Parts Manual

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4 Pipe,Knock. 5 3233019. 4 Bearing, .... 2 Pivot,Threaded .... 1 Pipe. 9 3086404. 3086794. 1. 1. Gauge, Oil (If built be
MAGNUM 325 4X4 Model #A00CD32AA Model #A00CD32CA 325 MAGNUM 4X4 HDS Model #A00CD32FA 325 MAGNUM 4X4 HDS II Model #A00CD32FB Rev. 02

E 2000 Polaris Sales Inc.

PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00

TABLE OF CONTENTS Magnum 325 4X4 A00CD32AA and Magnum 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB Parts Manual

A

A- ARM/STRUT MOUNTING . . . . . . . . . . . . . . . . . B13 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3

G

GEARCASE SELECTOR MOUNTING . . . . . . . . . . . C13

H

B

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12

C

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . . . . . D6

BREATHER BOX . . . . . . . . . . . . . . . . . . . . . . . . . D14 CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS - MASTER CYLINDER/BRAKE LINE . . CONTROLS - THROTTLE ASM./CABLE . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT and PISTON . . . . . . . . . . . . . . . . . CV JOINT - BTB . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D

D9-10 C3 B10 B9 D3 D5 B4 D4

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10 DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . B14- C1 DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . C2

E

ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . . . . . C4 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . B1-2 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . A13

F

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . FRONT RACK and BUMPER MOUNTING . . . . . . . . FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G

B8 A7 C8 A9 B6 B7 D13 A14

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . C12

I

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11 MAIN GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C9 MAIN GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . C10

O

OIL COOLING (If built after 1/1/00) . . . . . . . . . . . . A12 OIL COOLING (If built before 1/1/00) . . . . . . . . . . . A11 OIL PUMP and OIL FILTER . . . . . . . . . . . . . . . . . . D8

P

PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5

R

REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR CAB and SEAT . . . . . . . . . . . . . . . . . . . . . REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . REAR RACK MOUNTING . . . . . . . . . . . . . . . . . . . REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . .

C5-6 A5-6 C11 A8 C7 D7

SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . . . . . STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . STEERING POST . . . . . . . . . . . . . . . . . . . . . . . . . SWING ARM/REAR GEARCASE MOUNTING . . . . .

D1 D12 B11 C14

S

T

TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1 TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . . D2

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

2000 MAGNUM 325 4x4 SPECIFICATIONS BRAKES Type - Front Type - Rear Type - Auxiliary Type - Parking

ENGINE Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic Lock, All Wheel

CAPACITIES Fuel Tank (gallon) Gearcase Oil (ounces) Engine Oil (quarts) 0W40 Engine Counter Balance Oil (quarts) Injector Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight

3.75 400 (ml) 1.9 N/A N/A 90 180 30 Standard 850

DRIVE TRAIN Type

Shaft Ride System

DRIVE CLUTCH Drive System Type Center Distance (inches) Clutch Offset (inches) Clutch Weight (grams) Spring Color

PVT 10 1/2 16 MH Blue/Green

DRIVEN CLUTCH Helix Angle Outside Diameter (inches) Spring Position

Compound 9.5 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)

65 588 N/A 7.25 46 81 34 620 49.75 46

GEARCASE Trans. Number and Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type

PRD Side Lever 7.46/1 5.12/1 3.3/1 3.7/1 3.1/1 N/A N/A N/A

TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center

Titan 24x8-12 24x11.5-10 N/A 4 3 N/A

Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc’s) Compression Ratio Cooling Alternator Output (watts) Elec. Start w/Recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Pilot Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust

ES32PFE01 4 Stroke, Single Cylinder Wet Sump 78x68 325 9:2 Full Stroke Air w/Fan Assisted Oil Cooler 200 Standard 1/BST31 (CV Type) 142.5 50 P-0 (829) N/A 2 5F14-2 CDI 30@3500 .028 NGKBKR5E USFS Appr. Pending

GRAPHICS Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color

N/A N/A Eddie B. Green Eddie B. Green Black Black Eddie B. Green Black Black Black Black Aluminum Sable Brown Eddie B. Green Black Black N/A N/A

ELECTRICAL Headlight - Front Hood (watts) Headlight - Grill (watts) Taillight (watts) Brake Light (watts) Indicator Bulb Battery

N/A 2 Single Beam/30 W 12 V/8.26 W 12 V/26.9 W 12 V/1.0 W 12 V/14 AH

SUSPENSION Front Type Front Travel (inches) Rear Type Rear Travel (inches) Shock Adjustment

MacPherson Strut 6.7 Progressive Rate Swing Arm 6.5 2² Gas Charged Monotube Cam

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’S MANUAL

OWNER’S MANUAL SUPPLEMENT

PARTS MANUAL

PARTS MICROFICHE

ASSEMBLY INSTRUCTIONS

Magnum 325 4X4

A00CD32AA

9915299

9914939

9914940

9916574

9914942

Magnum 325 4X4

A00CD32CA

9915299

9914939

9914940

9916574

9914942

325 Magnum 325 4X4 HDS

A00CD32FA

9915299

9914939

9914940

9916574

9914942

325 Magnum 325 4X4 HDS II

A00CD32FB

9915299

9914939

9914940

9916574

9914942

REAR CAB and SEAT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

E 2000 Polaris Sales Inc. 15 6

14

7 8

5

9 1

16

13

17 19

10

18

12 11

4 3 2

42

41

43

45

20 40

6

21

3

39 22

33 44

23

38 37 25 36

35

26 33

34

32

27 28 29 30 31

A5

24

REAR CAB and SEAT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

Ref. Part No.

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

10 2 6 1 1 4 1 1 4 4 2 1 2 2 1 1 1 1 1 1 8 2 1 1 1 4

18 19 20 21 22 23

7661645 7511930 7555792 5811107 5432117-195 7541925 5224592 5811308 7512242 7555859 7512085 5431786 7621403 5211033 1040387 7041370 2682441-276 2681747-276 5811104 5811105 5410414 7517599 5431787 5410896 5243188-067 7661637

Description

Rivet Bolt Washer Foil, Rear Cab, Rear Cab, Rear, E.B. Green Nut, Nylok Retainer, Seat Latch Foil, Tape, Rear Cab Screw Washer Screw Box, Tool Rivet Bracket, Lever Retainer Latch, Seat Spring, Latch Seat, Sable Brown Covering, Seat, Sable Brown Foil, Seat Base, Large Foil, Seat Base, Small Bumper, Rubber Screw and Washer Cover, Tool Box Cap, Drain Guard, Clutch Rivet

Ref. Part No.

Qty.

24 7621509 25 5243829-067 26 - - - - - - -

2 Rivet 1 Strap, Fuel Pump 1 Asm., Front Gearcase (See Front Gearcase Pg. C10 for Details) 4 Washer 4 Screw 1 Guard, Rock 7 Washer 9 Screw 2 Washer, Flat 21 Screw 8 Nut 8 Mount, Rubber 8 Screw 1 Frame, Main 1 Footwell, LH, Black 1 Footwell, RH, Black 1 Foil, Foam, Rear Fender 2 Foil, Rear Cab, Front 1 Decal - Carb Information 1 Decal - Filter Element 1 Foil, Foam 12 Nut, U-Type Speed 1 Guard, Mud, Rear, LH (AA)(AB) 1 Guard, Mud, Rear, RH (AA)(AB) 8 Washer, Flat (FA)(FB) 1 Kit - Mud Skirt, Full Set (FA)(FB)

27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

7552603 7512492 5433435 7556065 7517386 7558301 7512232 7542122 5411548 7517264 1012764-067 5432221-070 5433219-070 5811111 5811106 7073761 7078396 5811087 7670057 5431796 5431797 7555913 2873213

Description

2/00

A6

FRONT CAB MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3

1

4

2

5 12 2

11

8

6 7

9 10

2

6

2

14 13

15

Ref. Part No.

1 2632084-195 2632284-195 2 3 4 5 6 7

2632101-195 7512232 5432088-195 7670085 2632144-195 7670057 7670068

Qty.

16

Description

1 Asm., Panel w/Foam, LH, E.B. Green (If built before 3/20/00) 1 Asm., Panel w/Foam, LH, E.B. Green (If built after 3/20/00) 1 Asm., Panel w/Foil, RH, E.B. Green 12 Screw 1 Cover, Front, E.B. Green 2 Clip, Spring 1 Cab, Front, E.B. Green 10 Nut, U-Type Speed 2 Nut, Push-on

Ref. Part No.

8 7661645 9 5431798 5431799 10 7541925 11 7555792 12 7512085 13 7555931 14 7542122 15 7621509 16 5811917

Qty.

Description

4 Rivet 1 1 2 2 2 2 2 4 2

Guard, Mud, Front, LH Guard, Mud, Front, RH Nut, Nylok Washer Screw Washer Nut, Nylok Rivet Shield, Deflector 10/00

A7

REAR RACK MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2

3

2

4 5 6 7

8 10 11

6 9

Ref. Part No.

1 7517685 2 7517686 3 2670174 4 2670070 5 1040490-067 6 7542324

Qty.

Description

2 Screw 4 Screw 1 Asm., Rack, Rear (Incl. Ref. 4 and Warning Decal) 2 Reflector, Red 1 Support, Rear Rack 8 Nut, Nylok

10

Ref. Part No.

7 7670096 8 7512329 9 1040524-067 1040525-067 10 7558402 11 5333332-067 12 7515385

12

Qty.

2 4 1 1 2 4 4

Description

Nut, Chimney Bolt Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH Washer Spacer Screw 2/00

A8

FRONT RACK and BUMPER MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2 5 3

4

7

6

14

8

13

15

12

11

16 17 6 24

10

9

4 18 19

23 22

20 21

Ref. Part No.

1 7517685 2 2670180 3 4 5 6 7 8 9 10 11 12

2670071 7515399 2200775 7542324 7558403 5432155-070 7515391 7515390 7555954 1040554-067 1040555-067 1013210-067 1013211-067

13 7517386

Qty.

Description

4 Screw 1 Asm., Front Rack (Incl. Ref. 3 and Warning Decal) 2 Reflector, Amber 6 Screw 1 Kit - Front Rack Mount 4 Nut, Nylok 2 Washer 1 Bumper 2 Screw 2 Screw 2 Washer 1 Support, Front Rack, LH (If built before 11/15/99) 1 Support, Front Rack, RH (If built before 11/15/99) 1 Support, Front Rack, LH (If built after 11/15/99) 1 Support, Front Rack, RH (If built after 11/15/99) 4 Screw

Ref. Part No.

14 2431011 2431012 4030059 15 7515382 16 7558402 17 5810467 18 5241583-067 19 5240591-067 20 7621330 21 7670094 22 7512097 23 5431814 5431815 24 5241398-067 5241399-067 5244623-067 5244624-067

Qty.

Description

1 1 2 2 4 1 1 1 7 6 6 1 1 1

Headlight, LH Headlight, RH Bulb, Replacement, 27W Bolt Washer Plug, Frame Guard, Brush Grill, Brush Guard Rivet Nut, U-Type Screw Shield, Radiator Side, LH Shield, Radiator Side, RH Extension, Frame, LH (If built before 12/01/99) 1 Extension, Frame, RH (If built before 12/01/99) 1 Extension, Frame, LH (If built after 12/01/99) 1 Extension, Frame, RH (If built after 12/01/99) 2/00

A9

DECALS MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

2 3

4 5

6

7

8

RH

10 9

13 16

12

14

11

4

15

17

18

1

LH

Ref. Part No.

1 2 3 4 5 6 7

7074954 7074110 7078022 7077780 7078017 7074935 7078315 7078465

8 7074220 9 7078354

Qty.

2 1 1 2 1 1 1

Description

Decal - Rack/Warning Decal - Load Distribution, 4W Decal - “4x4”, Shaft Ride Sys., RH Decal - ‘‘POLARIS” Side Panel Decal - Tank Side, RH Decal - Warning, AWD Switch Logo, “45th Anniversary” (If built before 1/01/00) 1 Logo, Polaris Star (If built after 1/01/00) 1 Decal - “Macpherson Strut” 1 Decal - Discretionary Warning, ATV

Ref. Part No.

Qty.

10 7078577 11 7078015 7079007 7079008 12 7077919 13 7079604 14 7078016 15 7078253 16 7078018 17 7077920 18 7078004

1 1 1 1 1 1 1 1 1 1 1

Description

Decal - Drain Recoil Decal - “325” Front Cover (AA)(AB) Decal - “325 4 Stroke HDS” (FA) Decal - “325 4 Stroke HDS II” (FB) Decal - Warning, General, CPSC Decal - Warning, Override, AWD Decal - Tank Side, LH Decal - Age Warning, ATV Decal - “4x4”, Shaft Ride Sys., LH Decal - Passenger Warning Decal - Tire Pressure 10/00

A10

OIL COOLING (If built before 1/01/00) MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

4

2

1

3

2

4

9

3 4

4

10

5

7

6

8

5

11

17 20

21

18 19

22 16 12 4

15 4 10

14 4

15

4

13 4 14 Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11

7547069 3110032 5242924-067 7542122 7080474 5411813 7670111 5433353 4010274 7515158 1240064

Qty.

2 2 2 10 2 1 4 1 1 4 1

Description

Ref. Part No.

Nutsert Mount, Rubber Bracket, Cooling Fan Nut, Nylok Clamp, Hose Hose, Cooler Inlet U-Clip Shroud, Fan Thermister Screw Cooler, Oil

12 13 14 15 16 17 18 19 20 21 22

7052244 5242983-067 7558301 3110050 2410157 7517659 7080862 7080866 5411768 8450086-07 7080869

Qty.

1 2 2 2 1 4 1 1 1 1 1

Description

Valve, Drain Mount, Oil Cooler Washer, Flat Mount, Carburetor Motor, Fan Screw Clamp, Hose Clamp, Hose Hose, Oil Cooler Outlet, Flared Tubing, Convoluted P-Clamp 2/00

A11

OIL COOLING (If built after 1/01/00) MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2

5 3

4

6 7

19 18

8 17

9

16

15

10

11

14

6

13

Ref. Part No.

1 2 3 4 5 6 7 8 9 10

7080474 5411813 7542122 5243783-067 7080869 7515158 7517659 2410157 7670111 5433353

Qty.

2 1 4 1 1 8 4 1 4 1

Description

Ref. Part No.

Clamp, Hose Hose, Inlet Nut Bracket, Top Clamp, Rubber Coated Screw Screw Motor, Fan U-Clip Shroud

11 12 13 14 15 16 17 18 19

4010274 7052244 1240064 3021186 5244069-067 7080862 7080866 5411768 8450086-07

Qty.

1 1 1 4 1 1 1 1 AR

12

6

Description

Thermister Plug, Drain Cooler, Oil to Air Mount, Rubber Bracket, Bottom Clamp Clamp, Hose Hose, Outlet, Flared Tubing, Convoluted 11/99

A12

EXHAUST SYSTEM MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2 3 4

5 6 8

7 12 16 9

14 10

12

11 8

15

13

12

16

13 14

17

11

10

16

(If built after 7/01/99) 13 Ref. Part No.

1 2 3 4 5

7542324 7555716 5410436 7555863 5010192 5132295 6 5410241 5411790 7 7515316 7515339 7515394 8 1260977-029 1260961-029

Qty. Description

1 1 1 1 1 1 1 1 1 1 1 1 1

Nut, Nylok Washer Washer, Rubber Washer (If built before 7/01/99) Bushing (If built before 7/01/99) Bushing (If built after 7/01/99) Dampener, Vib. (If built before 7/01/99) Dampener, Vib. (If built after 7/01/99) Bolt, Carriage (If built before 7/01/99) Bolt (If built after 7/01/99) Screw, Carriage (If built after 8/12/99) Silencer (If built before 7/01/99) Silencer (If built after 7/01/99)

Ref. Part No.

9 10 11 12 13

Qty. Description

7512666 3110064 7542301 7041804 7042029

1 2 2 4 2

14 1260976-029 1260987-029 15 1260960-029 16 5243517 17 7041789

1 1 1 2 1

Bolt Mount, Torque Stop Nut Spring, Exhaust Spring, Exhaust (If built before 7/01/99) (Only 1 used if built after 7/01/99) Headpipe (If built before 7/01/99) Headpipe (If built after 7/01/99) Manifold, Black Seal, Exhaust Spring, Exhaust (If built after 7/01/99) 2/00

A13

FUEL TANK MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2 4

3

6 5

7 8

9 10

24 11 22

23 12 21

21 20 19

20

13 17

18

16 15

Ref. Part No.

1 2 3 4 5 6 7 8 9

5430725 5810144 5811899 8360009-600 5431053 7517451 7552801 7558301 5222154-067 5222155-067 10 5811796 11 5332457 5333936

Qty.

1 1 1 AR 1 2 2 2 1 1 1 2 2

14

Description

Ref. Part No.

Cap, Gas Tank Gasket, Fuel Cap Seal, Foam Line, Fuel Vent, Tank Bolt Washer Washer Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH Foam, Intake, Splash Spacer (If built before 1/17/00) Spacer (If built after 1/17/00)

12 13 14 15 16 17 18 19 20 21 22 23 24

7547069 5810317 7517505 5432559 5432733 7052161 7661637 5240577-067 8450040-600 7080003 7052149 7052146 2520183

Qty.

4 2 1 1 1 1 2 1 AR 4 1 1 1

Description

Nutsert Pad, Fuel Tank Bracket Screw Knob, Fuel Valve Nut, Fuel Valve Valve, 3-Way Rivet Bracket, Fuel Valve Line, Fuel Clamp, Hose, Red Fitting, Fuel Outlet, Reserve Fitting, Fuel Outlet, Main Asm., Fuel Tank (Incl. 5,22,23) 2/00

A14

ENGINE MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 9 3

2

6

10

11

7 8

12

4 14

37

33

32

6

5

36

35

13

33

33 15 32 34 33

16

32 31

17

30

6 7

29

27 28

26

6

22 23

21

24

25

18 7

19 20

19

B1

6

ENGINE MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

Ref. Part No.

Qty.

1 2 3 4 5

8450003-1525 7052075 5243720-067 3084205 3085823

AR 1 1 2 1

6 7 8 9 10 11 12 13 14 15 16 17

7542403 7555806 5243641-067 7552901 7512315 7512232 4010132 7555823 3110068 5411721 7080511 8360009-600

4 2 1 2 2 1 1 1 1 1 1 AR

Description

Ref. Part No.

Line, Fuel Fitting, Tee Bracket, Carburetor Screw and Washer Engine, Short Block NOTE: The Short Block assembly contains a crankcase assembly., cylinder & cylinder head assembly and a piston & crankshaft assembly. Prior authorization is required for warranty consideration. Nut Washer Bracket, Motor Mount Washer Bolt Screw Cable, Ground Engine Washer Mount, Rubber Rear Boot, Clutch Intake Clamp, Narrow Band Line, Fuel

18 1012960-067 1013133-067 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

7547108 7517289 3021119 7555815 7515417 5243288-067 3021181 5430261 5210748 7575202 7512566 4010095 7080482 8450040-600 7080003 2530009 7546601 3110079 7517615

Qty.

Description

1 Mount, Engine, Rear (If built before 12/01/99) 1 Mount, Engine, Rear (If built after 12/01/99) 4 Nut 2 Screw 1 Mount, Rubber, Rear 2 Washer 2 Screw 1 Mount, Lower Front 1 Mount, Rubber, Rear 1 Bushing 1 Washer 1 Washer 1 Bolt 1 Cable, Battery/Engine 1 T-Clip AR Line, Fuel 8 Clamp, Hose 1 Filter 2 Nut, Nylok 2 Mount, Rubber 2 Screw 2/00

B2

AIR BOX MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 26 2

3

4 5 6 7 25 12

8 24

9

23

10 11

22

12

18

21

13 14

17

20

19 9

16 15

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

7517541 5432859 5411422 5432868 5811482 7515180 7558301 5433396 7080699 5830128 5433180 7080413 5411588 7080511

Qty.

4 1 1 1 1 2 2 1 2 1 1 2 1 1

Description

Ref. Part No.

Screw Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover Screw Washer Cap, End Clamp, Hose Gasket, Duct Duct, Carburetor Inlet Clamp Boot, Carb Clamp

15 7080694 16 5411746 5411848 17 5432774 5433678 18 5431863 19 5811650 20 5432377 21 8450059-150 22 7080650 23 5243694 24 5432601 25 7080595 26 5811633

Qty.

1 AR AR 1 1 2 1 1 AR 1 6 1 1 1

Description

Clamp, Hose Hose, Breather (If built before 7/26/99) Hose, Breather (If built after 7/26/99) Box, Air (If built before 7/26/99) Box, Air (If built after 7/26/99) Insulator Foil, Air Box Plug Line, Fuel Clamp, Hose Clip Collar, Carburetor Inlet Filter, Air Intake Filter, Precleaner Sleeve 2/00

B3

CV JOINT - BTB MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

BTB 7 2

1

3

4

6

5

8

9

10

11 12

13

Ref. Part No.

1 2 3 4 5 6 7

1380119 5222299 3260115 7670091 5411106 1380094 1380092

Qty.

2 1 1 1 1 1 1

Description

Ref. Part No.

Asm., CV Housing w/Sleeve Sleeve, Drive Shaft Seal Clamp, CV Joint, Large Circlip Boot, CV Joint Shaft Replacement (Incl. 4) Cardan Replacement (Incl. 4,6,8,9)

8 9 10 11 12

2200771 3260130 7661913 7080627 2200773

13 2200961

Qty.

Description

1 1 1 1 1

Kit - Cross and Bearing Yoke, Splined Pin, Spring Clamp, Small Band Kit - Boot Replacement, CV Joint (Incl. 3,5,11) 1 Kit - Drive Shaft w/Sleeve 11/98

B4

PROP SHAFT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

4

2

3

5

6

Ref. Part No.

Qty.

1380138 1 3260133 2 3260104 3 3260140

1 1 2 1

Description

Ref. Part No.

Asm., Prop Shaft (Incl. 1-4) Yoke, Gear Case, Front Kit - Cross and Bearing Shaft, Prop, Front

4 3260131 5 5411092 6 7661913

Qty.

Description

1 Yoke, Splined 1 O-Ring 1 Pin, Spring 11/98

B5

FRONT STRUT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

26

1

25 24

2

23

6

3

21

7

5 4

22 10

20

8

11

4

9

13

18 17

19

12 11

14

16

10 15

Ref. Part No.

Qty.

1 2 3 4 5 6 7 8 9

5411608 7041761 5211115 7558402 7080573 7542303 7517445 5810439 -------

2 2 2 6 2 4 4 2 1

10 11 12 13 14

3554509 3554507 5222193 7080306 2410133

4 4 2 2 2

Description

Bumper Strut, Front Washer Washer Clamp, Rubber Coated Nut Screw Retainer, Strut Casting Wire Asm., Front Brake Caliper, RH (See Front Brake Pg. B8 for Details) Bearing, Tapered Roller Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal Fitting, Lubrication Coil, Magnetic

Ref. Part No.

15 2201311 2201312 16 17 18 19 20 21

7041375-067 5243364 5432871 7515339 5132062 -------

22 23 24 25 26

3610028 5432872 5810291 7555749 7547104

Qty.

Description

1 Asm., Hubstrut, LH (32mm) (Incl. 8,11-14,22) 1 Asm., Hubstrut, RH (32mm) (Incl. 8,11-14,22) 2 Spring, Coil 2 Retainer, Spring 2 Ball, Pivot, Bottom 4 Bolt 2 Spacer 1 Kit - Drive Shaft w/Sleeve (See CV Joint - BTB Pg. B4, Ref. 13) 2 Seal, Hubstrut 2 Ball, Pivot, Top 2 Spacer, Rubber 2 Washer 2 Nut 2/00

B6

FRONT WHEEL MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

2 3

4

12 13

11

10

14

5 6

7

9

8

15

16 25 24

19

7 6

17

18

20

21

23 22

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13

7512325 5211869 3610019 5211148 1520281 3554506 3554507 7515523 1520243 3250028 3250010 3250032 1321814

Qty.

8 2 2 2 2 4 4 8 2 2 12 2 2

Description

Ref. Part No.

Bolt Disc, Brake Seal, Front Hub Plate, Armature Clutch, Front Hub, Elec./Mech. Bearing, Tapered Roller Cone Bearing, Tapered Roller Cup Stud Asm., Hub w/Bearing Race (Incl.3,7,8) Cage, Roll Roll Spring, Garter Spacer

14 15 16 17 18 19 20 21 22 23 24 25

3250030 7052045 5411709 7556004 7542810 7661401 5410470 5432611 7512027 7542459 1520269-117 1525017

Qty.

2 2 2 2 2 2 2 2 6 8 2 2

Description

Cam Plug, Magnetic Drain Tire (24x8-12) Washer Nut, Slotted Pin, Cotter O-Ring Cap, Hub Screw Nut Rim, Front Valve, Rim 11/98

B7

FRONT BRAKE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3

2

4

1

5

6

7

12 11

10

8

9

Ref. Part No.

1910271 1910264 1 7080352 2 7515489 3 5131115 5131116 1930642 4 1930665 5 5410779

Qty.

Description

1 Asm., Front Brake Caliper, LH (Incl. 1-7,9,10) 1 Asm., Front Brake Caliper, RH (Incl. 1-7,9,10) 1 Screw, Bleeder 1 Screw, Socket Set 1 Caliper, Brake, LH 1 Caliper, Brake, RH 1 Kit - Front Brake Boot 1 Kit - Piston and Insulator Seal (Incl. 5-7) 1 Ring, Molded Square (.094)

Ref. Part No.

Qty.

6 5410780 7 5132294 8 2200465 2200901 2201149 9 1910265 1910412 10 5410495 11 5410494 12 - - - - - - -

1 1 1 1 1 1 1 1 1 4

Description

Ring, Molded Square (.103 x .134) Piston, Brake, Long Kit - Front Brake Pad, General Duty Kit - Front Brake Pad, Severe Duty Kit - Front Brake Pad, Soft Duty Mount, Caliper (If built before 7/09/99) Mount, Caliper (If built after 7/09/99) Boot, Bushing Boot, Pin Seal Screw (See Front Strut Pg. B6, Ref. 7) 10/00

B8

CONTROLS - THROTTLE ASM./CABLE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2

3

4

5

6

Ref. Part No.

1 5432721 5433806 2 5410193 3 5411439

Qty.

Description

Ref. Part No.

1 Cover, Throttle Control (If built before 11/22/99) 1 Cover, Throttle Control (If built after 11/22/99) 1 O-Ring 1 O-Ring

4 7080709 7080857 5 2010188 6 2010191

Qty.

Description

1 Cable, Throttle Control (If built before 2/10/99) 1 Cable, Throttle Snap-In (If built after 2/10/99) 1 Asm., Throttle Control (Incl.1,3,6) 1 Asm., Throttle Clamp 2/00

B9

CONTROLS - MASTER CYLINDER/BRAKE LINE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2

3 4 14

13

15

5

12

28 27

6

11 16

25

26 17

22 20

24

7

18

8

19 9

21 23 Ref. Part No.

2050078 2200809 1 2 3 4 5 6 7

1930797 1930796 1930795 2200808 1930799 1930804 2201034

8 9 10 11 12

------2201090 1930806 1930792 1930805

Qty.

10

22 Description

1 Asm., Master Cylinder (Incl. 1-13) 1 Kit - Master Cylinder Reservoir (Incl. 1-3,13) 2 Bolt, Cap 1 Cap, Reservoir 1 Diaphragm 1 Kit - Master Cylinder Clamp 1 Asm., Master Cylinder Piston 1 Rivet 1 Kit - Brake Lever w/Parking Latch (Incl. 6-9) 1 Spring, Flat 1 Kit - Park Brake Lever (Incl. 6,8) 1 Nut 2 Bolt, Reservoir 1 Bolt, Lever

Ref. Part No.

13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

------5411297 5410988 4110164 1910286 7621462 7080539 8360031-30 1930752 7080138 7512084 8360011-38 1930753 7052237 1930816 1930674

Qty.

1 1 2 1 1 1 1 1 1 8 2 1 1 1 1 1

Description

Ring, Square, Reservoir Boot, Rubber Brake Line Seal Switch Line, Hand Brake, Front Rivet Clamp, Nylon Conduit, Convoluted Line, Brake, Left Front w/Fittings Cable Tie Screw Tubing, Convoluted Line, Brake, Right Front w/Fittings Fitting, Cross Line, Brake Bolt, Banjo 11/98

B10

STEERING POST MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 16 2 15 14 3

4

13 12

5

11

6 10

6 5 7 5 8 9 Ref. Part No.

1 1843067 2 5431573 5433415 3 7080424 4 7515321 5 7555878 6 5410772 7 5431571 8 7543203

Qty.

1 1 1 1 2 3 2 1 1

Description

Asm., Steering Post (Incl. 12,13) Bushing,Console (If built before 7/12/99) Bushing,Console (If built after 7/12/99) Fitting, Lubrication Bolt Washer O-Ring Spacer, Steering Post Nut

Ref. Part No.

9 10 11 12 13 14

7661633 5431570 7661632 5431574 7080433 5431572 5433416 15 5222999-067 16 7542324

Qty.

1 1 2 1 1 1 1 1 2

Description

Pin, Cotter Bushing, Steering, Lower Rivet Plug, Steering Grease Fitting, Lubrication Bushing, Steering (If built before 7/12/99) Bushing,Steering (If built after 7/12/99) Bracket, Steering Bushing, Upper Nut, Nylok 2/00

B11

HANDLEBAR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

A00CD32FA and A00CD32FB

2

27 28 2

3 10 29

4

9 7

26 22 23 24

33 32

8

12

11

6 25

5

31 25

A00CD32FA and A00CD32FB

21

14

13

30

15

17 16

20

17 18 19

Ref. Part No.

Qty.

1 5432247-070 2 5432420 3 5432246-070 5433183-070 4 7517216 7517224 5 5241397-067 5241698-067 6 -------

1 2 1 1 4 4 1 1 1

7 7080726 2200188 8 5432926 9 4010262 10 5431030 11 5432952 12 7517625 13 5224715-067 14 5132382 15 4010298 16 7517658 17 5630629 18 7542122 19 7080631

1 1 1 1 2 1 1 1 1 1 1 4 4 1

Description

Cover, Logo Cover, Screw Panel, Instrument (AA)(CA) Panel, Instrument (FA)(FB) Screw (AA)(CA) Screw (FA)(FB) Bracket, Instrument Panel (AA)(CA) Bracket, Accessory Panel (FA)(FB) Asm., Master Cylinder (See Control - Master Cyl./Brake Line Pg. B10 for Details) Cable, Choke w/Adjuster Kit - Choke Lever Spacer, Switch, LH Switch, Handlebar, Hi/Lo/Rev. Override Grip, Handlebar Plug, Hole Screw Tube, Handlebar Cap, Hall Sensor (FA)(FB) Sensor, Hall Effect (FA)(FB) Screw (FA)(FB) Block, Handlebar Nut, Nylok Clip, Cable Retaining

Ref. Part No.

20 - - - - - - 21 2460715 2460841 22 4040054 23 4040053 24 5430967 4010313 25 4110264 4010278 4010321

26 27 28 29 30 31 32 33

5433733 5431964 7080229 3280337 3280345 7512024 3280201 5630633 7541933 7558212 7555868

Qty.

Description

1 Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B9, Ref. 5) 1 Harness, Control Panel (AA)(CA) 1 Harness, Control Panel (FA)(FB) 1 Indicator, Neutral/Reverse 1 Indicator, “Hot Temperature” 1 Plug, Indicator Hole (AA)(CA)(FB) 1 Indicator, “P” Park (FA) 1 Switch, Ignition 1 Key, Blank, Series 2000, 6700, 6800. NOTE: Spare key must be cut from existing key. 1 Key, Blank, Series 2200, 2300, 2700, 2800. NOTE: Spare key must be cut from existing key. 1 Nut, Ignition 1 Cover, Key 1 Nut, Choke Slide 1 Speedometer (FB) 1 Speedometer (FA) 2 Screw (FA)(FB) 1 Clamp (FA)(FB) 1 Block, Riser (FA)(FB) 2 Nut, Brass (FA)(FB) 2 Washer, Flat (FA)(FB) 2 Washer, Lock (FA)(FB) 10/00

B12

A-ARM/STRUT MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

5 2

4

6 7 8

9

3

30

31

10

11 9 12

29 28

13 14 28

29

23

22

27 15

26 22

23

16

24 25 19

20

1 7542403 2 5333367 3 1820567 1820805 4 5 6 7 8 9 10 11 12 13 14 15

5411291 7061034 7542711 5020926 7547028 7061033 7061054 5411920 7517674 7555806 7556099 7546904 7661203 7080927

Qty. Description

2 Nut, FLEXLOC 1 Bushing 2 Asm., Tie Rod (Incl. 4-9)(If Built before 8/16/99) 2 Asm., Tie Rod (Incl. 4-9)(If Built after 8/16/99) 2 Boot, Seal, Rod End 2 Rod End 2 Nut 2 Tie Rod 2 Nut, LH 2 Rod End, LH (If Built before 8/16/99) 2 Rod End, LH (If Built after 8/16/99) 1 Boot, Seal, Rod End 2 Bolt (If Built after 8/16/99) 4 Washer, Flat (If Built before 8/16/99) 4 Washer, Flat (If Built after 8/16/99) 2 Nut 4 Pin, Cotter 2 Joint, Ball

17

14

21 Ref. Part No.

18

Ref. Part No.

16 17 18 19 20

Qty. Description

26 27

5211121 7512284 5410548 7542438 5431150 5431149 7517756 5433066 5020677 5020681 2201609 2201610 7080433 --------

2 4 2 2 1 1 6 4 4 2 1 1 2 1

28 29 30 31

7512492 7552603 7517527 7515415

4 4 1 1

21 22 23 24 25

Bracket, Ball Joint Screw Boot, Rubber Nut, Castle Shield, CV Joint, LH Shield, CV Joint, RH Screw Bushing, A-Arm, Long Bushing Shaft, A-Arm Kit - A-Frame, LH Kit - A-Frame, RH Fitting, Lubrication Asm., Heavy Hubstrut (See Front Strut Pg. B6, Ref. 15) Screw Washer, Spring Lock Bolt Screw 10/00

B13

DRIVE CLUTCH MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA

3 1

4

5

7

8

2 6

13

12

11

10 9

5

14

Ref. Part No.

1 2 3 4 5 6

7512176 7552801 5430945 1321457 5431936 5210752 5242981 5210753 5210754

Qty.

6 6 6 3 6 AR AR AR AR

Description

Ref. Part No.

Bolt Washer Washer, Multilube Roller and Bushing Button, Clutch Spacer (.020) Spacer (.025) Spacer (.032) Spacer (.050)

7 8 9 10 11 12 13 14

5630279 7512266 7541906 3576504 5020422 7041157 3576510 1321632

Qty.

3 3 3 1 3 1 1 1

Description

Weight, Shift, 16 Bolt, Shoulder Nut, FLEXLOC Bearing, Moveable (1/2I) Pin, Roller Spring, Clutch Cover, Bearing Asm., Drive Clutch, ATV-08 (Incl. All Less 7,12) 2/00

B14

DRIVE CLUTCH 325 MAGNUM 4X4 A00CD32FA and 325 MAGNUM 4X4 A00CD32FB

5 6

4 1

2

7

3

9 8 10

18 12

15

16

11

5

14 13

17

Ref. Part No.

1 2 3 4 5 6 7 8 9 10

1520231 7556009 5131646 7541906 5431936 5020422 3585712 7547130 3576510 7552801

Qty. Description

1 1 1 3 6 3 1 1 1

Clutch, One Way Drive Washer Spacer Nut, FLEXLOC Button, Clutch, Stemless Pin, Roller Bearing Nut, Jam Cover, Bearing Washer, Spring Lock

Ref. Part No.

11 12 13 14 15 16 17

7512176 7041157 1321457 5430945 7512266 5630279 1321706

18 7556008

Qty. Description

6 1 3 6 3 3 1

Bolt Spring, Clutch Roller and Bushing Washer, Multilube Bolt, Shoulder Weight, Shift, 16 MH Asm., Drive Clutch, Braking (Incl. All Less 12,7) 1 Washer 2/00

C1

DRIVEN CLUTCH MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

A00CD32AA A00CD32CA 8

9

7

2 6

10

11

3

4

5 12 13 14

5

15

1 A00CD32FA A00CD23FB

17 18

21 9 10

22

20

2

3

16

4

19

26 25

13

24

23

20

Ref. Part No.

Qty. Description

Ref. Part No.

7556120 5220646 7552901 7515382 1321855

AR 1 1 1 1

3211077 5430766 7511854 7710448 5210752 5132344 5131447 12 7041782 13 3576511

1 3 3 1 1 1 1 1 1

14 3576504 15 7556804 16 7555898 7556076 17 7556013 18 7556010 19 7710461 20 1322184

1 2 3 4 5 6 7 8 9 10 11

Bushing Washer, Domed Washer, Spring Lock Bolt Asm., Driven Clutch, 3 Angle, Heavy (Incl. 7-16)(AA)(CA) Belt, Drive Button, Ramp Bolt Ring, Retaining Spacer Ramp, Stationary (If built before 4/01/00) Ramp, Stationary (If built after 4/01/00) Spring, Clutch Bearing, Moveable (1”)

21 22 23 24 25 26

3211069 7517323 3585710 5211115 7041635 5131674

Qty. Description

1 AR AR AR 1 1 1 1 1 3 1 1 1 1

Bearing, Moveable (1/2”) Washer (.030”) Washer, Spacer (.020”) Washer, Spacer (.025”) Washer Bushing Ring, Retaining Asm., Driven Clutch, Braking (Incl. 2,9,10,13,18,19,23-26)(FA)(FB) Belt, Drive Screw Bearing Washer Spring Ramp, Stationary 9/02

C2

CLUTCH COVER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

4 2

3

6

5

9

7

10

11

8 25

12 13

24 23

22

21

20

14

15

18 19 17 16 Ref. Part No.

1 2 3 4

Qty.

7512232 2632116 5433453 2201520

2 1 1 1

2201676

1

5 5433363 6 7517601 7517599

1 3 5

7 7080909 8 5521301 9 5432849

1 1 1

5433540

1

5433451-328

1

10 7670051 11 7512093 7512094

1 5 5

Description

Ref. Part No.

Screw Foam, Clutch Air Inlet Plate, Backing Kit - Inner Clutch Cover (Incl. 8,11,15) (If built before 1/03/00) Kit - Clutch Cover, Inner (If built after 1/03/00) Duct, Inlet, Down Tube Bolt and Washer (If built before 1/03/00) Bolt and Washer (If built after 1/03/00) Clamp, Narrow Band Seal, Clutch Cover 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) Clip, Clutch Cover Screw (If built before 1/03/00) Screw (If built after 1/03/00)

12 7074946 7078689 13 7077377 14 7074782 7077666 7512094 5411489 7080761 7558301 7517386 5433172 5433744 21 - - - - - - 15 16 17 18 19 20

22 23 24 25

5240409-067 5410575 5411795 5410489 5411901

Qty.

Description

1 Decal - Clutch Cover (If built before 10/04/99) 1 Decal - Warning, Clutch Cover (If built after 10/04/99) 1 Decal - Engine/Clutch Modification 1 Decal - “Automatic Transmission” (AA)(AC) 1 Decal - “Automatic/EBS’ (FA)(FB) 9 Screw 1 Boot, Duct 2 Cable Tie 2 Washer, Flat 2 Screw 1 Duct, Air Outlet (If built before 11/05/99) 1 Duct, Air Outlet (If built after 11/05/99) 3 Screw and Washer (See Crankcase Pg. D3, Ref. 6) 1 Bracket, Retainer, Seal 1 Seal, Cover Case 1 Stopper, Inner Clutch Cover 1 Seal, Cover Case (If built before 1/03/00) 1 Seal, Clutch Cover (If built after 1/03/00) 2/00

C3

ELECTRICAL/TAILLIGHT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

15

17

16

3

6 7

2

11

19 20 21

13 12

10

38

14

8

9

37

18

5

4

1

11 12 30

22

28

23 27

29

24 25

36

26

35 33

34 31 32

Ref. Part No.

1 2460737 2460821 2460833 2460834 2 2200593 3 2201795 4 2432034 5 6 7 8 9 10 11 12 13 14 15 16 17

4032046 4032029 4030043 4032045 4032064 7670054 7541925 7571602 7512027 5810290 4010311 4010310 7517386

Qty.

Description

1 Harness, Main Wire (AA)(CA) (If built before 8/01/99) 1 Harness, Main Wire (AA)(CA) (If built after 8/01/99) 1 Harness, Main Wire (FA) 1 Harness, Main Wire (FB) 1 Kit - Circuit Breaker, 20 AMP 1 Kit - Circuit Breaker, 10 AMP 1 Asm., Taillight w/Brake Light (Incl. 5-10) 1 Lens, Taillight 2 Screw, Taillight 1 Bulb, Taillight 1 Gasket, Taillight 1 Backing, Taillight/Brake Light 2 Nut, Speed 4 Nut, Nylok 4 Washer 2 Screw 3 Pad, Battery 1 Switch, Horn 1 Horn 1 Screw

Ref. Part No.

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

5810317 2200361 4010095 7010032 5410424 5432077 4140006 7511876 4010354 5431769 4010094 4010093 7512007 5132214 4010249 7512018 4060191 4010195 7512017 4020149 7670109

Qty.

1 1 1 2 1 AR 1 2 1 1 1 1 2 1 1 5 1 1 2 7 3

Description

Pad Kit - Battery Bolt, Short Cable, Battery/Engine Hook, Battery Strap Strap, Battery Holddown Tube, Battery Vent Battery Screw Limiter, Speed (FA)(FB) Cover, Battery Cable, Battery/Solenoid Cable, Solenoid/Starter Bolt Sink, Heat Switch, Thermister LR-60 Screw Rectifier, Regulator, LR 35 Limiter, RPM LR 83-3 (AA)(CA) Screw Clip, Rosebud Clip, Routing 2/00

C4

REAR BRAKE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

2 3

5

9

6

10 11

8

4 7

12 1 13 5 14

15 16

19

17 18

7 13

19

18 17 5

21

22

20

30 24 28

29

27

27

22

26

24 25

9 23

C5

19

21

REAR BRAKE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

Ref. Part No.

Qty.

1 2201189 1910339 1930860 2 7515406 3 7555806 4 1910270

1 1 1 2 2 1

1910367

1

2201428 2201467 2201385 5410988 1910286 1910288 7080573 7517386 7080762 7661048 7080816

1 1 1 6 1 1 1 2 3 2 1

5 6 7 8 9 10 11 12

Description

Ref. Part No.

Kit - Brake Pad (Incl. Spacer and Pin) Pad, Spacer Pin Screw Washer Asm., Brake Caliper, Rear (If built before 2/09/99) Asm., Brake Caliper (If built after 2/09/99) Kit, Bleeder Replacement Piston, Caliper, DH2P, Rear Kit, Caliper Seal Seal Line, Brake, Front Hand Line, Brake, Rear Foot Clamp Screw Clip, Brake Line Rivet T-Clip, Dual

13 1930674

3 Bolt, Banjo

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

2 1 1 2 1 3 1 2 2 1 2 1 1 2 2 1 1

7542403 7542153 1930854 7080003 1910331 7512240 1012753-067 7542122 7558301 1012752-067 7555919 7661401 7556090 5433189 7515158 1910311 7041750

Qty.

Description

Nut Nut, Nylok Reservoir, Brake, Rear Clamp, Hose Hose, Reservoir Bolt Pivot, Brake Mount, Rear Nut, Nylok Washer Rod, Brake Washer Pin, Cotter Washer Bushing, Pedal Pivot Screw Master Cylinder, Foot Spring, Torsion 9/02

C6

REAR WHEEL DRIVE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3

2

4 5 1

9 10 11 12

Ref. Part No.

1 2 3 4 5 6

7661404 7542714 5131777 7512673 7670081 5411710

Qty.

2 8 2 8 8 2

8

6

7

Description

Ref. Part No.

Pin, Cotter Nut Hub, Wheel, Rear Bolt Pushnut Tire, 24x11.5-10

7 8 9 10 11 12

1525017 1520183-117 7555745 7555796 7543005 5411164

Qty.

2 2 2 2 2 2

Description

Valve, Rim Rim, Rear, Silver Washer Washer Nut Hub, Dust Cover 7/99

C7

FRONT HOUSING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

9 10 11

14

12 13

16

15

17

18

19

21

20

2

22

1

8 7

12 11

24 23

6 5 4 3 2 1

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12

1341253 3233319 3233252 3233573 3233588 3233574 3233589 3233590 3233591 7080756 8450003-1525 3233253 3233254

Qty.

1 2 11 1 1 1 1 1 1 1 AR 2 2

Description

Ref. Part No.

Asm., Front Gearcase (Incl. 1-24) Seal, Oil Screw Cover, Gearcase O-Ring Nut Bearing, Ball Shaft, Input, Front Housing Bushing Clip Line, Vent Plug, Drain Washer

13 14 15 16 17 18 19 20 21 22 23 24

3233524 3233592 3233593 3233594 3233595 3233020 3233554 3233596 3233597 3233248 3233583 3233582

Qty.

1 1 1 1 1 1 1 1 1 1 1 1

Description

Tube, Vent Housing, Front, Gearcase Bushing Gear, 37T, Bevel Shaft, Output, Front Bearing Shim O-Ring Cover, Output, Front Housing Seal Shim Button, Thrust 11/98

C8

MAIN GEARCASE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2

3 4 5 9 6

38

37 36

7

40

39

35

8

25 27

9

41

34 24 30 32

33 9

31 10

28

11 12

42

30

43

29

13 14

26

15 16

44 45

27

46

25

48

23 24 22 9

17 18

47

17 49 5 25 51 52 50

19

5

53

54 55

2

56

1 20

21

58 4

66 65 64 63 62 61 60

C9

59

5

57

1

MAIN GEARCASE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

Ref. Part No.

1341296 1341336 1 3233248 3233788 2 3233252 3 3233610 3233763 4 3233529 5 3233019 6 3233604 3233756 7 3233036 8 3233603 3233755 9 3233018 10 3233055 3233961 11 3233054 12 3233153 13 3233045 14 3233040 15 8360009-600 16 3233037 17 3233749 18 3233615 19 3233902 3233765 20 3233711 21 3233324 22 3233628 23 3233629 3233758 24 3233306 25 3233619 26 3233631 3233760 27 3233103 28 3233602 29 3233598 3233761 30 3233012

Qty.

Description

1 Asm., Gearcase, Main (Incl. all less 11)(AA)(CA)(FB) 1 Asm., Gearcase, Main (Incl. 1-48,50-66)(FA) 3 Seal (FA) 3 Seal (AA)(CA)(FB) 17 Screw 1 Gearcase, LH (AA)(CA)(FB) 1 Cover, LH (FA) 4 Pipe, Knock 4 Bearing, Ball 1 Shaft, Input, 31T (AA)(CA)(FB) 1 Shaft, Input, 31T (FA) 1 Chain, Silent 1 Gear, 16T w/22T Spline (AA)(CA)(FB) 1 Gear, 14/19T (FA) 4 Bearing, Ball 2 Nut, FLEXLOC (FA) 2 Nut, Lock (AA)(CA)(FB) 2 Washer, Flat (FA) 2 Bellcrank 2 Ring, Retaining 2 Washer AR Line, Vent 1 Tube, Vent 8 Screw 1 Switch, 3 Position (Qty. 2 for FA) 1 Gearcase, Main (AA)(CA)(FB) 1 Gearcase, RH (FA) 1 Plug 1 Washer 1 Washer 1 Engagement Dog, Low (AA)(CA)(FB) 1 Engagement Dog, Low/Park (FA) 2 Ring, Retaining 3 Washer, Thrust 1 Gear (AA)(CA)(FB) 1 Gear, 36T (FA) 2 Bearing, Needle 1 Fork, Shift, H/R 1 Shaft, Reverse (AA)(CA)(FB) 1 Shaft, Reverse (FA) 2 Washer, Thrust

Ref. Part No.

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66

3233014 3233599 3233029 3233533 3233600 3233613 3233708 3233762 3233309 3233032 3233308 3233747 3233709 3233764 3233608 3233609 3233106 3233607 3233606 3233605 3233759 3233617 3233620 3233621 3233622 3233582 3233583 3233623 3233781 3233253 3233777 3233254 3233611 3233625 3233093 3233626 3233552 3233624 3233627 3233548 3233618

Qty.

1 1 1 1 1 1 1 1 1 1 2 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2

Description

Bearing, Needle Sprocket, 24T Ring, Retaining Engagement Dog, H/R, HLR Gear, 30T Spacer Gear, Helical, 36T (AA)(CA)(FB) Gear, Helical, 34T (FA) Bracket, Interlock Spring, Shifting, Interlock Pin, Interlock Screw Gear, Helical, 48T (AA)(CA)(FB) Gear, Helical, 50T (FA) Screw (Qty. 8 for FA) Cover, Bearing, Center Ring, Retaining Bearing, Ball Shaft, 10T, Spiral Bevel Fork, Shift, Low (AA)(CA)(FB) Fork, Shift, Low/Park (FA) Switch, 2 Position (AA)(CA)(FB) Sprocket, 12T w/18T Spline Gear, Spiral, Bevel, 31T Shaft, Rear Output Button, Thrust Shim Cover, Output (FA) Cover, Output (AA)(CA)(FB) Plug, Drain (FA) Plug, Drain (AA)(CA)(FB) Washer Shim Shaft, Front Output Sprocket, 12T Chain, Roller Bushing, Garlock Shaft, Shift, Low Shaft, Shift, H/R O-Ring Ring, Retaining 5/01

C10

REAR HOUSING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

2 3 4 5 6 7

26

8

25

9

10 11 12 13 16 17

15

8 14

3 17 16

Ref. Part No.

1341254 1341309 1341321 1 2 3 4

3233585 3233252 3233256 3233584 3233741

5 3233529 6 7 8 9 10

3233587 3233581 3233268 3233580 3233579 3233740

11 7670102 12 8450003-1525

Qty. Description

1 Asm., Gearcase, Rear (Incl. 1-10, 14-26) (If built before 2-21-99) 1 Asm., Gearcase, Rear (Incl. 1-10, 14-26) (If built before 7-01-99) 1 Asm., Gearcase, Rear (Incl. 1-10, 14-26) (If built after 7-01-99) 2 Screw 10 Screw 2 Seal 1 Cover, Gearcase, Output (For Gearcase 1341254 and 1341309) 1 Cover, Gearcase, Output (For Gearcase 1341321) 1 Pipe, Knock (For Gearcase 1341254 and 1341309) 1 O-Ring 1 Shim 2 Bearing, Ball 1 Shaft, Rear Axle 1 Gear, Bevel, 31T, Rear (For Gearcase 1341254 and 1341309) 1 Gear, Bevel, 31T, Rear (For Gearcase 1341321) 3 Clip AR Line, Vent

24

18

19

20

Ref. Part No.

13 7080307 14 3233524 15 3233586 3233739 16 17 18 19

3233711 3233324 3233577 3233576 3233707 3233738

20 3233575 3233714 21 22 23 24 25 26

3233588 3233319 3233573 3233574 3233582 3233583

23

21

2 22 Qty. Description

1 Clamp,Hose 1 Tube, Vent 1 Gearcase, Rear Housing (For Gearcase 1341254 and 1341309) 1 Gearcase, Rear Housing (For Gearcase 1341321) 2 Plug 2 Washer 1 Bushing 1 Shaft, Pinion, 10T, Bevel, Rear (For Gearcase 1341254) 1 Shaft, Pinion, 10T, Bevel, Rear (For Gearcase 1341309) 1 Shaft, Pinion, 10T, Bevel, Rear (For Gearcase 1341321) 1 Bearing, Ball (For Gearcase 1341254 and 1341309) 1 Bearing, Ball (For Gearcase 1341321) 1 O-Ring 1 Seal, Oil 1 Gearcase, Cover, Input 1 Nut, Lock 1 Button, Thrust 1 Shim 2/00

C11

GEAR SELECTOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2 3 4

5

6 10

16

7

11

8 15 9 10 11

14 12

Ref. Part No.

1341271 1341337 1 3233195 3233767 2 7512024 3 3233649 4 3233131 5 3233648 6 3233658 3233766

Qty.

Description

1 Asm., Gear Selector (Incl. 1-16)(AA)(CA)(FB) 1 Asm., Gear Selector (Incl. 1-16)(FA) 1 Asm., Knob (AA)(CA)(FB) 1 Asm., Knob (FA) 1 Screw 4 Screw 1 Strap, Wire 1 Cover, Gear Selector Boot 1 Handle, Gear Selector (AA)(CA)(FB) 1 Handle, Gear Selector (FA)

13

Ref. Part No.

7 8 9 10 11 12 13 14 15 16

3233646 3233754 3233644 3233642 3233060 3233076 3233639 3233640 3233641 3233643

Qty.

1 1 1 2 2 2 1 1 1 1

Description

Sphere, Plastic Pin, Groove Pin, Dowel Spring, Detent Bullet, Detent O-Ring Slide, Low (AA)(CA)(FB) Slide, High/Reverse (FA use Qty. 2) Body, Gear Selector Spring, Centering 9/00

C12

GEARCASE SELECTOR MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 2

4 3

6 5

2

2

13

8

7

9

6 2 12

10

9

11

Ref. Part No.

1 2 3 4 5 6 7

7061013 7546707 7546702 5020974 7546701 7061014 1012822-067

Qty.

2 4 2 1 2 2 1

Description

Ref. Part No.

Rod End, LH Nut, FLEXLOC Nut, LH Rod, Low Nut Rod End, RH Bracket, Shifter

8 9 10 11 12 13

7512130 7542122 7555827 7512126 7517386 5020973

Qty.

2 4 2 2 4 1

Description

Screw Nut, Nylok Washer Bolt Screw Rod, High, Rev 10/00

C13

SWING ARM/REAR GEARCASE MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

9 1

10

11

12 13

2 3

4 5

6

19

14 15

16

17

18

7

15 14 13 12

8

38 37

36

35

34

20

33 5 32 20 31

30 29

11

10

9

21

28

24

25

23

22

26 27

Ref. Part No.

1 5132152 2 ------3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

3513523 5411653 7517604 7512084 7555721 7542703 5411532 5131863 5131864 3610072 3554506 3554507 5411602 1541323 5132201 7080433 18 5411092 19 1380137 20 7553201

Qty.

Description

1 Hub, Brake Disc 1 Asm., Rear Brake Caliper (See Rear Brake Pg C6, Ref. 4) 2 Bearing, Ball 1 Shield, Brake Line, Rear 3 Bolt 2 Screw 3 Washer 3 Nut, FLEXLOC 2 Cap, Swing Arm Pivot 2 Nut 2 Pivot, Threaded 2 Seal, Swing Arm Pivot 2 Bearing, Tapered Roller Cone 2 Bearing, Tapered Roller Cup 2 Seal, Swing Arm Pivot 1 Asm., Swing Arm (Incl. 14,15) 1 Coupling, Prop Shaft, Greased 1 Fitting, Lubricating 1 O-Ring 1 Asm., Prop Shaft, Rear 8 Washer

Ref. Part No.

21 22 23 24 25

Qty.

7517585 5131862 7710482 7517612 1012881 5242851-067 5811716 26 - - - - - - -

8 1 1 3 1 1 1 1

27 28 29 30 31 32 33 34 35 36 37 38

1 1 1 1 1 1 3 1 1 1 1 1

5411531 5131930 5411707 7072533 7661913 1012740-067 7515481 7710471 5132075 3610071 5211849 5411092

Description

Bolt Axle, Rear Ring, Retaining Screw Asm., Skid Plate Plate, Rear Housing Skid, Pad, Rubber Asm., Gearcase, Rear (See Rear Housing Pg. C11 for Details) O-Ring Collar, Rear Axle O-Ring Decal - Hitch Pin Tube, Axle, LH Screw Ring, Retaining Spacer, Bearing Seal, Axle, Rear Disc, Brake O-Ring 4/00

C14

SHOCK MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

2 3

5

4

6

7

11

8 1

10

Ref. Part No.

1 2 3 4 5 6

7542439 5433213 7515415 5132022 5241147 7041777-067 7041849-067 7041815-067

Qty. Description

2 2 1 1 1 1

Nut, Nylok Bushing (If built before 6/21/99) Screw Tube (If built before 6/21/99) Retainer, Shock Spring (For 7041774)(If built before 6/21/99) 1 Spring (For 7041890)(If built after 6/21/99) 1 Spring (FA)(FB)

9

Ref. Part No.

7 7041774 7041890 8 5630921 5630551 9 5132021 10 5433212 11 7515438

Qty. Description

1 Shock (If built before 6/21/99) 1 Shock (If built after 6/21/99) 1 Cam, Adjuster (For 7041774)(If built before 6/21/99) 1 Cam, Adjuster (For 7041890)(If built after 6/21/99) 1 Tube 2 Bushing 1 Screw 2/00

D1

TRANSMISSION MOUNTING MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

2 1

2 4

3

5

9

8 5

1

6

7

7

8

11

9 2 10 2

Ref. Part No.

------1 2 3 4 5

7515417 7547108 7515398 7542321 7555976

6 5242819-067

Qty. Description

1 Asm., Main Gearcase (See Main Gearcase Pg. C10 for Details) 2 Screw 6 Nut 2 Screw 2 Nut 3 Washer

Ref. Part No.

7 8 9 10 11

7517289 7552603 7515522 5242820-067 -------

Qty. Description

4 4 4 1 1

Screw Washer Bolt Mount, Transmission Mount, Engine,Rear (See Engine Mounting Pg. B2, Ref. 18)

1 Mount, Rear Transmission 11/98

D2

CRANKCASE MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

6

5 7 8 3

1

4 9

2 10 11

12 22

21

20 19

13 18 15

14

16 17 Ref. Part No.

1 3083669 2 3080103 3 3086394 3086793 4 5 6 7 8 9

3086395 3084840 3084205 3084839 3085850 3086404 3086794 10 3086405

Qty. Description

1 Bushing, Starter 2 Pin, Dowel 1 Asm., Crankcase (Incl. 1-5,7,8,12, 18,21,22)(If built before 3/1/99) 1 Asm., Crankcase (Incl. 1-5,7,8,12, 18,21,22)(If built after 3/1/99) 1 Bearing, Ball 2 Pin, Dowel 3 Screw and Washer 1 Seal, Oil 1 Pipe 1 Gauge, Oil (If built before 3/1/99) 1 Gauge, Oil (If built after 3/1/99) 1 O-Ring

Ref. Part No.

11 12 13 14 15 16 17 18 19 20 21 22

3084838 3086397 3084842 3086400 3086403 3086402 3086401 3084841 3083453 3082956 3086398 3086399

Qty. Description

2 1 1 1 1 1 1 8 1 1 2 1

Pin, Straight Plug Union Gasket, Oil Cooler Union Adapter, Oil Cooler (Incl. 13,15) Connector, Oil Cooler Bolt, Flange Plug Gasket Bolt, Flange Bolt, Flange 3/99

D3

CYLINDER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

2

1

3

4

5

27 2

1

26 6 25 21

6 7 8

9

11

10 8

9

12 24 23

22 13

14

15

9 14 20

16

15

17

19 4 18 Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12

3086413 3086414 3086412 3084874 3086417 3086410 3084858 3084994 3084798 3084859 3086418 3086408

Qty. Description

13 3086421

Cover, Valve O-Ring Bolt, Flange Bolt, Flange Plug, Cylinder Block Pin, Straight Seal, Intake Valve Guide, Valve Fin Damper A Seal, Exhaust Valve Bolt and Washer Asm., Cylinder Head (Incl. 3,4,6-10, 12,14,26)(If built before 3/1/99) 1 Asm., Cylinder Head (Incl. 3,4,6-10, 12,14,26)(If built after 3/1/99) 1 Gasket, Exhaust

14 3085326

2 Stud

3086796

2 2 4 6 1 2 1 2 3 1 4 1

Ref. Part No.

15 16 17 18 19 20 21 22 23 24 25 26

3080530 3080285 3084838 3086407 3086406 3086795 3086415 3086416 3086420 3083166 3081497 3081330 3086491

27 3086419

Qty. Description

2 2 2 1 1 1 1 1 1 1 1 2 1

Washer Nut Pin, Straight Gasket, Cylinder Cylinder (If built before 3/1/99) Cylinder (If built after 3/1/99) Gasket, Head Gasket, Cam Adapter Asm., Adapter Band (Incl. 24) Screw Bolt Cover, Rocker (If built before 3/1/99 only) 2 Bolt, Flange

3/99

D4

CRANKSHAFT and PISTON MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 4

2 3 4 5

5

6 14

8

7 16

8 9 10 11 13

12 14

6 15

Ref. Part No.

Qty. Description

1 3085774 3085775 3085776 2 3086431 3086432 3086433

1 1 1 1 1 1

3086800

1

3086801 3086802 3086846 3084167 3086425 3086424 3086422 3086423 3086797

1 1 1 2 2 1 1 1 1

3 4 5 6 7

Piston Ring Set (STD) Piston Ring Set (0.25 O/S) Piston Ring Set (0.50 O/S) 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 built before 3/1/99 use above Set) Piston Set (STD)(Incl. 3,4)(If built after 3/1/99 use Set below) Piston Set (0.25 O/S)(Incl. 3,4) Piston Set (0.50 O/S)(Incl. 3,4) Pin, Piston Clip Bolt Asm., Connecting Rod (Incl. 5,15) Crankshaft, Complete (Incl. 16) Crankshaft (If built before 3/1/99) Crankshaft (If built after 3/1/99)

Ref. Part No.

8 3240168 9 3086434 3086435 3086436 3086437 10 3086492 11 3085528 12 3083904 13 3083905 14 3086427 3086798 3086799 15 3086426 16 3085815

Qty. Description

2 1 1 1 1 1 1 1 1 2 2 2 2 2

Key, Woodruff Spacer Spacer Spacer Spacer Sprocket 1 Nut Washer Nut Bearing (STD) Bearing (0.05 U/S)(If built after 3/1/99) Bearing (0.25 U/S)(If built after 3/1/99) Nut Bearing, Ball

8/00

D5

INTAKE and EXHAUST MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3

1 2

1 2

5 6 7

7 8

4

6 9

10 11

8 12 19

18

17

20

22

21 16

23

14

13

24 15

Ref. Part No.

1 2 3 4 5 6 7 8 9 10

3084911 3084912 3084910 3086442 3085836 3084908 3084907 3084906 3086439 3086440 3086804 11 3086438 3086803

Qty. Description

2 2 2 1 1 4 2 2 1 1 1 1

Screw, Adjusting Nut Asm., Rocker Arm (Incl. 1,2) Shaft, Rocker Washer Collet, Valve Retainer, Spring Spring, Valve Lever, Release Spring, Return (If built before 3/1/99) Spring, Return (If built after 3/1/99) Camshaft (Incl. 9,10,12)(If built before 3/1/99) 1 Camshaft (Incl. 9,10,12)(If built after 3/1/99)

Ref. Part No.

12 13 14 15 16 17 18 19 20 21 22 23 24

3084899 3085778 3086441 3086445 3086444 3086448 3086493 3083361 3086443 3083663 3086449 3086446 3084924

Qty. Description

1 1 1 1 1 1 1 2 1 1 1 1 1

Pin, Dowel Valve, Intake Valve, Exhaust Guide, Chain Chain, Timing Gasket, Tensioner Tensioner Bolt, Flange Sprocket 2 Washer Bolt, Flange Lever Bolt, Pivot 7/99

D6

RECOIL STARTER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3

2

1

5

4

6

7 8 9 15

11

10

12

14

8

13

7 Ref. Part No.

1 2 3 4 5 6 7 8

3084822 3083463 3083378 3083379 3084744 3085266 3083453 3082956

Qty. Description

1 1 1 1 1 1 2 2

Reel Spring, Return Ratchet Spring, Friction Plate, Friction Bolt and Washer Plug Gasket

Ref. Part No.

9 10 11 12 13 14

3083669 3083185 3084750 3084933 3084877 3085856 3085943 15 3085083

Qty. Description

1 1 1 1 9 1 1 1

Bushing, Starter Spring, Spiral Bushing Gasket, Recoil Bolt, Flange Asm., Recoil (Incl. 1-6,9-11,14,15) Starter Case (Incl. 11) Rope 11/98

D7

OIL PUMP and OIL FILTER MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

2 3 4

5 6

11 10 9 8

7

Ref. Part No.

1 2 3 4 5 6

3083453 3082956 3086455 3086222 3083568 3086454 3087015

Qty. Description

1 1 1 1 1 1 1

Plug Gasket Spring Valve, Relief Bolt, Flange Strainer, Oil Strainer, Oil (For Engine Serial Numbers 35878-39057 Only)

Ref. Part No.

7 3084963 8 3086451 3086805 9 3086450 10 3086452 11 3086453

Qty. Description

1 5 5 1 1 1

Filter, Oil Screw (If built before 3/1/99) Screw (If built after 3/1/99) Cover, Oil Pump Rotor, Inner Rotor, Outer

7/00

D8

CARBURETOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1

2

3

52

4 51 5 50 7 8

6

44 47

49

9

46

48

45 42

43

41 40

10 11

39

14

13

12

12

15 25

16

24

35

26 27 28 29

34 33

30

32 31

17

23

22

18

21 20 19

D9

36

37

38

CARBURETOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

Ref. Part No.

Qty. Description

1 2 3 4 5 6 7 8 9 10 11

3130507 3130508 3130730 3130752 3130732 3131130 3130541 3130540 3131128 3130014 3130566 3130567

1 1 1 1 1 1 2 2 1 1 1 1

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

3130515 3130517 3130518 3130519 3130361 3130594 3130532 3130520 3130590 3130521 3130529 3130591 3130531 3130533 3131132 3130522

2 1 1 1 1 1 1 4 1 1 1 2 1 1 1 1

Ring E-Ring Needle, Jet Ring Diaphragm Jet, Needle (P-0M) Screw Washer, Spring Asm., Jet Block Washer Jet, Main (#142.5)(If built before 3/1/99) Jet, Main (#145)(If built after 3/1/99) Seal Packing E-Ring Cap Pin, Float Plate O-Ring Screw Asm., Float Body Screw Asm., Float Screw Valve, Needle (1.5) O-Ring Jet, Pilot (#50) O-Ring

Ref. Part No.

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

49 50 51 52

Qty. Description

3130523 3130525 3131131 3130905 3130546 3130545 3130544 3131126 3130589 3130514 3130501 3130513 3130543 3130535 3130511 3130512 3130199 3130538 3130593 3131133 3131125

1 1 1 1 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1 1

3131147

1

3084205 3131129 3131127 3130592

2 1 1 4

Washer Spring Adjuster Plug (If built before 3/1/99 only) Screw, Adjust Ring Spring Valve, Throttle (120) Spring Ring Screw Asm., Throttle Shaft Guide, Cable Screw Cover O-Ring Holder, Guide Spring Asm., Plunger Jet, Air (#175) 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) Screw and Washer Spring Asm., Cover Screw 3/99

D10

MAGNETO MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

2

1

3

10 9 12

11

4 6

13

5

14

7

8

6

Ref. Part No.

1 3086483 3086484 3086807 2 3086463 3 3084997 4 3084978 5 3086460 6 3086458

Qty. Description

1 1 1 1 1 1 1 1

Asm., Ignition Coil (Incl. 1,2) Ignition Coil (If built before 3/1/99) Ignition Coil (If built after 3/1/99) Cap, Spark Plug Plug, Spark O-Ring Bearing, Dry Asm., Plate (Incl. 5,8)(Incl. 9 if built before 3/1/99 only)

Ref. Part No.

7 3081657 8 3084973 9 3081256 10 11 12 13 14

D11

3086464 3083073 3080077 3085521 3086457

Qty. Description

5 Bolt and Washer 1 Seal, Oil 1 Screw and Washer (If built before 3/1/99 only) 1 CDI System 2 Nut 2 Washer, Spring 1 Switch, Magnetic 1 Flywheel w/Ring Gear 6/99

STARTING MOTOR MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

4

3

2

5

1 6

7 1

11

8

11 12

13

10 14

9 15

17

16

Ref. Part No.

1 2 3 4 5 6 7 8

3084981 3084982 3085353 3084406 3083649 3084408 3082038 3085034 3085033

Qty. Description

1 1 1 1 2 3 2 1 1

Motor, Starting (Incl. 1-5,7-11) Washer Set Armature Brush, Carbon Nut, Flange O-Ring Bolt and Washer Bracket, Rear Asm., Front Bracket (Incl. 9)

Ref. Part No.

9 10 11 12 13 14 15 16 17

3240114 3084983 3084405 3083737 3084412 3084411 3084410 3084409 3085394

Qty. Description

1 2 2 1 1 1 1 1 1

O-Ring Asm., Set Bolt (Incl. 5) Ring, Rubber Washer, Gear Shaft Clip Spring, Weight Spring, Return Clip Asm., Gear Shaft (Incl. 12-16) 11/98

D12

FUEL PUMP MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3

2

2

4

1

4

Ref. Part No.

3085275 1 3084999 2 3085000

Qty. Description

1 Asm., Fuel Pump (Incl. 1-4) 1 Screw and Washer 2 Screw and Washer

Ref. Part No.

3 3084591 4 3084998

Qty. Description

4 Screw 1 Diaphragm Gasket Set 11/98

D13

BREATHER BOX MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

5

2

6

4

5

3 1

7

16 13

8 15

17

14

18

5 14

7

9

23 5

19 22 21

20

13 12 10 11

Ref. Part No.

1 3085850 2 3086481 3 3086486 3086808 4 5 6 7

3086487 3085525 3084085 3086476 3083568

8 3086495 9 3086478 10 3086482

Qty. Description

1 Pipe 3 Bolt, Flange 1 Asm., Breather Box (Incl. 4,16-20, 21-23)(If built before 3/1/99) 1 Asm., Breather Box (Incl. 4,16-20, 21-23)(If built after 3/1/99) 1 Box, Breather (Incl. 1,4,16) 1 Pipe, Air Breather 4 Clamp 1 Pipe 1, Rubber 4 Bolt, Flange (Use 3 if built after 3/1/99) 1 Pipe 1 1 Pipe 3, Rubber 1 Bolt, Banjo

Ref. Part No.

11 12 13 14 15 16 17 18 19 20 21 22 23

D14

3082719 3086496 3083418 3084823 3086809 3083798 3086470 3086468 3086494 3083361 3081180 3086467 3086469

Qty. Description

2 1 2 3 1 1 1 1 1 1 4 1 1

Gasket Pipe 2 Clamp, Hose Band, Wire (Use 2 if built after 3/1/99) Pipe 2, Rubber Pipe, Pulse Gasket, Breather Plate Plate, Breather Bracket 1 Bolt, Flange Screw Plate, Breather Box Gasket, Plate 3/99

TOOL KIT MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

1 8

2

3 9 4

5

10

6

11

7

Ref. Part No.

1 2 3 4 5 6

3086485 2870725 3085001 3085002 3085567 3085569 3082657

Qty. Description

1 1 1 1 1 1 1

Kit - Tool (Incl. 2-7) Gauge, Tire Pressure Wrench, Open 8-10mm Wrench, Open 12-14mm Wrench, Box Puller, Spark Plug (Wrench Handle) Screwdriver

Ref. Part No.

7 2682572 8 2871515 9 9915299 9914939 10 2871095-067 11 2460442

Qty. Description

1 1 1 1

Pouch, Tool Kit Lube, U-Joint, 3 oz., Case Owner’s Manual, ‘00 ATV Supplement, Owner’s Manual, ’00 Magnum 325 4x4 1 Wrench, Spanner, Cam 1 Pigtail, Power 2/00

E1

PRINTED IN THE USA

PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00

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cover

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