2 Washer11 3233286 1 Plug, Vent Cap12 3233037 1 Tube, Vent13 3233749 8 Screw14 3233615 1 Switch, 3 Position15 3233902 1 Gearcase, RH16 3233711 1 Plug17 3233788 2 Seal18 3233324 1 Washer19 3233712 1 Deflector, Oil20 3233747 4 Screw, Tapping21 3233627 1 Shaft, Shift, H/R22 3233611 1 Shim23 3233529 4 Pipe, Knock24 3233777 1 Plug, Drain25 3233254 1 Washer26 3233252 17 Screw27 3233713 1 Cover, Front, Gearcase28 3233583 1 Shim29 3233582 1 Button, Thrust30 3233622 1 Shaft, Rear Output31 3233621 1 Gear, Spiral, Bevel, 31T

32 3233619 3 Washer, Thrust33 3233548 2 O-Ring34 3233618 2 Ring, Retaining35 3233624 1 Shaft, Shift, Low36 3233617 1 Switch, 2 Position37 3233606 1 Shaft, 10T, Spiral Bevel38 3233607 1 Bearing, Ball39 3233106 1 Ring, Retaining40 3233609 1 Cover, Bearing, Center41 3233608 4 Screw42 3233709 1 Gear, 48T43 3233605 1 Fork, Shift, Low44 3233628 1 Washer45 3233629 1 Engagement Dog, Low46 3233306 2 Ring, Retaining47 3233631 1 Gear48 3233103 2 Bearing, Needle49 3233602 1 Fork, Shift, H/R50 3233598 1 Shaft, Reverse51 3233012 2 Washer, Thrust52 3233014 1 Bearing, Needle53 3233599 1 Sprocket, 24T54 3233029 1 Ring, Retaining55 3233533 1 Engagement Dog, H/R, HLR56 3233600 1 Gear, 30T57 3233613 1 Spacer58 3233708 1 Gear, 36T59 3233610 1 Gearcase, LH60 3233309 1 Bracket, Interlock61 3233032 1 Spring, Shifting, Interlock62 3233308 2 Pin, Interlock

5/01

C7

REAR HOUSINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

9

16

7

4

1

15

21

6

5

23

2

2019

14

3

12

18 22

2417

825

10

8

317

2

26

11

16

13


1341254

1341309

1341321

1

1

1

Asm., Gearcase, Rear (Incl. 1-10,14-26) (If built before 2-21-99)Asm., Gearcase, Rear(Incl. 1-10, 14-26) (If built after2--21--99 and before 7-01-99)Asm., Gearcase, Rear (Incl. 1-10,14-26) (If built after 7-01-99)

1 3233585 2 Screw2 3233252 10 Screw3 3233256 2 Seal4 3233584

3233741

1

1

Cover, Gearcase, Output(For Gearcase 1341254 and 1341309)Cover, Gearcase, Output(For Gearcase 1341321)

5 3233529 1 Pipe, Knock(For Gearcase 1341254 and 1341309)

6 3233587 1 O-Ring7 3233581 1 Shim8 3233268 2 Bearing, Ball9 3233580 1 Shaft, Rear Axle10 3233579

3233740

1

1

Gear, Bevel, 31T, Rear(For Gearcase 1341254 and 1341309)Gear, Bevel, 31T, Rear(For Gearcase 1341321)

11 7670102 3 Clip12 8450003-1525 AR Line, Vent

13 7080307 1 Clamp,Hose14 3233524 1 Tube, Vent15 3233586

3233739

1

1

Gearcase, Rear Housing(For Gearcase 1341254 and 1341309)Gearcase, Rear Housing(For Gearcase 1341321)

16 3233711 2 Plug17 3233324 2 Washer18 3233577 1 Bushing19 3233576

3233707

3233738

1

1

1

Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341254)Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341309)Shaft, Pinion, 10T, Bevel, Rear(For Gearcase 1341321)

20 3233575

3233714

1

1

Bearing, Ball(For Gearcase 1341254 and 1341309)Bearing, Ball(For Gearcase 1341321)

21 3233588 1 O-Ring22 3233319 1 Seal, Oil23 3233573 1 Gearcase, Cover, Input24 3233574 1 Nut, Lock25 3233582 1 Button, Thrust26 3233583 1 Shim

5/01

C8

GEAR SELECTORMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

2

4

3

5

7

8

6

111610

15

1

13

14

9

12

1011


1341271 1 Asm., Gear Selector (Incl. 1-16)1 3233195 1 Asm., Knob2 7512024 1 Screw3 3233649 4 Screw4 3233131 1 Strap, Wire5 3233648 1 Cover, Gear Selector Boot6 3233658 1 Handle, Gear Selector7 3233646 1 Sphere, Plastic8 3233754 1 Pin, Groove

9 3233644 1 Pin, Dowel10 3233642 2 Spring, Detent11 3233060 2 Bullet, Detent12 3233076 2 O-Ring13 3233639 1 Slide, Low14 3233640 1 Slide, High/Reverse15 3233641 1 Body, Gear Selector16 3233643 1 Spring, Centering

9/00

C9

GEARCASE SELECTOR MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

2

8

10

11

4

3

5

712

2

2

6

6

2

10

8

9


1 7061013 2 Rod End, LH2 7546707 4 Nut, FLEXLOC3 7546702 2 Nut, LH4 5020974 1 Rod, Low5 7546701 2 Nut6 7061014 2 Rod End, RH

7 1012822-067 1 Bracket, Shifter8 7512126 4 Bolt9 7555827 2 Washer10 7542122 4 Nut, Nylok11 7517386 4 Screw12 5020973 1 Rod, High, Rev

11/98

C10

SWING ARM/REAR GEARCASE MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

12

23

33

11

20

18

24

28

38

2622

35

15

9

21

11

37

910

10

15

31

75

5

30

34

8

32

1

16

27

192

3

13

14

361213

14

29

25

64

31

17


1 5132152 1 Hub, Brake Disc2 ------ -- -- -- -- 1 Asm., Rear Brake Caliper

(See Rear Brake Pg C4, Ref. 4)3 3513523 2 Bearing, Ball4 5411653 1 Shield, Brake Line, Rear5 7517604 3 Bolt6 7512084 2 Screw7 7555721 3 Washer8 7542703 3 Nut, FLEXLOC9 5411532 2 Cap, Swing Arm Pivot10 5131863 2 Nut11 5131864 2 Pivot, Threaded12 3610072 2 Seal, Swing Arm Pivot13 3554506 2 Bearing, Tapered Roller Cone14 3554507 2 Bearing, Tapered Roller Cup15 5411602 2 Seal, Swing Arm Pivot16 1541323 1 Asm., Swing Arm (Incl. 14,15)17 5411092 1 O-Ring18 5132201

708043311

Coupling, Prop Shaft, GreasedFitting, Lubrication

19 1380137 1 Asm., Prop Shaft, Rear20 7517585 8 Bolt

21 5411531 1 O-Ring22 7710482 1 Ring, Retaining23 5131930 1 Collar, Rear Axle24 5131862 1 Axle, Rear25 7517612 3 Screw26 1012881

5242851-0675811716

111

Asm., Skid PlatePlate, Rear Housing SkidPad, Rubber

27 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See RearHousing Pg. C7 for Details)

28 5411707 1 O-Ring29 7072533 1 Decal - Hitch30 7661913 1 Pin31 7553201 8 Washer32 1012740-067 1 Tube, Axle, LH33 7515481 3 Screw34 5132075 1 Spacer, Bearing35 7710471 1 Ring, Retaining36 3610071 1 Seal, Axle, Rear37 5211849 1 Disc, Brake38 5411092 1 O-Ring

4/00

C11

SHOCK MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

3

8

4

711

5

6

1

9

2

10

1


1 7542439 2 Nut, Nylok2 5433213 2 Bushing (If built before 6/21/99)3 7515415 1 Screw4 5132022 1 Tube (If built before 6/21/99)5 5241147 1 Retainer, Shock6 7041777-067

7041849-067

7041815-067

1

1

1

Spring(For 7041774)(If built before 6/21/99)Spring(For 7041890)(If built after 6/21/99)Spring (FA)

7 70417747041890

11

Shock (If built before 6/21/99)Shock (If built after 6/21/99)

8 5630921

5630551

1

1

Cam, Adjuster(For 7041774)(If built before 6/21/99)Cam, Adjuster(For 7041890)(If built after 6/21/99)

9 5132021 1 Tube10 5433212 2 Bushing11 7515438 1 Screw

2/00

C12

TRANSMISSION MOUNTINGMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

1

2

34

9 8

77

89

5

2

15

6

10

11

2

2


-- -- -- -- -- -- -- 1 Asm., Main Gearcase (See MainGearcase Pg. C6 for Details)

1 7515417 2 Screw2 7547108 6 Nut3 7515398 2 Screw4 7542321 2 Nut5 7555976 3 Washer

6 5242819-067 1 Mount, Rear Transmission7 7517289 4 Screw8 7552603 4 Washer9 7515522 4 Bolt10 5242820-067 1 Mount, Transmission11 ------ -- -- -- -- 1 Mount, Engine, Rear (See Engine

Mounting Pg. A14, Ref. 18)2/00

C13

CRANKCASEMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

34

12

12

75

8

18

21

22

19

11

20

14

1716

15

13

9

10

6


1 3083669 1 Bushing, Starter2 3080103 2 Pin, Dowel3 3086394

3086793

1

1

Asm., 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)

4 3086395 1 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 3 Screw and Washer7 3084839 1 Seal, Oil8 3085850 1 Pipe9 3086404

308679411

Gauge, Oil (If built before 3/1/99)Gauge, Oil (If built after 3/1/99)

10 3086405 1 O-Ring

11 3084838 2 Pin, Straight12 3086397 1 Plug13 3084842 1 Union14 3086400 1 Gasket, Oil Cooler15 3086403 1 Union16 3086402 1 Adapter, Oil Cooler (Incl. 13,15)17 3086401 1 Connector, Oil Cooler18 3084841 8 Bolt, Flange19 3083453 1 Plug20 3082956 1 Gasket21 3086398 2 Bolt, Flange22 3086399 1 Bolt, Flange

3/99

C14

CYLINDERMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

3

19

18

12

8

266

4

7 10

14

12

20

21

5

9 11

27

17

2223

24

25

13

16

15

6

8

12

1415

4

9

9


1 3086413 2 Cover, Valve2 3086414 2 O-Ring3 3086412 4 Bolt, Flange4 3084874 6 Bolt, Flange5 3086417 1 Plug, Cylinder Block6 3086410 2 Pin, Straight7 3084858 1 Seal, Intake Valve8 3084994 2 Guide, Valve9 3084798 3 Fin Damper A10 3084859 1 Seal, Exhaust Valve11 3086418 4 Bolt and Washer12 3086408

3086796

1

1

Asm., 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)

13 3086421 1 Gasket, Exhaust

14 3085326 2 Stud15 3080530 2 Washer16 3080285 2 Nut17 3084838 2 Pin, Straight18 3086407 1 Gasket, Cylinder19 3086406

308679511

Cylinder (If built before 3/1/99)Cylinder (If built after 3/1/99)

20 3086415 1 Gasket, Head21 3086416 1 Gasket, Cam22 3086420 1 Adapter23 3083166 1 Asm., Adapter Band (Incl. 24)24 3081497 1 Screw25 3081330 2 Bolt26 3086491 1 Cover, Rocker (If built before 3/1/99 only)27 3086419 2 Bolt, Flange

3/99

D1

CRANKSHAFT and PISTONMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

7

16

6

5

15

14

10

8

11

2

1

4

9

1312

5

146

4

8

3


1 308577430857753085776

111

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

2 308643130864323086433

3086800

30868013086802

111

1

11

Piston Set (STD)(Incl. 3,4)Piston Set (0.25 O/S)(Incl. 3,4)Piston Set (0.50 O/S)(Incl. 3,4)(If builtbefore 3/1/99 use above Set)Piston Set (STD)(Incl. 3,4)(If built after3/1/99 use Set below)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 3086425 2 Bolt6 3087016 1 Asm., Connecting Rod (Incl. 5,15)7 3086422

30864233086797

111

Crankshaft, Complete (Incl. 16)Crankshaft (If built before 3/1/99)Crankshaft (If built after 3/1/99)

8 3240168 2 Key, Woodruff9 3086434

308643530864363086437

1111

SpacerSpacerSpacerSpacer

10 3086492 1 Sprocket 111 3085528 1 Nut12 3083904 1 Washer13 3083905 1 Nut14 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

4/00

D2

INTAKE and EXHAUSTMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

11

12

19

910

1314

8

76

4

2

16

20

2

15

23

1817

2122

24

1

31

76

8

5


1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1,2)4 3086442 1 Shaft, Rocker5 3085836 1 Washer6 3084908 4 Collet, Valve7 3084907 2 Retainer, Spring8 3084906 2 Spring, Valve9 3086439 1 Lever, Release10 3086440

308680411

Spring, Return (If built before 3/1/99)Spring, Return (If built after 3/1/99)

11 3086438

3086803

1

1

Camshaft (Incl. 9,10,12)(If built before3/1/99)Camshaft (Incl. 9,10,12)(If built after3/1/99)

12 3084899 1 Pin, Dowel13 3085778 1 Valve, Intake14 3086441 1 Valve, Exhaust15 3086445 1 Guide, Chain16 3086444 1 Chain, Timing17 3086448 1 Gasket, Tensioner18 3086493 1 Tensioner19 3083361 2 Bolt, Flange20 3086443 1 Sprocket 221 3083663 1 Washer22 3086449 1 Bolt, Flange23 3086446 1 Lever24 3084924 1 Bolt, Pivot

7/99

D3

CARBURETORMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

48

38

35

9

51

5

50

12

4

6

4243

39

37

1236

1312

1415

21

19

27

30

29

26

1110

3

22

20

16

24

18

25

41

23

52

4546

87

47

40

3433

32

28

17

49

44

31

D4

CARBURETORMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA


1 3130507 1 Ring2 3130508 1 E-Ring3 3130730 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Diaphragm6 3131130 1 Jet, Needle (P-0M)7 3130541 2 Screw8 3130540 2 Washer, Spring9 3131128 1 Asm., Jet Block10 3130014 1 Washer11 3130566

313056711

Jet, Main (#142.5)(If built before3/1/99)Jet, Main (#145)(If built after 3/1/99)

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 Screw24 3130531 1 Valve, Needle (1.5)25 3130533 1 O-Ring26 3131132 1 Jet, Pilot (#50)27 3130522 1 O-Ring

28 3130523 1 Washer29 3130525 1 Spring30 3131131 1 Adjuster31 3130905 1 Plug (If built before 3/1/99 only)32 3130546 1 Screw, Adjust33 3130545 1 Ring34 3130544 1 Spring35 3131126 1 Valve, Throttle (120)36 3130589 1 Spring37 3130514 1 Ring38 3130501 2 Screw39 3130513 1 Asm., Throttle Shaft40 3130543 1 Guide, Cable41 3130535 4 Screw42 3130511 1 Cover43 3130512 1 O-Ring44 3130199 1 Holder, Guide45 3130538 1 Spring46 3130593 1 Asm., Plunger47 3131133 1 Jet, Air (#175)48 3131125

3131147

1

1

Asm., 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)

49 3084205 2 Screw and Washer50 3131129 1 Spring51 3131127 1 Asm., Cover52 3130592 4 Screw

3/99

D5

RECOIL STARTERMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

14

6

4

7

10

5

31 2

11

8

12

13

15

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 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3085856

308594311

Asm., Recoil (Incl. 1-6,9-11,14,15)Starter Case (Incl. 11)

15 3085083 1 Rope

11/98

D6

OIL PUMP and OIL FILTERMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

11

9

1

10

8

2

4

7

5

6

3


1 3083453 1 Plug2 3082956 1 Gasket3 3086455 1 Spring4 3086222 1 Valve, Relief5 3083568 1 Bolt, Flange6 3086454

308701511

Strainer, OilStrainer, Oil (Engine Serial Numbers35878-39057 Only)

7 3084963 1 Filter, Oil8 3086451

308680555

Screw (If built before 3/1/99)Screw (If built after 3/1/99)

9 3086450 1 Cover, Oil Pump10 3086452 1 Rotor, Inner11 3086453 1 Rotor, Outer

7/00

D7

MAGNETOMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

14

4

7

12

10

13

3

911

12

6

6

5

8


1 308648330864843086807

111

Asm., Ignition Coil (Incl. 1,2)Ignition Coil (If built before 3/1/99)Ignition Coil (If built after 3/1/99)

2 3086463 1 Cap, Spark Plug3 3084997 1 Plug, Spark4 3084978 1 O-Ring5 3086460 1 Bearing, Dry6 3086458 1 Asm., Plate (Incl. 5,8)(Incl. 9 if built

before 3/1/99 only)

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3081256 1 Screw and Washer

(If built before 3/1/99 only)10 3086464 1 CDI System11 3083073 2 Nut12 3080077 2 Washer, Spring13 3085521 1 Switch, Magnetic14 3086457 1 Flywheel w/Ring Gear

6/99

D8

STARTING MOTORMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

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 3085394 1 Asm., Gear Shaft (Incl. 12-16)

11/98

D9

FUEL PUMPMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

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

D10

BREATHER BOXMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

3

22

18

16

4

10

23

17

19

2120

1

8

12

65

9

15

2

11

5

5

5

7

7

14

14

13

13


1 3085850 1 Pipe2 3086481 3 Bolt, Flange3 3086486

3086808

3086487

1

1

1

Asm., Breather Box (Incl. 4,16-20,21-23)(If built before 3/1/99)Asm., Breather Box (Incl. 4,16-20,21-23)(If built after 3/1/99)Box, Breather (Incl. 1,4,16)

4 3085525 1 Pipe, Air Breather5 3084085 4 Clamp6 3086476 1 Pipe 1, Rubber7 3083568 4 Bolt, Flange (Use 3 if built after

3/1/99)8 3086495 1 Pipe 19 3086478 1 Pipe 3, Rubber10 3086482 1 Bolt, Banjo

11 3082719 2 Gasket12 3086496 1 Pipe 213 3083418 2 Clamp, Hose14 3084823 3 Band, Wire (Use 2 if built after 3/1/99)15 3086809 1 Pipe 2, Rubber16 3083798 1 Pipe, Pulse17 3086470 1 Gasket, Breather Plate18 3086468 1 Plate, Breather19 3086494 1 Bracket 120 3083361 1 Bolt, Flange21 3081180 4 Screw22 3086467 1 Plate, Breather Box23 3086469 1 Gasket, Plate

3/99

D11

TOOL KITMAGNUM 325 2X4 A00CB32AA and MAGNUM 325 2X4 A00CB32CA and 325 MAGNUM 2X4 HDS A00CB32FA

2

6

1

8

3

4

10

7

9

5


3086485 1 Asm., Tool Kit (Incl. 2-6)1 2870725 1 Gauge, Tire Pressure2 3085001 1 Wrench, Open 8-10mm3 3085002 1 Wrench, Open 12-14mm4 3086791 1 Wrench, Box5 3082657 1 Screwdriver6 2682572 1 Pouch, Tool Kit

7 2871515 1 Lube, U-Joint, 3 oz., Case8 9915299

991493411

Owner’s Manual, ‘00 ATVSupplement, Owner’s Manual, ’00Magnum 325 2x4

9 2871095-067 1 Wrench, Spanner, Cam10 2460442 1 Pigtail, Power

2/00

PRINTED IN THE USA PARTS MANUAL PN 9914935 and MICROFICHE PN 9916574 3/00

Changed

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