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
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2000 MAGNUM 325 4x4 SPECIFICATIONS
BRAKES
ENGINE
Type - Front
Type - Rear
Hydraulic Disc
Hydraulic Disc
Engine Model Number
Engine Type
ES32PFE01
4 Stroke, Single Cylinder
Type - Auxiliary
Type - Parking
Hydraulic Disc
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
Wet Sump
Hydraulic Lock, All Wheel
78x68
325
CAPACITIES
9:2 Full Stroke
Air w/Fan Assisted Oil Cooler
Fuel Tank (gallon)
Gearcase Oil (ounces)
Engine Oil (quarts) 0W40
Engine Counter Balance
Oil (quarts) Injector
Rack, Front (pounds)
Rack, Rear (pounds)
Tongue Weight
3.75
400 (ml)
1.9
200
Standard
1/BST31 (CV Type)
N/A
142.5
N/A
Pilot Jet
50
90
Needle Jet
P-0 (829)
180
Cut Away
N/A
30
Pilot Screw
Jet Needle
2
5F14-2
Tow Hitch
Tow Weight
Standard
850
Ignition
CDI
Ignition (Type & Deg. BTDC)
Spark Plug Gap (inches)
Spark Plug (Type)
Exhaust
DRIVE TRAIN
30@3500
.028
Type
Shaft Ride System
NGKBKR5E
USFS Appr. Pending
DRIVE CLUTCH
Drive System Type
Center Distance (inches)
Clutch Offset (inches)
Clutch Weight (grams)
Spring Color
PVT
10
1/2
GRAPHICS
Bumper Caps/Polyprop.
Cargo Box or Bed
Fender, Front
Fender, Rear
Footwell
N/A
N/A
16 MH
Blue/Green
Eddie B. Green
Eddie B. Green
Black
DRIVEN CLUTCH
Helix Angle
Outside Diameter (inches)
Spring Position
Frame/Steel
Front Cover
Black
Compound
9.5
Black 2-2
Eddie B. Green
Black
Handlebar Cover
Headlight/Dash Pod
Rack, Front
Black
Black
DIMENSIONAL FEATURES
Rack, Rear
Black
Approx. Turning Radius (inches)
Box, Tool Volume (Cu. Inches)
Box Dimensions (inches)
Ground Clearance (inches)
Height (inches)
Length (inches)
Seat Height (inches)
Weight (dry)
65
588
N/A
7.25
46
81
34
620
49.75
46
Rims
Aluminum
Sable Brown
Eddie B. Green
Black
Seat Vinyl
Side Panel
Spring, Front
Spring, Rear
Tank Cover
Black
N/A
Tool Box Cover
w/lettering Color
N/A
Wheel Base (inches)
Width (inches)
ELECTRICAL
Headlight - Front Hood (watts)
Headlight - Grill (watts)
Taillight (watts)
Brake Light (watts)
Indicator Bulb
Battery
GEARCASE
Trans. Number and Type
Shift Type
N/A
2 Single Beam/30 W
12 V/8.26 W
PRD
Side Lever
7.46/1
5.12/1
3.3/1
Gear Reduction - Low
Gear Reduction - Reverse
Gear Reduction - High
Front Drive (ratio)
Final Drive (ratio)
Center Drive (ratio)
Axle to Axle
12 V/26.9 W
12 V/1.0 W
12 V/14 AH
3.7/1
SUSPENSION
Front Type -
Front Travel (inches)
Rear Type -
3.1/1
N/A
MacPherson Strut
N/A
6.7
Progressive Rate Swing Arm
6.5
Chain Type
N/A
Rear Travel (inches)
Shock
Adjustment
TIRES & WHEELS
Tire Manufacturer
Tire Size - Front
Tire Size - Rear
2N Gas Charged Monotube
Cam
Titan
24x8-12
24x11.5-10
Tire Size - Center
Tire Pressure - Front
Tire Pressure - Rear
Tire Pressure - Center
N/A
4
3
N/A
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.
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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
A00CD32FA
A00CD32FB
9915299
9915299
9915299
9914939
9914939
9914939
9914940
9914940
9914940
9916574
9916574
9916574
9914942
9914942
9914942
325 Magnum 325 4X4 HDS
325 Magnum 325 4X4 HDS II
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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
14
13
6
7
16
17
18
8
5
19
9
10
12
11
1
4
41
3
2
42
43
20
21
6
3
40
45
39
22
33
23
44
38
24
25
3
33
32
31
A5
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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. Description
Ref. Part No.
Qty. Description
1 7661645
2 7511930
3 7555792
4 5811107
10 Rivet
2 Bolt
6 Washer
1 Foil, Rear Cab, Rear
1 Cab, Rear, E.B. Green
4 Nut, Nylok
1 Retainer, Seat Latch
1 Foil, Tape, Rear Cab
4 Screw
4 Washer
2 Screw
1 Box, Tool
2 Rivet
2 Bracket, Lever Retainer
1 Latch, Seat
1 Spring, Latch
24 7621509
25 5243829-067
26 - - - - - - -
2 Rivet
1 Strap, Fuel Pump
1 Asm., Front Gearcase (See Front Gear-
case Pg. C10 for Details)
27 7552603
28 7512492
29 5433435
30 7556065
31 7517386
32 7558301
33 7512232
34 7542122
35 5411548
36 7517264
37 1012764-067
4 Washer
4 Screw
1 Guard, Rock
7 Washer
9 Screw
2 Washer, Flat
21 Screw
8 Nut
8 Mount, Rubber
8 Screw
5 5432117-195
6 7541925
7 5224592
8 5811308
9 7512242
10 7555859
11 7512085
12 5431786
13 7621403
14 5211033
15 1040387
16 7041370
1 Frame, Main
38 5432221-070
1 Footwell, LH, Black
5433219-070
1 Footwell, RH, Black
17 2682441-276
2681747-276
5811104
1 Seat, Sable Brown
39 5811111
40 5811106
41 7073761
42 7078396
43 5811087
44 7670057
1 Foil, Foam, Rear Fender
2 Foil, Rear Cab, Front
1 Decal - Carb Information
1 Decal - Filter Element
1 Foil, Foam
1 Covering, Seat, Sable Brown
1 Foil, Seat Base, Large
1 Foil, Seat Base, Small
5811105
18 5410414
19 7517599
20 5431787
21 5410896
22 5243188-067
23 7661637
8 Bumper, Rubber
2 Screw and Washer
1 Cover, Tool Box
1 Cap, Drain
1 Guard, Clutch
4 Rivet
12 Nut, U-Type Speed
45 5431796
1 Guard, Mud, Rear, LH (AA)(AB)
1 Guard, Mud, Rear, RH (AA)(AB)
8 Washer, Flat (FA)(FB)
5431797
7555913
2873213
1 Kit - Mud Skirt, Full Set (FA)(FB)
2/00
A6
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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
4
1
2
5
12
2
6
8
7
9
11
10
2
6
2
13
Ref. Part No.
1 2632084-195
2632284-195
Qty. Description
Ref. Part No.
Qty. Description
8 7661645
4 Rivet
1 Asm., Panel w/Foam, LH, E.B. Green
(If built before 3/20/00)
9 5431798
5431799
1 Guard, Mud, Front, LH
1 Guard, Mud, Front, RH
2 Nut, Nylok
2 Washer
2 Screw
2 Washer
2 Nut, Nylok
4 Rivet
2 Shield, Deflector
1 Asm., Panel w/Foam, LH, E.B. Green
(If built after 3/20/00)
10 7541925
11 7555792
12 7512085
13 7555931
14 7542122
15 7621509
16 5811917
2632101-195
2 7512232
3 5432088-195
4 7670085
5 2632144-195
6 7670057
7 7670068
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
10/00
A7
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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
7
8
11
6
10
12
9
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7517685
2 7517686
3 2670174
2 Screw
4 Screw
7 7670096
8 7512329
2 Nut, Chimney
4 Bolt
1 Asm., Rack, Rear
9 1040524-067
1 Mount, Front, Rear Rack, LH
(Incl. Ref. 4 and Warning Decal)
1040525-067
1 Mount, Front, Rear Rack, RH
4 2670070
5 1040490-067
6 7542324
2 Reflector, Red
1 Support, Rear Rack
8 Nut, Nylok
10 7558402
11 5333332-067
12 7515385
2 Washer
4 Spacer
4 Screw
2/00
A8
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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
4
8
7
6
14
13
15
12
11
9
10
16
17
6
4
24
18
19
20
23
22
21
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7517685
2 2670180
4 Screw
1 Asm., Front Rack
14 2431011
2431012
1 Headlight, LH
1 Headlight, RH
4030059
2 Bulb, Replacement, 27W
2 Bolt
(Incl. Ref. 3 and Warning Decal)
2 Reflector, Amber
6 Screw
15 7515382
16 7558402
17 5810467
18 5241583-067
19 5240591-067
20 7621330
21 7670094
22 7512097
3 2670071
4 7515399
5 2200775
6 7542324
7 7558403
8 5432155-070
9 7515391
10 7515390
11 7555954
12 1040554-067
4 Washer
1 Plug, Frame
1 Guard, Brush
1 Grill, Brush Guard
7 Rivet
6 Nut, U-Type
6 Screw
1 Kit - Front Rack Mount
4 Nut, Nylok
2 Washer
1 Bumper
2 Screw
2 Screw
2 Washer
23 5431814
1 Shield, Radiator Side, LH
5431815
1 Shield, Radiator Side, RH
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)
24 5241398-067
5241399-067
5244623-067
5244624-067
1 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)
1040555-067
1013210-067
1013211-067
1 Support, Front Rack, RH
(If built after 11/15/99)
13 7517386
4 Screw
2/00
A9
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DECALS
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
8
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7074954
2 7074110
3 7078022
4 7077780
5 7078017
6 7074935
7 7078315
2 Decal - Rack/Warning
1 Decal - Load Distribution, 4W
1 Decal - “4x4”, Shaft Ride Sys., RH
2 Decal - ‘‘POLARIS” Side Panel
1 Decal - Tank Side, RH
10 7078577
1 Decal - Drain Recoil
11 7078015
1 Decal - “325” Front Cover (AA)(AB)
1 Decal - “325 4 Stroke HDS” (FA)
1 Decal - “325 4 Stroke HDS II” (FB)
1 Decal - Warning, General, CPSC
1 Decal - Warning, Override, AWD
1 Decal - Tank Side, LH
1 Decal - Age Warning, ATV
1 Decal - “4x4”, Shaft Ride Sys., LH
1 Decal - Passenger Warning
1 Decal - Tire Pressure
7079007
7079008
12 7077919
13 7079604
14 7078016
15 7078253
16 7078018
17 7077920
18 7078004
1 Decal - Warning, AWD Switch
1 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
7078465
8 7074220
9 7078354
10/00
A10
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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
4
1
2
1
3
2
4
9
3
4
10
4
5
7
6
8
11
5
17
18
20
21
19
22
16
12
4
15
4
10
14
4
4
15
13
4
14
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7547069
2 3110032
2 Nutsert
2 Mount, Rubber
12 7052244
1 Valve, Drain
2 Mount, Oil Cooler
2 Washer, Flat
2 Mount, Carburetor
1 Motor, Fan
4 Screw
1 Clamp, Hose
1 Clamp, Hose
13 5242983-067
14 7558301
15 3110050
16 2410157
17 7517659
18 7080862
19 7080866
20 5411768
21 8450086-07
22 7080869
3 5242924-067
4 7542122
5 7080474
6 5411813
7 7670111
8 5433353
9 4010274
10 7515158
11 1240064
2 Bracket, Cooling Fan
10 Nut, Nylok
2 Clamp, Hose
1 Hose, Cooler Inlet
4 U-Clip
1 Shroud, Fan
1 Thermister
4 Screw
1 Hose, Oil Cooler Outlet, Flared
1 Tubing, Convoluted
1 P-Clamp
1 Cooler, Oil
2/00
A11
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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
19
6
13
12
6
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7080474
2 5411813
3 7542122
4 5243783-067
5 7080869
6 7515158
7 7517659
8 2410157
9 7670111
10 5433353
2 Clamp, Hose
1 Hose, Inlet
4 Nut
1 Bracket, Top
1 Clamp, Rubber Coated
8 Screw
4 Screw
1 Motor, Fan
4 U-Clip
11 4010274
12 7052244
13 1240064
14 3021186
15 5244069-067
16 7080862
17 7080866
18 5411768
19 8450086-07
1 Thermister
1 Plug, Drain
1 Cooler, Oil to Air
4 Mount, Rubber
1 Bracket, Bottom
1 Clamp
1 Clamp, Hose
1 Hose, Outlet, Flared
AR Tubing, Convoluted
1 Shroud
11/99
A12
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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
12
10
11
15
13
14
12
8
16
13
16
10
17
(If built after 7/01/99)
11
13
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7542324
2 7555716
3 5410436
4 7555863
1 Nut, Nylok
1 Washer
1 Washer, Rubber
1 Washer (If built before 7/01/99)
9 7512666
10 3110064
11 7542301
12 7041804
13 7042029
1 Bolt
2 Mount, Torque Stop
2 Nut
4 Spring, Exhaust
5 5010192
1 Bushing (If built before 7/01/99)
2 Spring, Exhaust (If built before 7/01/99)
5132295
1 Bushing (If built after 7/01/99)
(Only 1 used if built after 7/01/99)
6 5410241
5411790
1 Dampener, Vib. (If built before 7/01/99)
1 Dampener, Vib. (If built after 7/01/99)
14 1260976-029
1260987-029
15 1260960-029
16 5243517
1 Headpipe (If built before 7/01/99)
1 Headpipe (If built after 7/01/99)
1 Manifold, Black
2 Seal, Exhaust
1 Spring, Exhaust (If built after 7/01/99)
7 7515316
1 Bolt, Carriage (If built before 7/01/99)
7515339
1 Bolt (If built after 7/01/99)
7515394
1 Screw, Carriage (If built after 8/12/99)
17 7041789
8 1260977-029
1 Silencer (If built before 7/01/99)
1260961-029
1 Silencer (If built after 7/01/99)
2/00
A13
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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
12
22
23
21
21
20
20
13
19
17
18
16
15
14
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 5430725
2 5810144
3 5811899
4 8360009-600
5 5431053
6 7517451
7 7552801
8 7558301
1 Cap, Gas Tank
1 Gasket, Fuel Cap
1 Seal, Foam
AR Line, Fuel
1 Vent, Tank
2 Bolt
12 7547069
13 5810317
14 7517505
15 5432559
16 5432733
17 7052161
18 7661637
19 5240577-067
20 8450040-600
21 7080003
4 Nutsert
2 Pad, Fuel Tank Bracket
1 Screw
1 Knob, Fuel Valve
1 Nut, Fuel Valve
1 Valve, 3-Way
2 Rivet
1 Bracket, Fuel Valve
AR Line, Fuel
4 Clamp, Hose, Red
1 Fitting, Fuel Outlet, Reserve
1 Fitting, Fuel Outlet, Main
1 Asm., Fuel Tank (Incl. 5,22,23)
2 Washer
2 Washer
9 5222154-067
1 Bracket, Mounting, Rear, LH
5222155-067
1 Bracket, Mounting, Rear, RH
10 5811796
1 Foam, Intake, Splash
22 7052149
23 7052146
24 2520183
11 5332457
2 Spacer (If built before 1/17/00)
5333936
2 Spacer (If built after 1/17/00)
2/00
A14
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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
10
11
9
3
8
12
7
2
6
4
6
14
13
37
32
5
36
35
33
33
33
15
16
32
32
34
33
31
17
30
6
7
22
21
23
6
24
26
27
28
25
19
18
29
7
6
20
19
B1
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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. Description
Ref. Part No.
Qty. Description
1 8450003-1525
2 7052075
3 5243720-067
4 3084205
AR Line, Fuel
1 Fitting, Tee
1 Bracket, Carburetor
2 Screw and Washer
1 Engine, Short Block NOTE: The
Short Block assembly contains a
crankcase assembly., cylinder & cylin-
der head assembly and a piston &
crankshaft assembly. Prior authoriza-
tion is required for warranty consider-
ation.
4 Nut
2 Washer
1 Bracket, Motor Mount
2 Washer
2 Bolt
1 Screw
1 Cable, Ground Engine
1 Washer
1 Mount, Rubber Rear
1 Boot, Clutch Intake
1 Clamp, Narrow Band
AR Line, Fuel
18 1012960-067
1013133-067
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
19 7547108
20 7517289
21 3021119
22 7555815
23 7515417
24 5243288-067
25 3021181
26 5430261
27 5210748
28 7575202
29 7512566
30 4010095
31 7080482
32 8450040-600
33 7080003
34 2530009
35 7546601
36 3110079
37 7517615
5 3085823
6 7542403
7 7555806
8 5243641-067
9 7552901
10 7512315
11 7512232
12 4010132
13 7555823
14 3110068
15 5411721
16 7080511
17 8360009-600
2/00
B2
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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
3
8
9
12
18
19
9
16
15
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7517541
2 5432859
3 5411422
4 5432868
5 5811482
6 7515180
7 7558301
8 5433396
9 7080699
10 5830128
11 5433180
12 7080413
13 5411588
14 7080511
4 Screw
15 7080694
1 Clamp, Hose
AR Hose, Breather (If built before 7/26/99)
AR
1 Duct, Inlet
1 Gasket, Intake
1 Cover, Air Box
1 Seal, Cover
2 Screw
16 5411746
5411848
Hose, Breather (If built after 7/26/99)
1 Box, Air (If built before 7/26/99)
17 5432774
5433678
1
Box, Air (If built after 7/26/99)
18 5431863
19 5811650
20 5432377
21 8450059-150
22 7080650
23 5243694
24 5432601
25 7080595
26 5811633
2 Insulator
1 Foil, Air Box
1 Plug
AR Line, Fuel
1 Clamp, Hose
6 Clip
1 Collar, Carburetor Inlet
1 Filter, Air Intake
1 Filter, Precleaner Sleeve
2 Washer
1 Cap, End
2 Clamp, Hose
1 Gasket, Duct
1 Duct, Carburetor Inlet
2 Clamp
1 Boot, Carb
1 Clamp
2/00
B3
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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
6
3
4
2
5
10
8
9
1
11
12
13
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 1380119
2 5222299
3 3260115
4 7670091
5 5411106
6 1380094
7 1380092
2 Asm., CV Housing w/Sleeve
1 Sleeve, Drive Shaft Seal
1 Clamp, CV Joint, Large
1 Circlip
1 Boot, CV Joint
1 Shaft Replacement (Incl. 4)
1 Cardan Replacement (Incl. 4,6,8,9)
8 2200771
9 3260130
10 7661913
11 7080627
12 2200773
1 Kit - Cross and Bearing
1 Yoke, Splined
1 Pin, Spring
1 Clamp, Small Band
1 Kit - Boot Replacement, CV Joint
(Incl. 3,5,11)
13 2200961
1 Kit - Drive Shaft w/Sleeve
11/98
B4
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PROP SHAFT
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
4
1
2
3
5
6
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1380138
1 3260133
2 3260104
3 3260140
1 Asm., Prop Shaft (Incl. 1-4)
1 Yoke, Gear Case, Front
2 Kit - Cross and Bearing
1 Shaft, Prop, Front
4 3260131
5 5411092
6 7661913
1 Yoke, Splined
1 O-Ring
1 Pin, Spring
11/98
B5
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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
7
5
4
22
21
10
20
8
11
4
9
13
18
17
19
12
11
14
15
16
10
Ref. Part No.
Qty. Description
Ref. Part No.
15 2201311
2201312
Qty. Description
1 5411608
2 7041761
3 5211115
4 7558402
5 7080573
6 7542303
7 7517445
8 5810439
2 Bumper
2 Strut, Front
2 Washer
6 Washer
2 Clamp, Rubber Coated
4 Nut
1 Asm., Hubstrut, LH (32mm)
(Incl. 8,11-14,22)
1 Asm., Hubstrut, RH (32mm)
(Incl. 8,11-14,22)
16 7041375-067
17 5243364
18 5432871
19 7515339
20 5132062
21 - - - - - - -
2 Spring, Coil
2 Retainer, Spring
2 Ball, Pivot, Bottom
4 Bolt
4 Screw
2 Retainer, Strut Casting Wire
2 Spacer
9
- - - - - - -
1 Asm., Front Brake Caliper, RH (See
1 Kit - Drive Shaft w/Sleeve
Front Brake Pg. B8 for Details)
(See CV Joint - BTB Pg. B4, Ref. 13)
10 3554509
11 3554507
12 5222193
13 7080306
14 2410133
4 Bearing, Tapered Roller
4 Bearing, Tapered Roller Cup
2 Sleeve, Hubstrut Seal
2 Fitting, Lubrication
22 3610028
23 5432872
24 5810291
25 7555749
26 7547104
2 Seal, Hubstrut
2 Ball, Pivot, Top
2 Spacer, Rubber
2 Washer
2 Coil, Magnetic
2 Nut
2/00
B6
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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
14
3
13
12
11
10
4
5
6
7
9
8
16
25
24
19
20
7
6
17
18
21
23
22
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7512325
2 5211869
3 3610019
4 5211148
5 1520281
6 3554506
7 3554507
8 7515523
9 1520243
10 3250028
11 3250010
12 3250032
13 1321814
8 Bolt
2 Disc, Brake
14 3250030
15 7052045
16 5411709
17 7556004
18 7542810
19 7661401
20 5410470
21 5432611
22 7512027
23 7542459
2 Cam
2 Plug, Magnetic Drain
2 Tire (24x8-12)
2 Washer
2 Nut, Slotted
2 Pin, Cotter
2 O-Ring
2 Cap, Hub
6 Screw
8 Nut
2 Seal, Front Hub
2 Plate, Armature
2 Clutch, Front Hub, Elec./Mech.
4 Bearing, Tapered Roller Cone
4 Bearing, Tapered Roller Cup
8 Stud
2 Asm., Hub w/Bearing Race (Incl.3,7,8)
2 Cage, Roll
12 Roll
24 1520269-117
25 1525017
2 Rim, Front
2 Valve, Rim
2 Spring, Garter
2 Spacer
11/98
B7
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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.
Qty. Description
Ref. Part No.
Qty. Description
1910271
1 Asm., Front Brake Caliper, LH
(Incl. 1-7,9,10)
6 5410780
7 5132294
1 Ring, Molded Square (.103 x .134)
1 Piston, Brake, Long
1 Kit - Front Brake Pad, General Duty
1 Kit - Front Brake Pad, Severe Duty
1 Kit - Front Brake Pad, Soft Duty
1910264
1 Asm., Front Brake Caliper, RH
8 2200465
(Incl. 1-7,9,10)
2200901
1 7080352
2 7515489
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)
2201149
9 1910265
1 Mount, Caliper (If built before 7/09/99)
1910412
1 Mount, Caliper (If built after 7/09/99)
3 5131115
5131116
10 5410495
11 5410494
12 - - - - - - -
1 Boot, Bushing
1 Boot, Pin Seal
4 Screw (See Front Strut Pg. B6, Ref. 7)
1930642
4 1930665
5 5410779
10/00
B8
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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
Ref. Part No.
1 5432721
5433806
Qty. Description
Ref. Part No.
4 7080709
7080857
Qty. Description
1 Cover, Throttle Control
(If built before 11/22/99)
1 Cover, Throttle Control
(If built after 11/22/99)
1 Cable, Throttle Control
(If built before 2/10/99)
1 Cable, Throttle Snap-In
(If built after 2/10/99)
2 5410193
3 5411439
1 O-Ring
1 O-Ring
5 2010188
6 2010191
1 Asm., Throttle Control (Incl.1,3,6)
1 Asm., Throttle Clamp
2/00
B9
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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
14
13
15
28
27
11
16
26
25
17
22
7
18
20
8
24
19
21
9
22
23
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
2050078
2200809
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
13 - - - - - - -
14 5411297
15 5410988
16 4110164
17 1910286
18 7621462
19 7080539
20 8360031-30
21 1930752
22 7080138
23 7512084
24 8360011-38
25 1930753
26 7052237
27 1930816
28 1930674
1 Ring, Square, Reservoir
1 Boot, Rubber Brake Line
2 Seal
1 Switch
1 Line, Hand Brake, Front
1 Rivet
1 Clamp, Nylon
1 Conduit, Convoluted
1 Line, Brake, Left Front w/Fittings
8 Cable Tie
1 1930797
2 1930796
3 1930795
4 2200808
5 1930799
6 1930804
7 2201034
1 Kit - Brake Lever w/Parking Latch
(Incl. 6-9)
2 Screw
8
- - - - - - -
1 Spring, Flat
1 Kit - Park Brake Lever (Incl. 6,8)
1 Nut
2 Bolt, Reservoir
1 Bolt, Lever
1 Tubing, Convoluted
1 Line, Brake, Right Front w/Fittings
1 Fitting, Cross
1 Line, Brake
1 Bolt, Banjo
9 2201090
10 1930806
11 1930792
12 1930805
11/98
B10
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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
6
11
6
5
7
5
8
9
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 1843067
1 Asm., Steering Post (Incl. 12,13)
9 7661633
10 5431570
11 7661632
12 5431574
13 7080433
1 Pin, Cotter
1 Bushing, Steering, Lower
2 Rivet
1 Plug, Steering Grease
1 Fitting, Lubrication
2 5431573
1 Bushing,Console (If built before 7/12/99)
5433415
1 Bushing,Console (If built after 7/12/99)
3 7080424
4 7515321
5 7555878
6 5410772
7 5431571
8 7543203
1 Fitting, Lubrication
2 Bolt
3 Washer
2 O-Ring
1 Spacer, Steering Post
1 Nut
14 5431572
1 Bushing, Steering (If built before 7/12/99)
5433416
1 Bushing,Steering (If built after 7/12/99)
15 5222999-067
16 7542324
1 Bracket, Steering Bushing, Upper
2 Nut, Nylok
2/00
B11
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HANDLEBAR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
A00CD32FA and A00CD32FB
27
28
2
29
9
7
8
11
33
32
31
A00CD32FA and A00CD32FB
14
15
30
16
19
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
20 - - - - - - -
1 Asm., Throttle Control (See Controls -
Throttle Asm./Cable Pg. B9, Ref. 5)
1 5432247-070
2 5432420
1 Cover, Logo
2 Cover, Screw
21 2460715
2460841
22 4040054
23 4040053
1 Harness, Control Panel (AA)(CA)
3 5432246-070
1 Panel, Instrument (AA)(CA)
1 Harness, Control Panel (FA)(FB)
5433183-070
1 Panel, Instrument (FA)(FB)
1 Indicator, Neutral/Reverse
1 Indicator, “Hot Temperature”
4 7517216
7517224
4 Screw (AA)(CA)
4 Screw (FA)(FB)
24 5430967
1 Plug, Indicator Hole (AA)(CA)(FB)
5 5241397-067
1 Bracket, Instrument Panel (AA)(CA)
4010313
1 Indicator, “P” Park (FA)
5241698-067
- - - - - - -
1 Bracket, Accessory Panel (FA)(FB)
25 4110264
4010278
1 Switch, Ignition
6
1 Asm., Master Cylinder
(See Control - Master Cyl./Brake Line
Pg. B10 for Details)
1 Key, Blank, Series 2000, 6700, 6800.
NOTE: Spare key must be cut from ex-
isting key.
7 7080726
2200188
8 5432926
9 4010262
1 Cable, Choke w/Adjuster
4010321
1 Key, Blank, Series 2200, 2300, 2700,
2800. NOTE: Spare key must be cut
from existing key.
1 Kit - Choke Lever
1 Spacer, Switch, LH
1 Switch, Handlebar, Hi/Lo/Rev. Override
2 Grip, Handlebar
1 Plug, Hole
1 Screw
5433733
5431964
26 7080229
1 Nut, Ignition
1 Cover, Key
1 Nut, Choke Slide
10 5431030
11 5432952
12 7517625
13 5224715-067
14 5132382
15 4010298
16 7517658
17 5630629
18 7542122
19 7080631
27 3280337
1 Speedometer (FB)
3280345
1 Speedometer (FA)
1 Tube, Handlebar
28 7512024
29 3280201
30 5630633
31 7541933
32 7558212
33 7555868
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)
1 Cap, Hall Sensor (FA)(FB)
1 Sensor, Hall Effect (FA)(FB)
1 Screw (FA)(FB)
4 Block, Handlebar
4 Nut, Nylok
1 Clip, Cable Retaining
10/00
B12
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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
6
4
2
7
8
9
10
3
30
11
31
9
12
28
29
13
14
22
29
27
23
28
15
26
16
24
25
23
22
18
17
19
14
20
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7542403
2 5333367
3 1820567
2 Nut, FLEXLOC
1 Bushing
16 5211121
17 7512284
18 5410548
19 7542438
2 Bracket, Ball Joint
4 Screw
2 Boot, Rubber
2 Nut, Castle
2 Asm., Tie Rod
(Incl. 4-9)(If Built before 8/16/99)
2 Asm., Tie Rod
1820805
20 5431150
1 Shield, CV Joint, LH
(Incl. 4-9)(If Built after 8/16/99)
5431149
1 Shield, CV Joint, RH
4 5411291
5 7061034
6 7542711
7 5020926
8 7547028
2 Boot, Seal, Rod End
2 Rod End
2 Nut
2 Tie Rod
2 Nut, LH
21 7517756
22 5433066
23 5020677
24 5020681
6 Screw
4 Bushing, A-Arm, Long
4 Bushing
2 Shaft, A-Arm
25 2201609
1 Kit - A-Frame, LH
9 7061033
2 Rod End, LH (If Built before 8/16/99)
2201610
1 Kit - A-Frame, RH
7061054
2 Rod End, LH (If Built after 8/16/99)
26 7080433
27 - - - - - - - -
2 Fitting, Lubrication
10 5411920
11 7517674
1 Boot, Seal, Rod End
2 Bolt (If Built after 8/16/99)
1 Asm., Heavy Hubstrut
(See Front Strut Pg. B6, Ref. 15)
12 7555806
4 Washer, Flat (If Built before 8/16/99)
28 7512492
29 7552603
30 7517527
31 7515415
4 Screw
4 Washer, Spring Lock
1 Bolt
7556099
4 Washer, Flat (If Built after 8/16/99)
13 7546904
14 7661203
15 7080927
2 Nut
4 Pin, Cotter
2 Joint, Ball
1 Screw
10/00
B13
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DRIVE CLUTCH
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA
8
5
7
4
3
1
2
6
13
12
10
11
9
5
14
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7512176
2 7552801
3 5430945
4 1321457
5 5431936
6 Bolt
6 Washer
7 5630279
8 7512266
9 7541906
10 3576504
11 5020422
12 7041157
13 3576510
14 1321632
3 Weight, Shift, 16
3 Bolt, Shoulder
3 Nut, FLEXLOC
1 Bearing, Moveable (1/2I)
3 Pin, Roller
6 Washer, Multilube
3 Roller and Bushing
6 Button, Clutch
AR Spacer (.020)
AR Spacer (.025)
AR Spacer (.032)
AR Spacer (.050)
6 5210752
1 Spring, Clutch
1 Cover, Bearing
5242981
5210753
1 Asm., Drive Clutch, ATV-08
5210754
(Incl. All Less 7,12)
2/00
B14
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DRIVE CLUTCH
325 MAGNUM 4X4 A00CD32FA and 325 MAGNUM 4X4 A00CD32FB
5
6
4
7
9
1
2
3
8
10
18
12
11
5
14
15
16
13
17
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 1520231
2 7556009
3 5131646
4 7541906
5 5431936
6 5020422
7 3585712
8 7547130
9 3576510
10 7552801
1 Clutch, One Way Drive
1 Washer
1 Spacer
3 Nut, FLEXLOC
6 Button, Clutch, Stemless
3 Pin, Roller
1 Bearing
1 Nut, Jam
1 Cover, Bearing
Washer, Spring Lock
11 7512176
12 7041157
13 1321457
14 5430945
15 7512266
16 5630279
17 1321706
6 Bolt
1 Spring, Clutch
3 Roller and Bushing
6 Washer, Multilube
3 Bolt, Shoulder
3 Weight, Shift, 16 MH
1 Asm., Drive Clutch, Braking
(Incl. All Less 12,7)
18 7556008
1 Washer
2/00
C1
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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
3
6
4
10
11
5
12
13
14
15
16
1
A00CD32FA
A00CD23FB
17
18
2
21
3
4
9
10
19
22
20
26
25
13
24
23
20
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7556120
2 5220646
3 7552901
4 7515382
5 1321855
AR Bushing
1 Washer, Domed
1 Washer, Spring Lock
1 Bolt
14 3576504
15 7556804
1 Bearing, Moveable (1/2”)
AR Washer (.030”)
16 7555898
AR Washer, Spacer (.020”)
7556076
AR Washer, Spacer (.025”)
17 7556013
18 7556010
19 7710461
20 1322184
1 Washer
1 Bushing
1 Ring, Retaining
1 Asm., Driven Clutch, 3 Angle, Heavy
(Incl. 7-16)(AA)(CA)
6 3211077
7 5430766
8 7511854
9 7710448
10 5210752
1 Belt, Drive
3 Button, Ramp
3 Bolt
1 Ring, Retaining
1 Spacer
1 Asm., Driven Clutch, Braking (Incl.
2,9,10,13,18,19,23-26)(FA)(FB)
21 3211069
22 7517323
23 3585710
24 5211115
25 7041635
26 5131674
1 Belt, Drive
3 Screw
1 Bearing
1 Washer
1 Spring
11 5132344
1 Ramp, Stationary (If built before 4/01/00)
5131447
1 Ramp, Stationary (If built after 4/01/00)
12 7041782
13 3576511
1 Spring, Clutch
1 Bearing, Moveable (1”)
1 Ramp, Stationary
9/02
C2
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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
6
2
3
5
10
9
11
7
25
12
13
24
23
22
21
14
20
15
18
19
17
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
12 7074946
1 Decal - Clutch Cover
(If built before 10/04/99)
1 7512232
2 2632116
3 5433453
4 2201520
2 Screw
1 Foam, Clutch Air Inlet
1 Plate, Backing
1
7078689
Decal - Warning, Clutch Cover
(If built after 10/04/99)
1 Decal - Engine/Clutch Modification
1 Kit - Inner Clutch Cover (Incl. 8,11,15)
13 7077377
14 7074782
(If built before 1/03/00)
Kit - Clutch Cover, Inner
(If built after 1/03/00)
1 Decal - “Automatic Transmission”
1
2201676
(AA)(AC)
Decal - “Automatic/EBS’ (FA)(FB)
1
7077666
15 7512094
16 5411489
17 7080761
18 7558301
19 7517386
5 5433363
1 Duct, Inlet, Down Tube
9 Screw
1 Boot, Duct
2 Cable Tie
2 Washer, Flat
2 Screw
6 7517601
3 Bolt and Washer (If built before
5
7517599
1/03/00)
Bolt and Washer (If built after 1/03/00)
7 7080909
8 5521301
9 5432849
1 Clamp, Narrow Band
1 Seal, Clutch Cover
1 Cover, Clutch, Outer
20 5433172
1 Duct, Air Outlet (If built before 11/05/99)
1
5433744
Duct, Air Outlet (If built after 11/05/99)
(If built before 2/13/99)
1
1
5433540
Cover, Clutch, Outer
(If built before 1/03/00)
Cover, Clutch, Outer
(If built after 1/03/00)
21 - - - - - - -
3 Screw and Washer
(See Crankcase Pg. D3, Ref. 6)
5433451-328
22 5240409-067
23 5410575
24 5411795
1 Bracket, Retainer, Seal
1 Seal, Cover Case
10 7670051
11 7512093
7512094
1 Clip, Clutch Cover
1 Stopper, Inner Clutch Cover
1 Seal, Cover Case (If built before 1/03/00)
5 Screw (If built before 1/03/00)
25 5410489
5
Screw (If built after 1/03/00)
1
5411901
Seal, Clutch Cover (If built after 1/03/00)
2/00
C3
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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
18
16
5
4
1
3
6
7
2
14
19
8
20
21
9
13
10
22
38
12
11
37
11
28
29
23
12
27
30
24
25
26
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 2460737
1 Harness, Main Wire (AA)(CA)
(If built before 8/01/99)
18 5810317
19 2200361
20 4010095
21 7010032
22 5410424
23 5432077
24 4140006
25 7511876
26 4010354
27 5431769
28 4010094
29 4010093
30 7512007
31 5132214
32 4010249
33 7512018
34 4060191
35 4010195
36 7512017
37 4020149
38 7670109
1 Pad
1 Kit - Battery Bolt, Short
1 Cable, Battery/Engine
2 Hook, Battery Strap
1 Strap, Battery Holddown
AR Tube, Battery Vent
1 Battery
2 Screw
1 Limiter, Speed (FA)(FB)
1 Cover, Battery
1 Cable, Battery/Solenoid
1 Cable, Solenoid/Starter
2 Bolt
1 Sink, Heat
1 Switch, Thermister LR-60
5 Screw
2460821
1 Harness, Main Wire (AA)(CA)
(If built after 8/01/99)
2460833
2460834
2 2200593
3 2201795
4 2432034
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)
5 4032046
6 4032029
7 4030043
8 4032045
9 4032064
10 7670054
11 7541925
12 7571602
13 7512027
14 5810290
15 4010311
16 4010310
17 7517386
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 Rectifier, Regulator, LR 35
1 Limiter, RPM LR 83-3 (AA)(CA)
2 Screw
7 Clip, Rosebud
3 Clip, Routing
1 Screw
2/00
C4
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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
9
10
6
3
5
11
8
4
7
12
1
13
5
14
15
16
19
22
17
18
7
13
19
18
17
5
21
20
30
24
27
28
27
29
21
22
26
19
9
24
25
23
C5
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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. Description
Ref. Part No.
Qty. Description
13 1930674
3 Bolt, Banjo
1 2201189
1910339
1 Kit - Brake Pad (Incl. Spacer and Pin)
1 Pad, Spacer
1 Pin
14 7542403
15 7542153
16 1930854
17 7080003
18 1910331
19 7512240
20 1012753-067
21 7542122
22 7558301
23 1012752-067
24 7555919
25 7661401
26 7556090
27 5433189
28 7515158
29 1910311
30 7041750
2 Nut
1 Nut, Nylok
1930860
2 7515406
3 7555806
4 1910270
2 Screw
2 Washer
1 Reservoir, Brake, Rear
2 Clamp, Hose
1 Hose, Reservoir
3 Bolt
1 Pivot, Brake Mount, Rear
2 Nut, Nylok
2 Washer
1 Rod, Brake
2 Washer
1 Pin, Cotter
1 Washer
2 Bushing, Pedal Pivot
2 Screw
1 Master Cylinder, Foot
1 Spring, Torsion
1 Asm., Brake Caliper, Rear
(If built before 2/09/99)
1910367
1 Asm., Brake Caliper
(If built after 2/09/99)
2201428
2201467
2201385
1 Kit, Bleeder Replacement
1 Piston, Caliper, DH2P, Rear
1 Kit, Caliper Seal
5 5410988
6 1910286
7 1910288
8 7080573
9 7517386
10 7080762
11 7661048
12 7080816
6 Seal
1 Line, Brake, Front Hand
1 Line, Brake, Rear Foot
1 Clamp
2 Screw
3 Clip, Brake Line
2 Rivet
1 T-Clip, Dual
9/02
C6
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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
8
11
6
7
12
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7661404
2 7542714
3 5131777
4 7512673
5 7670081
6 5411710
2 Pin, Cotter
8 Nut
2 Hub, Wheel, Rear
8 Bolt
8 Pushnut
2 Tire, 24x11.5-10
7 1525017
8 1520183-117
9 7555745
10 7555796
11 7543005
12 5411164
2 Valve, Rim
2 Rim, Rear, Silver
2 Washer
2 Washer
2 Nut
2 Hub, Dust Cover
7/99
C7
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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
11
21
2
12
1
2
1
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1341253
1 3233319
2 3233252
3 3233573
4 3233588
5 3233574
6 3233589
7 3233590
8 3233591
9 7080756
1 Asm., Front Gearcase (Incl. 1-24)
2 Seal, Oil
11 Screw
1 Cover, Gearcase
1 O-Ring
1 Nut
1 Bearing, Ball
1 Shaft, Input, Front Housing
1 Bushing
13 3233524
14 3233592
15 3233593
16 3233594
17 3233595
18 3233020
19 3233554
20 3233596
21 3233597
22 3233248
23 3233583
24 3233582
1 Tube, Vent
1 Housing, Front, Gearcase
1 Bushing
1 Gear, 37T, Bevel
1 Shaft, Output, Front
1 Bearing
1 Shim
1 O-Ring
1 Cover, Output, Front Housing
1 Seal
1 Shim
1 Clip
10 8450003-1525
11 3233253
12 3233254
AR Line, Vent
2 Plug, Drain
2 Washer
1 Button, Thrust
11/98
C8
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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
38
6
37
36
35
40
39
7
8
25
34
27
24
9
41
33
30
32
9
31
30
42
10
28
43
45
46
47
11
12
13
14
29
27
26
25
15
16
48
17
23
24
17
18
22
9
49
5
54
55
2
25
50
53
58
51
19
52
5
56
1
20
21
4
57
66 65
1
63
64
62
61
60
59
5
C9
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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
Qty. Description
Ref. Part No.
Qty. Description
1 Asm., Gearcase, Main
(Incl. all less 11)(AA)(CA)(FB)
1 Asm., Gearcase, Main
(Incl. 1-48,50-66)(FA)
31 3233014
32 3233599
33 3233029
34 3233533
35 3233600
36 3233613
1 Bearing, Needle
1 Sprocket, 24T
1 Ring, Retaining
1 Engagement Dog, H/R, HLR
1 Gear, 30T
1341336
1 3233248
3233788
2 3233252
3 Seal (FA)
3 Seal (AA)(CA)(FB)
17 Screw
1 Spacer
3 3233610
1 Gearcase, LH (AA)(CA)(FB)
37 3233708
1 Gear, Helical, 36T (AA)(CA)(FB)
3233763
1 Cover, LH (FA)
3233762
1 Gear, Helical, 34T (FA)
4 3233529
5 3233019
4 Pipe, Knock
4 Bearing, Ball
38 3233309
39 3233032
40 3233308
41 3233747
1 Bracket, Interlock
1 Spring, Shifting, Interlock
2 Pin, Interlock
6 3233604
1 Shaft, Input, 31T (AA)(CA)(FB)
3233756
1 Shaft, Input, 31T (FA)
2 Screw
7 3233036
1 Chain, Silent
42 3233709
1 Gear, Helical, 48T (AA)(CA)(FB)
8 3233603
1 Gear, 16T w/22T Spline (AA)(CA)(FB)
3233764
1 Gear, Helical, 50T (FA)
3233755
1 Gear, 14/19T (FA)
43 3233608
44 3233609
45 3233106
46 3233607
47 3233606
4 Screw (Qty. 8 for FA)
1 Cover, Bearing, Center
1 Ring, Retaining
1 Bearing, Ball
1 Shaft, 10T, Spiral Bevel
9 3233018
4 Bearing, Ball
10 3233055
2 Nut, FLEXLOC (FA)
3233961
2 Nut, Lock (AA)(CA)(FB)
11 3233054
12 3233153
13 3233045
14 3233040
15 8360009-600
16 3233037
17 3233749
18 3233615
2 Washer, Flat (FA)
2 Bellcrank
2 Ring, Retaining
2 Washer
AR Line, Vent
1 Tube, Vent
48 3233605
1 Fork, Shift, Low (AA)(CA)(FB)
3233759
1 Fork, Shift, Low/Park (FA)
49 3233617
50 3233620
51 3233621
52 3233622
53 3233582
54 3233583
1 Switch, 2 Position (AA)(CA)(FB)
1 Sprocket, 12T w/18T Spline
1 Gear, Spiral, Bevel, 31T
1 Shaft, Rear Output
1 Button, Thrust
8 Screw
1 Switch, 3 Position (Qty. 2 for FA)
19 3233902
1 Gearcase, Main (AA)(CA)(FB)
1 Shim
3233765
1 Gearcase, RH (FA)
55 3233623
1 Cover, Output (FA)
20 3233711
21 3233324
22 3233628
1 Plug
1 Washer
1 Washer
3233781
1 Cover, Output (AA)(CA)(FB)
56 3233253
3233777
1 Plug, Drain (FA)
1 Plug, Drain (AA)(CA)(FB)
23 3233629
1 Engagement Dog, Low (AA)(CA)(FB)
57 3233254
58 3233611
59 3233625
60 3233093
61 3233626
62 3233552
63 3233624
64 3233627
65 3233548
66 3233618
1 Washer
1 Shim
3233758
1 Engagement Dog, Low/Park (FA)
24 3233306
25 3233619
2 Ring, Retaining
3 Washer, Thrust
1 Shaft, Front Output
1 Sprocket, 12T
1 Chain, Roller
1 Bushing, Garlock
1 Shaft, Shift, Low
1 Shaft, Shift, H/R
2 O-Ring
26 3233631
1 Gear (AA)(CA)(FB)
3233760
1 Gear, 36T (FA)
27 3233103
28 3233602
2 Bearing, Needle
1 Fork, Shift, H/R
29 3233598
1 Shaft, Reverse (AA)(CA)(FB)
3233761
1 Shaft, Reverse (FA)
2 Ring, Retaining
30 3233012
2 Washer, Thrust
5/01
C10
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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
4
5
6
7
11
13
8
16
17
21
3
1
22
18
19
2
20
Ref. Part No.
1341254
Qty. Description
Ref. Part No.
Qty. Description
1 Asm., Gearcase, Rear (Incl. 1-10,
14-26) (If built before 2-21-99)
13 7080307
14 3233524
15 3233586
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
1341309
1 Asm., Gearcase, Rear (Incl. 1-10,
14-26) (If built before 7-01-99)
1341321
1 Asm., Gearcase, Rear (Incl. 1-10,
3233739
14-26) (If built after 7-01-99)
1 3233585
2 3233252
3 3233256
4 3233584
2 Screw
10 Screw
2 Seal
1 Cover, Gearcase, Output
(For Gearcase 1341254 and 1341309)
1 Cover, Gearcase, Output
(For Gearcase 1341321)
16 3233711
17 3233324
18 3233577
19 3233576
1 Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341254)
3233741
3233707
3233738
1 Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341309)
5 3233529
1 Pipe, Knock
1 Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341254 and 1341309)
(For Gearcase 1341321)
6 3233587
7 3233581
8 3233268
9 3233580
10 3233579
1 O-Ring
1 Shim
20 3233575
3233714
1 Bearing, Ball
(For Gearcase 1341254 and 1341309)
1 Bearing, Ball
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)
(For Gearcase 1341321)
21 3233588
22 3233319
23 3233573
24 3233574
25 3233582
26 3233583
1 O-Ring
1 Seal, Oil
1 Gearcase, Cover, Input
1 Nut, Lock
1 Button, Thrust
1 Shim
3233740
11 7670102
12 8450003-1525
3 Clip
AR Line, Vent
2/00
C11
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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
10
11
Ref. Part No.
1341271
Qty. Description
Ref. Part No.
Qty. Description
1 Asm., Gear Selector
7 3233646
8 3233754
9 3233644
10 3233642
11 3233060
12 3233076
13 3233639
14 3233640
15 3233641
16 3233643
1 Sphere, Plastic
1 Pin, Groove
1 Pin, Dowel
2 Spring, Detent
2 Bullet, Detent
2 O-Ring
1 Slide, Low (AA)(CA)(FB)
1 Slide, High/Reverse (FA use Qty. 2)
1 Body, Gear Selector
1 Spring, Centering
(Incl. 1-16)(AA)(CA)(FB)
1341337
1 Asm., Gear Selector (Incl. 1-16)(FA)
1 3233195
1 Asm., Knob (AA)(CA)(FB)
3233767
1 Asm., Knob (FA)
2 7512024
3 3233649
4 3233131
5 3233648
1 Screw
4 Screw
1 Strap, Wire
1 Cover, Gear Selector Boot
6 3233658
1 Handle, Gear Selector (AA)(CA)(FB)
3233766
1 Handle, Gear Selector (FA)
9/00
C12
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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
6
2
8
2
6
9
2
9
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
8 7512130
9 7542122
10 7555827
11 7512126
12 7517386
13 5020973
2 Screw
1 7061013
2 7546707
3 7546702
4 5020974
5 7546701
6 7061014
7 1012822-067
2 Rod End, LH
4 Nut, FLEXLOC
2 Nut, LH
1 Rod, Low
2 Nut
4 Nut, Nylok
2 Washer
2 Bolt
4 Screw
1 Rod, High, Rev
2 Rod End, RH
1 Bracket, Shifter
10/00
C13
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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
11
5
10
1
12
13
19
14
15
2
18
16
17
4
3
6
7
15
14
13
12
8
38
10
11
36
9
37
35
34
20
21
33
5
20
32
31
28
29
30
23
22
24
25
26
27
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 5132152
1 Hub, Brake Disc
21 7517585
22 5131862
23 7710482
24 7517612
25 1012881
8 Bolt
1 Axle, Rear
1 Ring, Retaining
3 Screw
2
- - - - - - -
1 Asm., Rear Brake Caliper
(See Rear Brake Pg C6, Ref. 4)
2 Bearing, Ball
3 3513523
4 5411653
5 7517604
6 7512084
7 7555721
8 7542703
9 5411532
10 5131863
11 5131864
12 3610072
13 3554506
14 3554507
15 5411602
16 1541323
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 Asm., Skid Plate
5242851-067
5811716
1 Plate, Rear Housing Skid,
1 Pad, Rubber
26 - - - - - - -
1 Asm., Gearcase, Rear (See Rear
Housing Pg. C11 for Details)
27 5411531
28 5131930
29 5411707
30 7072533
31 7661913
32 1012740-067
33 7515481
34 7710471
35 5132075
36 3610071
37 5211849
38 5411092
1 O-Ring
1 Collar, Rear Axle
1 O-Ring
1 Decal - Hitch
1 Pin
1 Tube, Axle, LH
3 Screw
1 Ring, Retaining
1 Spacer, Bearing
1 Seal, Axle, Rear
1 Disc, Brake
1 O-Ring
17 5132201
1 Coupling, Prop Shaft, Greased
7080433
1 Fitting, Lubricating
18 5411092
19 1380137
20 7553201
1 O-Ring
1 Asm., Prop Shaft, Rear
8 Washer
4/00
C14
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SHOCK MOUNTING
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
3
11
1
10
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 7542439
2 5433213
3 7515415
4 5132022
5 5241147
6 7041777-067
2 Nut, Nylok
2 Bushing (If built before 6/21/99)
1 Screw
1 Tube (If built before 6/21/99)
1 Retainer, Shock
7 7041774
7041890
8 5630921
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
5630551
(For 7041890)(If built after 6/21/99)
1 Spring
9 5132021
10 5433212
11 7515438
1 Tube
2 Bushing
1 Screw
(For 7041774)(If built before 6/21/99)
1 Spring
7041849-067
7041815-067
(For 7041890)(If built after 6/21/99)
1 Spring (FA)(FB)
2/00
D1
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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
1
5
6
7
7
8
9
2
10
2
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
7 7517289
8 7552603
9 7515522
10 5242820-067
11 - - - - - - -
4 Screw
4 Washer
4 Bolt
- - - - - - -
1 Asm., Main Gearcase (See Main
Gearcase Pg. C10 for Details)
2 Screw
6 Nut
2 Screw
2 Nut
3 Washer
1 7515417
2 7547108
3 7515398
4 7542321
5 7555976
1 Mount, Transmission
1 Mount, Engine,Rear
(See Engine Mounting Pg. B2, Ref.
18)
6 5242819-067
1 Mount, Rear Transmission
11/98
D2
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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
4
9
2
1
10
11
12
22
21
20
19
14
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3083669
2 3080103
3 3086394
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
11 3084838
12 3086397
13 3084842
14 3086400
15 3086403
16 3086402
17 3086401
18 3084841
19 3083453
20 3082956
21 3086398
22 3086399
2 Pin, Straight
1 Plug
1 Union
1 Gasket, Oil Cooler
1 Union
1 Adapter, Oil Cooler (Incl. 13,15)
1 Connector, Oil Cooler
8 Bolt, Flange
1 Plug
3086793
4 3086395
5 3084840
6 3084205
7 3084839
8 3085850
1 Gasket
2 Bolt, Flange
1 Bolt, Flange
1 Pipe
9 3086404
1 Gauge, Oil (If built before 3/1/99)
3086794
1 Gauge, Oil (If built after 3/1/99)
10 3086405
1 O-Ring
3/99
D3
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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
4
5
27
1
2
26
6
9
6
11
10
8
7
25
8
21
9
12
24
22
23
14
15
9
14
16
15
20
17
19
4
18
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
15 3080530
16 3080285
17 3084838
18 3086407
2 Washer
2 Nut
2 Pin, Straight
1 Gasket, Cylinder
1 3086413
2 3086414
3 3086412
4 3084874
5 3086417
6 3086410
7 3084858
8 3084994
9 3084798
10 3084859
11 3086418
12 3086408
2 Cover, Valve
2 O-Ring
4 Bolt, Flange
6 Bolt, Flange
1 Plug, Cylinder Block
2 Pin, Straight
1 Seal, Intake Valve
2 Guide, Valve
19 3086406
1 Cylinder (If built before 3/1/99)
3086795
1 Cylinder (If built after 3/1/99)
20 3086415
21 3086416
22 3086420
23 3083166
24 3081497
25 3081330
26 3086491
1 Gasket, Head
1 Gasket, Cam
1 Adapter
1 Asm., Adapter Band (Incl. 24)
1 Screw
3 Fin Damper A
1 Seal, Exhaust Valve
4 Bolt and Washer
2 Bolt
1 Asm., Cylinder Head (Incl. 3,4,6-10,
1 Cover, Rocker (If built before 3/1/99
12,14,26)(If built before 3/1/99)
only)
3086796
1 Asm., Cylinder Head (Incl. 3,4,6-10,
12,14,26)(If built after 3/1/99)
27 3086419
2 Bolt, Flange
13 3086421
14 3085326
1 Gasket, Exhaust
2 Stud
3/99
D4
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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
7
8
16
8
9
10
11
12
13
14
6
15
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3085774
3085775
1 Piston Ring Set (STD)
8 3240168
2 Key, Woodruff
1 Piston Ring Set (0.25 O/S)
1 Piston Ring Set (0.50 O/S)
9 3086434
1 Spacer
1 Spacer
1 Spacer
1 Spacer
1 Sprocket 1
1 Nut
3085776
3086435
3086436
2 3086431
1 Piston Set (STD)(Incl. 3,4)
3086437
3086432
1 Piston Set (0.25 O/S)(Incl. 3,4)
3086433
1 Piston Set (0.50 O/S)(Incl. 3,4)(If built
before 3/1/99 use above Set)
10 3086492
11 3085528
12 3083904
13 3083905
3086800
1 Piston Set (STD)(Incl. 3,4)(If built after
3/1/99 use Set below)
1 Washer
1 Nut
3086801
3086802
3 3086846
4 3084167
5 3086425
6 3086424
1 Piston Set (0.25 O/S)(Incl. 3,4)
1 Piston Set (0.50 O/S)(Incl. 3,4)
14 3086427
2 Bearing (STD)
3086798
2 Bearing (0.05 U/S)(If built after 3/1/99)
2 Bearing (0.25 U/S)(If built after 3/1/99)
1 Pin, Piston
2 Clip
2 Bolt
3086799
15 3086426
16 3085815
2 Nut
2 Bearing, Ball
1 Asm., Connecting Rod (Incl. 5,15)
7 3086422
1 Crankshaft, Complete (Incl. 16)
1 Crankshaft (If built before 3/1/99)
1 Crankshaft (If built after 3/1/99)
3086423
3086797
8/00
D5
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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
5
2
24
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3084911
2 3084912
3 3084910
4 3086442
5 3085836
6 3084908
7 3084907
8 3084906
9 3086439
2 Screw, Adjusting
2 Nut
2 Asm., Rocker Arm (Incl. 1,2)
1 Shaft, Rocker
1 Washer
4 Collet, Valve
2 Retainer, Spring
2 Spring, Valve
12 3084899
13 3085778
14 3086441
15 3086445
16 3086444
17 3086448
18 3086493
19 3083361
20 3086443
21 3083663
22 3086449
23 3086446
24 3084924
1 Pin, Dowel
1 Valve, Intake
1 Valve, Exhaust
1 Guide, Chain
1 Chain, Timing
1 Gasket, Tensioner
1 Tensioner
2 Bolt, Flange
1 Sprocket 2
1 Washer
1 Lever, Release
10 3086440
1 Spring, Return (If built before 3/1/99)
3086804
1 Spring, Return (If built after 3/1/99)
1 Bolt, Flange
1 Lever
1 Bolt, Pivot
11 3086438
3086803
1 Camshaft (Incl. 9,10,12)(If built before
3/1/99)
1 Camshaft (Incl. 9,10,12)(If built after
3/1/99)
7/99
D6
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RECOIL STARTER
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
8
7
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3084822
2 3083463
3 3083378
4 3083379
5 3084744
6 3085266
7 3083453
8 3082956
1 Reel
1 Spring, Return
1 Ratchet
1 Spring, Friction
1 Plate, Friction
1 Bolt and Washer
2 Plug
9 3083669
10 3083185
11 3084750
12 3084933
13 3084877
1 Bushing, Starter
1 Spring, Spiral
1 Bushing
1 Gasket, Recoil
9 Bolt, Flange
14 3085856
1 Asm., Recoil (Incl. 1-6,9-11,14,15)
3085943
1 Starter Case (Incl. 11)
15 3085083
1 Rope
2 Gasket
11/98
D7
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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
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3083453
2 3082956
3 3086455
4 3086222
5 3083568
1 Plug
1 Gasket
1 Spring
1 Valve, Relief
1 Bolt, Flange
7 3084963
1 Filter, Oil
8 3086451
5 Screw (If built before 3/1/99)
3086805
5 Screw (If built after 3/1/99)
9 3086450
10 3086452
11 3086453
1 Cover, Oil Pump
1 Rotor, Inner
1 Rotor, Outer
6 3086454
1 Strainer, Oil
3087015
1 Strainer, Oil (For Engine Serial Num-
bers 35878-39057 Only)
7/00
D8
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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
45
46
47
48
49
9
42
43
41
40
10
11
39
37
38
36
12
13
12
14
15
35
34
33
26
27
28
29
30
25
24
16
32
31
17
18
21
1
D9
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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
Ref. Part No.
Qty. Description
1 3130507
2 3130508
3 3130730
4 3130752
5 3130732
6 3131130
7 3130541
8 3130540
9 3131128
10 3130014
1 Ring
1 E-Ring
28 3130523
29 3130525
30 3131131
31 3130905
32 3130546
33 3130545
34 3130544
35 3131126
36 3130589
37 3130514
38 3130501
39 3130513
40 3130543
41 3130535
42 3130511
43 3130512
44 3130199
45 3130538
46 3130593
47 3131133
48 3131125
1 Washer
1 Spring
1 Adjuster
1 Plug (If built before 3/1/99 only)
1 Screw, Adjust
1 Ring
1 Spring
1 Valve, Throttle (120)
1 Spring
1 Ring
2 Screw
1 Asm., Throttle Shaft
1 Guide, Cable
4 Screw
1 Cover
1 O-Ring
1 Holder, Guide
1 Spring
1 Asm., Plunger
1 Jet, Air (#175)
1 Needle, Jet
1 Ring
1 Diaphragm
1 Jet, Needle (P-0M)
2 Screw
2 Washer, Spring
1 Asm., Jet Block
1 Washer
11 3130566
1 Jet, Main (#142.5)(If built before
3130567
1 3/1/99)
Jet, Main (#145)(If built after 3/1/99)
12 3130515
13 3130517
14 3130518
15 3130519
16 3130361
17 3130594
18 3130532
19 3130520
20 3130590
21 3130521
22 3130529
23 3130591
24 3130531
25 3130533
26 3131132
27 3130522
2 Seal
1 Packing
1 E-Ring
1 Cap
1 Pin, Float
1 Plate
1 O-Ring
4 Screw
1 Asm., Float Body
1 Screw
1 Asm., Float
2 Screw
1 Asm., Carburetor (Incl. 1-39,44-52)
(If built before 3/1/99)
3131147
1 Asm., Carburetor (Incl. 1-39,44-52)
(If built after 3/1/99)
49 3084205
50 3131129
51 3131127
52 3130592
2 Screw and Washer
1 Spring
1 Asm., Cover
4 Screw
1 Valve, Needle (1.5)
1 O-Ring
1 Jet, Pilot (#50)
1 O-Ring
3/99
D10
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MAGNETO
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
1
10
9
11
4
12
6
13
5
14
7
8
6
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3086483
3086484
1 Asm., Ignition Coil (Incl. 1,2)
1 Ignition Coil (If built before 3/1/99)
1 Ignition Coil (If built after 3/1/99)
1 Cap, Spark Plug
1 Plug, Spark
1 O-Ring
7 3081657
8 3084973
9 3081256
5 Bolt and Washer
1 Seal, Oil
3086807
1 Screw and Washer
2 3086463
3 3084997
4 3084978
5 3086460
6 3086458
(If built before 3/1/99 only)
10 3086464
11 3083073
12 3080077
13 3085521
14 3086457
1 CDI System
2 Nut
2 Washer, Spring
1 Switch, Magnetic
1 Flywheel w/Ring Gear
1 Bearing, Dry
1 Asm., Plate (Incl. 5,8)(Incl. 9 if built
before 3/1/99 only)
6/99
D11
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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
5
1
2
6
7
1
11
8
11
12
13
10
14
9
15
17
16
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
3084981
1 3084982
2 3085353
3 3084406
4 3083649
5 3084408
6 3082038
7 3085034
8 3085033
1 Motor, Starting (Incl. 1-5,7-11)
1 Washer Set
1 Armature
1 Brush, Carbon
2 Nut, Flange
3 O-Ring
2 Bolt and Washer
1 Bracket, Rear
1 Asm., Front Bracket (Incl. 9)
9 3240114
10 3084983
11 3084405
12 3083737
13 3084412
14 3084411
15 3084410
16 3084409
17 3085394
1 O-Ring
2 Asm., Set Bolt (Incl. 5)
2 Ring, Rubber
1 Washer, Gear Shaft
1 Clip
1 Spring, Weight
1 Spring, Return
1 Clip
1 Asm., Gear Shaft (Incl. 12-16)
11/98
D12
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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.
Qty. Description
Ref. Part No.
Qty. Description
3085275
1 3084999
2 3085000
1 Asm., Fuel Pump (Incl. 1-4)
1 Screw and Washer
2 Screw and Washer
3 3084591
4 3084998
4 Screw
1 Diaphragm Gasket Set
11/98
D13
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BREATHER BOX
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB
6
5
2
5
1
7
13
8
17
14
7
23
19
21
20
13
10
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
1 3085850
2 3086481
3 3086486
1 Pipe
3 Bolt, Flange
11 3082719
12 3086496
13 3083418
14 3084823
15 3086809
16 3083798
17 3086470
18 3086468
19 3086494
20 3083361
21 3081180
22 3086467
23 3086469
2 Gasket
1 Pipe 2
1 Asm., Breather Box (Incl. 4,16-20,
2 Clamp, Hose
3 Band, Wire (Use 2 if built after 3/1/99)
1 Pipe 2, Rubber
1 Pipe, Pulse
1 Gasket, Breather Plate
1 Plate, Breather
1 Bracket 1
1 Bolt, Flange
4 Screw
1 Plate, Breather Box
1 Gasket, Plate
21-23)(If built before 3/1/99)
3086808
1 Asm., Breather Box (Incl. 4,16-20,
21-23)(If built after 3/1/99)
3086487
4 3085525
5 3084085
6 3086476
7 3083568
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)
8 3086495
9 3086478
10 3086482
1 Pipe 1
1 Pipe 3, Rubber
1 Bolt, Banjo
3/99
D14
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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
9
5
10
6
11
Ref. Part No.
Qty. Description
Ref. Part No.
Qty. Description
3086485
1 2870725
2 3085001
3 3085002
4 3085567
5 3085569
6 3082657
1 Kit - Tool (Incl. 2-7)
1 Gauge, Tire Pressure
1 Wrench, Open 8-10mm
1 Wrench, Open 12-14mm
1 Wrench, Box
7 2682572
8 2871515
1 Pouch, Tool Kit
1 Lube, U-Joint, 3 oz., Case
1 Owner’s Manual, ‘00 ATV
1 Supplement, Owner’s Manual, ’00
Magnum 325 4x4
1 Wrench, Spanner, Cam
1 Pigtail, Power
9 9915299
9914939
10 2871095-067
11 2460442
1 Puller, Spark Plug (Wrench Handle)
1 Screwdriver
2/00
E1
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PRINTED IN THE USA
PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00
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