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  • 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 (ccs)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

    30@3500.028

    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. OWNERSMANUAL

    OWNERSMANUAL

    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

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

    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

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

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

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