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 G
A- ARM/STRUT MOUNTING . . . . . . . . . . . . . . . . . B13 GEARCASE SELECTOR MOUNTING . . . . . . . . . . . C13
AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
H
B HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
BREATHER BOX . . . . . . . . . . . . . . . . . . . . . . . . . D14
I
C INTAKE and EXHAUST . . . . . . . . . . . . . . . . . . . . . D6
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . D9-10
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . C3 M
CONTROLS - MASTER CYLINDER/BRAKE LINE . . B10 MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11
CONTROLS - THROTTLE ASM./CABLE . . . . . . . . B9 MAIN GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . C9
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3 MAIN GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . C10
CRANKSHAFT and PISTON . . . . . . . . . . . . . . . . . D5
CV JOINT - BTB . . . . . . . . . . . . . . . . . . . . . . . . . . B4
O
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 OIL COOLING (If built after 1/1/00) . . . . . . . . . . . . A12
OIL COOLING (If built before 1/1/00) . . . . . . . . . . . A11
D OIL PUMP and OIL FILTER . . . . . . . . . . . . . . . . . . D8
DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . B14- C1 P
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . C2 PROP SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . B5
E R
ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . . . . . C4 REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . C5-6
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . B1-2 REAR CAB and SEAT . . . . . . . . . . . . . . . . . . . . . A5-6
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . A13 REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . C11
REAR RACK MOUNTING . . . . . . . . . . . . . . . . . . . A8
F REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . C7
FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . B8 RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . . D7
FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . C8 S
FRONT RACK and BUMPER MOUNTING . . . . . . . . A9 SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . . . . . D1
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . B6 STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . D12
FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . B7 STEERING POST . . . . . . . . . . . . . . . . . . . . . . . . . B11
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D13 SWING ARM/REAR GEARCASE MOUNTING . . . . . C14
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
T
G TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E1
GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . C12 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 ENGINE
Type - Front Hydraulic Disc Engine Model Number ES32PFE01
Type - Rear Hydraulic Disc Engine Type 4 Stroke, Single Cylinder
Type - Auxiliary Hydraulic Disc Lubrication Type Wet Sump
Type - Parking Hydraulic Lock, All Wheel Bore & Stroke (mm) 78x68
Displacement (cc’s) 325
CAPACITIES Compression Ratio 9:2 Full Stroke
Fuel Tank (gallon) 3.75 Cooling Air w/Fan Assisted Oil Cooler
Gearcase Oil (ounces) 400 (ml) Alternator Output (watts) 200
Engine Oil (quarts) 0W40 1.9 Elec. Start w/Recoil Back Up Standard
Engine Counter Balance N/A Carburetors (no. of/size) 1/BST31 (CV Type)
Oil (quarts) Injector N/A Main Jet 142.5
Rack, Front (pounds) 90 Pilot Jet 50
Rack, Rear (pounds) 180 Needle Jet P-0 (829)
Tongue Weight 30 Cut Away N/A
Tow Hitch Standard Pilot Screw 2
Tow Weight 850 Jet Needle 5F14-2
Ignition CDI
DRIVE TRAIN Ignition (Type & Deg. BTDC) 30@3500
Spark Plug Gap (inches) .028
Type Shaft Ride System
Spark Plug (Type) NGKBKR5E
DRIVE CLUTCH Exhaust USFS Appr. Pending
Drive System Type PVT GRAPHICS
Center Distance (inches) 10
Clutch Offset (inches) 1/2 Bumper Caps/Polyprop. N/A
Clutch Weight (grams) 16 MH Cargo Box or Bed N/A
Spring Color Blue/Green Fender, Front Eddie B. Green
Fender, Rear Eddie B. Green
DRIVEN CLUTCH Footwell Black
Frame/Steel Black
Helix Angle Compound Front Cover Eddie B. Green
Outside Diameter (inches) 9.5 Handlebar Cover Black
Spring Position Black 2-2 Headlight/Dash Pod Black
DIMENSIONAL FEATURES Rack, Front Black
Rack, Rear Black
Approx. Turning Radius (inches) 65 Rims Aluminum
Box, Tool Volume (Cu. Inches) 588 Seat Vinyl Sable Brown
Box Dimensions (inches) N/A Side Panel Eddie B. Green
Ground Clearance (inches) 7.25 Spring, Front Black
Height (inches) 46 Spring, Rear Black
Length (inches) 81 Tank Cover N/A
Seat Height (inches) 34 Tool Box Cover N/A
Weight (dry) 620 w/lettering Color
Wheel Base (inches) 49.75
Width (inches) 46
ELECTRICAL
GEARCASE Headlight - Front Hood (watts) N/A
Trans. Number and Type PRD Headlight - Grill (watts) 2 Single Beam/30 W
Shift Type Side Lever Taillight (watts) 12 V/8.26 W
Gear Reduction - Low 7.46/1 Brake Light (watts) 12 V/26.9 W
Gear Reduction - Reverse 5.12/1 Indicator Bulb 12 V/1.0 W
Gear Reduction - High 3.3/1 Battery 12 V/14 AH
Front Drive (ratio) 3.7/1
Final Drive (ratio) 3.1/1 SUSPENSION
Center Drive (ratio) N/A Front Type - MacPherson Strut
Axle to Axle N/A Front Travel (inches) 6.7
Chain Type N/A Rear Type - Progressive Rate Swing Arm
TIRES & WHEELS Rear Travel (inches)
Shock 2² Gas Charged Monotube
6.5

Tire Manufacturer Titan Adjustment Cam

Tire Size - Front 24x8-12
Tire Size - Rear 24x11.5-10
Tire Size - Center N/A
Tire Pressure - Front 4
Tire Pressure - Rear 3
Tire Pressure - Center 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.
 2000 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’S OWNER’S PARTS PARTS ASSEMBLY

MANUAL MANUAL MANUAL MICROFICHE INSTRUCTIONS
SUPPLEMENT
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

14
6 7 16
13
8 17
5
19
9 18
10 12
11
1 4
41
3 42 20
2
43 6 21
40 3
45
39
33 22 23

44 38

37
24
25

36

35 26

33
34 32 27
28
29
30
31

A5
 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 10 Rivet 24 7621509 2 Rivet

2 7511930 2 Bolt 25 5243829-067 1 Strap, Fuel Pump
3 7555792 6 Washer 26 - - - - - - - 1 Asm., Front Gearcase (See Front Gear-
4 5811107 1 Foil, Rear Cab, Rear case Pg. C10 for Details)
5 5432117-195 1 Cab, Rear, E.B. Green 27 7552603 4 Washer
6 7541925 4 Nut, Nylok 28 7512492 4 Screw
7 5224592 1 Retainer, Seat Latch 29 5433435 1 Guard, Rock
8 5811308 1 Foil, Tape, Rear Cab 30 7556065 7 Washer
9 7512242 4 Screw 31 7517386 9 Screw
10 7555859 4 Washer 32 7558301 2 Washer, Flat
11 7512085 2 Screw 33 7512232 21 Screw
12 5431786 1 Box, Tool 34 7542122 8 Nut
13 7621403 2 Rivet 35 5411548 8 Mount, Rubber
14 5211033 2 Bracket, Lever Retainer 36 7517264 8 Screw
15 1040387 1 Latch, Seat 37 1012764-067 1 Frame, Main
16 7041370 1 Spring, Latch 38 5432221-070 1 Footwell, LH, Black
5433219-070 1 Footwell, RH, Black
17 2682441-276 1 Seat, Sable Brown
2681747-276 1 Covering, Seat, Sable Brown 39 5811111 1 Foil, Foam, Rear Fender
5811104 1 Foil, Seat Base, Large 40 5811106 2 Foil, Rear Cab, Front
5811105 1 Foil, Seat Base, Small 41 7073761 1 Decal - Carb Information
18 5410414 8 Bumper, Rubber 42 7078396 1 Decal - Filter Element
19 7517599 2 Screw and Washer 43 5811087 1 Foil, Foam
20 5431787 1 Cover, Tool Box 44 7670057 12 Nut, U-Type Speed
21 5410896 1 Cap, Drain 45 5431796 1 Guard, Mud, Rear, LH (AA)(AB)
22 5243188-067 1 Guard, Clutch 5431797 1 Guard, Mud, Rear, RH (AA)(AB)
23 7661637 4 Rivet 7555913 8 Washer, Flat (FA)(FB)
2873213 1 Kit - Mud Skirt, Full Set (FA)(FB)
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

1 4
2

12
2 6
8
7
9
11
10

2
6
2

14 13

15
16

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

1 2632084-195 1 Asm., Panel w/Foam, LH, E.B. Green 8 7661645 4 Rivet

(If built before 3/20/00) 9 5431798 1 Guard, Mud, Front, LH
2632284-195 1 Asm., Panel w/Foam, LH, E.B. Green 5431799 1 Guard, Mud, Front, RH
(If built after 3/20/00)
2632101-195 1 Asm., Panel w/Foil, RH, E.B. Green 10 7541925 2 Nut, Nylok
2 7512232 12 Screw 11 7555792 2 Washer
3 5432088-195 1 Cover, Front, E.B. Green 12 7512085 2 Screw
4 7670085 2 Clip, Spring 13 7555931 2 Washer
5 2632144-195 1 Cab, Front, E.B. Green 14 7542122 2 Nut, Nylok
6 7670057 10 Nut, U-Type Speed 15 7621509 4 Rivet
7 7670068 2 Nut, Push-on 16 5811917 2 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

5
6
7

10

11
6
10
9 12

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

1 7517685 2 Screw 7 7670096 2 Nut, Chimney

2 7517686 4 Screw 8 7512329 4 Bolt
3 2670174 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 2 Reflector, Red 10 7558402 2 Washer
5 1040490-067 1 Support, Rear Rack 11 5333332-067 4 Spacer
6 7542324 8 Nut, Nylok 12 7515385 4 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

3
4

8
7
6
14

13
15 12
11 9
10
16
17

6
4
24 18

23 19
22
20
21

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

1 7517685 4 Screw 14 2431011 1 Headlight, LH

2 2670180 1 Asm., Front Rack 2431012 1 Headlight, RH
(Incl. Ref. 3 and Warning Decal) 4030059 2 Bulb, Replacement, 27W
3 2670071 2 Reflector, Amber 15 7515382 2 Bolt
4 7515399 6 Screw 16 7558402 4 Washer
5 2200775 1 Kit - Front Rack Mount 17 5810467 1 Plug, Frame
6 7542324 4 Nut, Nylok 18 5241583-067 1 Guard, Brush
7 7558403 2 Washer 19 5240591-067 1 Grill, Brush Guard
8 5432155-070 1 Bumper 20 7621330 7 Rivet
9 7515391 2 Screw 21 7670094 6 Nut, U-Type
10 7515390 2 Screw 22 7512097 6 Screw
11 7555954 2 Washer 23 5431814 1 Shield, Radiator Side, LH
12 1040554-067 1 Support, Front Rack, LH 5431815 1 Shield, Radiator Side, RH
(If built before 11/15/99) 24 5241398-067 1 Extension, Frame, LH
1040555-067 1 Support, Front Rack, RH (If built before 12/01/99)
(If built before 11/15/99) 5241399-067 1 Extension, Frame, RH
1013210-067 1 Support, Front Rack, LH (If built before 12/01/99)
(If built after 11/15/99) 5244623-067 1 Extension, Frame, LH
1013211-067 1 Support, Front Rack, RH (If built after 12/01/99)
(If built after 11/15/99) 5244624-067 1 Extension, Frame, RH
(If built after 12/01/99)
13 7517386 4 Screw
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 6
4 5 7

10
RH
9
13

12 16 17
14 15 4 18
11
1

LH

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

1 7074954 2 Decal - Rack/Warning 10 7078577 1 Decal - Drain Recoil

2 7074110 1 Decal - Load Distribution, 4W 11 7078015 1 Decal - “325” Front Cover (AA)(AB)
3 7078022 1 Decal - “4x4”, Shaft Ride Sys., RH 7079007 1 Decal - “325 4 Stroke HDS” (FA)
7079008 1 Decal - “325 4 Stroke HDS II” (FB)
4 7077780 2 Decal - ‘‘POLARIS” Side Panel
5 7078017 1 Decal - Tank Side, RH 12 7077919 1 Decal - Warning, General, CPSC
6 7074935 1 Decal - Warning, AWD Switch 13 7079604 1 Decal - Warning, Override, AWD
7 7078315 1 Logo, “45th Anniversary” 14 7078016 1 Decal - Tank Side, LH
(If built before 1/01/00) 15 7078253 1 Decal - Age Warning, ATV
7078465 1 Logo, Polaris Star 16 7078018 1 Decal - “4x4”, Shaft Ride Sys., LH
(If built after 1/01/00) 17 7077920 1 Decal - Passenger Warning
8 7074220 1 Decal - “Macpherson Strut” 18 7078004 1 Decal - Tire Pressure
9 7078354 1 Decal - Discretionary Warning, ATV
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
3 1
4 2
3 9

4
10

4
5
7
6
8 11

5 17

20 18
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 Nutsert 12 7052244 1 Valve, Drain

2 3110032 2 Mount, Rubber 13 5242983-067 2 Mount, Oil Cooler
3 5242924-067 2 Bracket, Cooling Fan 14 7558301 2 Washer, Flat
4 7542122 10 Nut, Nylok 15 3110050 2 Mount, Carburetor
5 7080474 2 Clamp, Hose 16 2410157 1 Motor, Fan
6 5411813 1 Hose, Cooler Inlet 17 7517659 4 Screw
7 7670111 4 U-Clip 18 7080862 1 Clamp, Hose
8 5433353 1 Shroud, Fan 19 7080866 1 Clamp, Hose
9 4010274 1 Thermister 20 5411768 1 Hose, Oil Cooler Outlet, Flared
10 7515158 4 Screw 21 8450086-07 1 Tubing, Convoluted
11 1240064 1 Cooler, Oil 22 7080869 1 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

2 5
3 4 6

7
19
8
18 9
17
16 10
11

15 14

13 12 6

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

1 7080474 2 Clamp, Hose 11 4010274 1 Thermister

2 5411813 1 Hose, Inlet 12 7052244 1 Plug, Drain
3 7542122 4 Nut 13 1240064 1 Cooler, Oil to Air
4 5243783-067 1 Bracket, Top 14 3021186 4 Mount, Rubber
5 7080869 1 Clamp, Rubber Coated 15 5244069-067 1 Bracket, Bottom
6 7515158 8 Screw 16 7080862 1 Clamp
7 7517659 4 Screw 17 7080866 1 Clamp, Hose
8 2410157 1 Motor, Fan 18 5411768 1 Hose, Outlet, Flared
9 7670111 4 U-Clip 19 8450086-07 AR Tubing, Convoluted
10 5433353 1 Shroud
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
15
11 13 12
8
16
13
14

10 16
17 11

(If built after 7/01/99)

13

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

1 7542324 1 Nut, Nylok 9 7512666 1 Bolt

2 7555716 1 Washer 10 3110064 2 Mount, Torque Stop
3 5410436 1 Washer, Rubber 11 7542301 2 Nut
4 7555863 1 Washer (If built before 7/01/99) 12 7041804 4 Spring, Exhaust
5 5010192 1 Bushing (If built before 7/01/99) 13 7042029 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 1 Dampener, Vib. (If built before 7/01/99) 14 1260976-029 1 Headpipe (If built before 7/01/99)
5411790 1 Dampener, Vib. (If built after 7/01/99) 1260987-029 1 Headpipe (If built after 7/01/99)
7 7515316 1 Bolt, Carriage (If built before 7/01/99) 15 1260960-029 1 Manifold, Black
7515339 1 Bolt (If built after 7/01/99) 16 5243517 2 Seal, Exhaust
7515394 1 Screw, Carriage (If built after 8/12/99)
17 7041789 1 Spring, Exhaust (If built after 7/01/99)
8 1260977-029 1 Silencer (If built before 7/01/99)
1260961-029 1 Silencer (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

2
3 4

6
5 7
8

9
10

24

11

22
23
12

21
21

20

20
13
19

17
18
16
15
14
Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 5430725 1 Cap, Gas Tank 12 7547069 4 Nutsert

2 5810144 1 Gasket, Fuel Cap 13 5810317 2 Pad, Fuel Tank Bracket
3 5811899 1 Seal, Foam 14 7517505 1 Screw
4 8360009-600 AR Line, Fuel 15 5432559 1 Knob, Fuel Valve
5 5431053 1 Vent, Tank 16 5432733 1 Nut, Fuel Valve
6 7517451 2 Bolt 17 7052161 1 Valve, 3-Way
7 7552801 2 Washer 18 7661637 2 Rivet
8 7558301 2 Washer 19 5240577-067 1 Bracket, Fuel Valve
9 5222154-067 1 Bracket, Mounting, Rear, LH 20 8450040-600 AR Line, Fuel
5222155-067 1 Bracket, Mounting, Rear, RH 21 7080003 4 Clamp, Hose, Red
10 5811796 1 Foam, Intake, Splash 22 7052149 1 Fitting, Fuel Outlet, Reserve
11 5332457 2 Spacer (If built before 1/17/00) 23 7052146 1 Fitting, Fuel Outlet, Main
5333936 2 Spacer (If built after 1/17/00)
24 2520183 1 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
10
9 11
3 7 8 12
2
6
4

6
14 13
37
5
35 36
33 32
33
33
15
16
32 34 32
33
31
17

30

6
7 22

23 21
6 24
26
29 27 25 18
28 19 7
6
20

19

B1
 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 AR Line, Fuel 18 1012960-067 1 Mount, Engine, Rear

2 7052075 1 Fitting, Tee (If built before 12/01/99)
3 5243720-067 1 Bracket, Carburetor 1013133-067 1 Mount, Engine, Rear
(If built after 12/01/99)
4 3084205 2 Screw and Washer 19 7547108 4 Nut
5 3085823 1 Engine, Short Block NOTE: The 20 7517289 2 Screw
Short Block assembly contains a
crankcase assembly., cylinder & cylin- 21 3021119 1 Mount, Rubber, Rear
der head assembly and a piston & 22 7555815 2 Washer
crankshaft assembly. Prior authoriza- 23 7515417 2 Screw
tion is required for warranty consider- 24 5243288-067 1 Mount, Lower Front
ation.
6 7542403 4 Nut 25 3021181 1 Mount, Rubber, Rear
7 7555806 2 Washer 26 5430261 1 Bushing
8 5243641-067 1 Bracket, Motor Mount 27 5210748 1 Washer
9 7552901 2 Washer 28 7575202 1 Washer
10 7512315 2 Bolt 29 7512566 1 Bolt
11 7512232 1 Screw 30 4010095 1 Cable, Battery/Engine
12 4010132 1 Cable, Ground Engine 31 7080482 1 T-Clip
13 7555823 1 Washer 32 8450040-600 AR Line, Fuel
14 3110068 1 Mount, Rubber Rear 33 7080003 8 Clamp, Hose
15 5411721 1 Boot, Clutch Intake 34 2530009 1 Filter
16 7080511 1 Clamp, Narrow Band 35 7546601 2 Nut, Nylok
17 8360009-600 AR Line, Fuel 36 3110079 2 Mount, Rubber
37 7517615 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

26
2

5
6

7
25

8
12
24
9
23
10
11
22
12
21 18
13
14
17
20
19
9
16

15

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

1 7517541 4 Screw 15 7080694 1 Clamp, Hose

2 5432859 1 Duct, Inlet 16 5411746 AR Hose, Breather (If built before 7/26/99)
3 5411422 1 Gasket, Intake 5411848 AR Hose, Breather (If built after 7/26/99)
4 5432868 1 Cover, Air Box 17 5432774 1 Box, Air (If built before 7/26/99)
5433678 1 Box, Air (If built after 7/26/99)
5 5811482 1 Seal, Cover
18 5431863 2 Insulator
6 7515180 2 Screw
19 5811650 1 Foil, Air Box
7 7558301 2 Washer
20 5432377 1 Plug
8 5433396 1 Cap, End
21 8450059-150 AR Line, Fuel
9 7080699 2 Clamp, Hose
22 7080650 1 Clamp, Hose
10 5830128 1 Gasket, Duct
23 5243694 6 Clip
11 5433180 1 Duct, Carburetor Inlet
24 5432601 1 Collar, Carburetor Inlet
12 7080413 2 Clamp
25 7080595 1 Filter, Air Intake
13 5411588 1 Boot, Carb
26 5811633 1 Filter, Precleaner Sleeve
14 7080511 1 Clamp
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

6
2 3 4 5 8 9 10
1

11

12

13

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

1 1380119 2 Asm., CV Housing w/Sleeve 8 2200771 1 Kit - Cross and Bearing

2 5222299 1 Sleeve, Drive Shaft Seal 9 3260130 1 Yoke, Splined
3 3260115 1 Clamp, CV Joint, Large 10 7661913 1 Pin, Spring
4 7670091 1 Circlip 11 7080627 1 Clamp, Small Band
5 5411106 1 Boot, CV Joint 12 2200773 1 Kit - Boot Replacement, CV Joint
6 1380094 1 Shaft Replacement (Incl. 4) (Incl. 3,5,11)
7 1380092 1 Cardan Replacement (Incl. 4,6,8,9) 13 2200961 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

4
1 5
2
3

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

1380138 1 Asm., Prop Shaft (Incl. 1-4) 4 3260131 1 Yoke, Splined

1 3260133 1 Yoke, Gear Case, Front 5 5411092 1 O-Ring
2 3260104 2 Kit - Cross and Bearing 6 7661913 1 Pin, Spring
3 3260140 1 Shaft, Prop, Front
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
23 2

6
3 7
5

4
22
21

20 10
11 8

4
9
19 18 13
17
12

14 11
16
10
15

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

1 5411608 2 Bumper 15 2201311 1 Asm., Hubstrut, LH (32mm)

2 7041761 2 Strut, Front (Incl. 8,11-14,22)
3 5211115 2 Washer 2201312 1 Asm., Hubstrut, RH (32mm)
(Incl. 8,11-14,22)
4 7558402 6 Washer 16 7041375-067 2 Spring, Coil
5 7080573 2 Clamp, Rubber Coated 17 5243364 2 Retainer, Spring
6 7542303 4 Nut 18 5432871 2 Ball, Pivot, Bottom
7 7517445 4 Screw 19 7515339 4 Bolt
8 5810439 2 Retainer, Strut Casting Wire 20 5132062 2 Spacer
9 ------- 1 Asm., Front Brake Caliper, RH (See 21 ------- 1 Kit - Drive Shaft w/Sleeve
Front Brake Pg. B8 for Details) (See CV Joint - BTB Pg. B4, Ref. 13)
10 3554509 4 Bearing, Tapered Roller 22 3610028 2 Seal, Hubstrut
11 3554507 4 Bearing, Tapered Roller Cup 23 5432872 2 Ball, Pivot, Top
12 5222193 2 Sleeve, Hubstrut Seal 24 5810291 2 Spacer, Rubber
13 7080306 2 Fitting, Lubrication 25 7555749 2 Washer
14 2410133 2 Coil, Magnetic 26 7547104 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 10 11 12 13 14
4
5
6
7
9

15

16
25

24 7 19
6
17
18
20
21

23
22

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

1 7512325 8 Bolt 14 3250030 2 Cam

2 5211869 2 Disc, Brake 15 7052045 2 Plug, Magnetic Drain
3 3610019 2 Seal, Front Hub 16 5411709 2 Tire (24x8-12)
4 5211148 2 Plate, Armature 17 7556004 2 Washer
5 1520281 2 Clutch, Front Hub, Elec./Mech. 18 7542810 2 Nut, Slotted
6 3554506 4 Bearing, Tapered Roller Cone 19 7661401 2 Pin, Cotter
7 3554507 4 Bearing, Tapered Roller Cup 20 5410470 2 O-Ring
8 7515523 8 Stud 21 5432611 2 Cap, Hub
9 1520243 2 Asm., Hub w/Bearing Race (Incl.3,7,8) 22 7512027 6 Screw
10 3250028 2 Cage, Roll 23 7542459 8 Nut
11 3250010 12 Roll 24 1520269-117 2 Rim, Front
12 3250032 2 Spring, Garter 25 1525017 2 Valve, Rim
13 1321814 2 Spacer
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

2 3

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 6 5410780 1 Ring, Molded Square (.103 x .134)
(Incl. 1-7,9,10) 7 5132294 1 Piston, Brake, Long
1910264 1 Asm., Front Brake Caliper, RH 8 2200465 1 Kit - Front Brake Pad, General Duty
(Incl. 1-7,9,10) 2200901 1 Kit - Front Brake Pad, Severe Duty
1 7080352 1 Screw, Bleeder 2201149 1 Kit - Front Brake Pad, Soft Duty
2 7515489 1 Screw, Socket Set 9 1910265 1 Mount, Caliper (If built before 7/09/99)
3 5131115 1 Caliper, Brake, LH 1910412 1 Mount, Caliper (If built after 7/09/99)
5131116 1 Caliper, Brake, RH 10 5410495 1 Boot, Bushing
1930642 1 Kit - Front Brake Boot 11 5410494 1 Boot, Pin Seal
4 1930665 1 Kit - Piston and Insulator Seal (Incl. 5-7) 12 - - - - - - - 4 Screw (See Front Strut Pg. B6, Ref. 7)
5 5410779 1 Ring, Molded Square (.094)
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

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

1 5432721 1 Cover, Throttle Control 4 7080709 1 Cable, Throttle Control

(If built before 11/22/99) (If built before 2/10/99)
5433806 1 Cover, Throttle Control 7080857 1 Cable, Throttle Snap-In
(If built after 11/22/99) (If built after 2/10/99)
2 5410193 1 O-Ring 5 2010188 1 Asm., Throttle Control (Incl.1,3,6)
3 5411439 1 O-Ring 6 2010191 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

14 13

15

28 12 5

6
27 11
16
26
25
17
22
7
18
24 20 8
19
9
21

22 10
23

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

2050078 1 Asm., Master Cylinder (Incl. 1-13) 13 ------- 1 Ring, Square, Reservoir
2200809 1 Kit - Master Cylinder Reservoir 14 5411297 1 Boot, Rubber Brake Line
(Incl. 1-3,13)
15 5410988 2 Seal
1 1930797 2 Bolt, Cap 16 4110164 1 Switch
2 1930796 1 Cap, Reservoir 17 1910286 1 Line, Hand Brake, Front
3 1930795 1 Diaphragm 18 7621462 1 Rivet
4 2200808 1 Kit - Master Cylinder Clamp 19 7080539 1 Clamp, Nylon
5 1930799 1 Asm., Master Cylinder Piston 20 8360031-30 1 Conduit, Convoluted
6 1930804 1 Rivet 21 1930752 1 Line, Brake, Left Front w/Fittings
7 2201034 1 Kit - Brake Lever w/Parking Latch 22 7080138 8 Cable Tie
(Incl. 6-9)
8 ------- 1 Spring, Flat 23 7512084 2 Screw
9 2201090 1 Kit - Park Brake Lever (Incl. 6,8) 24 8360011-38 1 Tubing, Convoluted
10 1930806 1 Nut 25 1930753 1 Line, Brake, Right Front w/Fittings
11 1930792 2 Bolt, Reservoir 26 7052237 1 Fitting, Cross
12 1930805 1 Bolt, Lever 27 1930816 1 Line, Brake
28 1930674 1 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

16
2
15
14

13

12
5
6 11

10

6
5
7
5
8

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

1 1843067 1 Asm., Steering Post (Incl. 12,13) 9 7661633 1 Pin, Cotter

2 5431573 1 Bushing,Console (If built before 7/12/99) 10 5431570 1 Bushing, Steering, Lower
5433415 1 Bushing,Console (If built after 7/12/99) 11 7661632 2 Rivet
3 7080424 1 Fitting, Lubrication 12 5431574 1 Plug, Steering Grease
4 7515321 2 Bolt 13 7080433 1 Fitting, Lubrication
5 7555878 3 Washer 14 5431572 1 Bushing, Steering (If built before 7/12/99)
6 5410772 2 O-Ring 5433416 1 Bushing,Steering (If built after 7/12/99)
7 5431571 1 Spacer, Steering Post 15 5222999-067 1 Bracket, Steering Bushing, Upper
8 7543203 1 Nut 16 7542324 2 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

A00CD32FA and A00CD32FB 1

2
27
28
2 3

10
29 4 9
26 7 8 11
12
22 23 24 6
33
25 5
32
31
25
A00CD32FA and A00CD32FB
21
13 14
15
30
17
16
20 17

18
19

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

1 5432247-070 1 Cover, Logo 20 - - - - - - - 1 Asm., Throttle Control (See Controls -

2 5432420 2 Cover, Screw Throttle Asm./Cable Pg. B9, Ref. 5)
21 2460715 1 Harness, Control Panel (AA)(CA)
3 5432246-070 1 Panel, Instrument (AA)(CA) 2460841 1 Harness, Control Panel (FA)(FB)
5433183-070 1 Panel, Instrument (FA)(FB)
22 4040054 1 Indicator, Neutral/Reverse
4 7517216 4 Screw (AA)(CA)
7517224 4 Screw (FA)(FB) 23 4040053 1 Indicator, “Hot Temperature”
5 5241397-067 1 Bracket, Instrument Panel (AA)(CA) 24 5430967 1 Plug, Indicator Hole (AA)(CA)(FB)
5241698-067 1 Bracket, Accessory Panel (FA)(FB) 4010313 1 Indicator, “P” Park (FA)
6 ------- 1 Asm., Master Cylinder 25 4110264 1 Switch, Ignition
(See Control - Master Cyl./Brake Line 4010278 1 Key, Blank, Series 2000, 6700, 6800.
Pg. B10 for Details) NOTE: Spare key must be cut from ex-
7 7080726 1 Cable, Choke w/Adjuster isting key.
2200188 1 Kit - Choke Lever 4010321 1 Key, Blank, Series 2200, 2300, 2700,
2800. NOTE: Spare key must be cut
8 5432926 1 Spacer, Switch, LH from existing key.
9 4010262 1 Switch, Handlebar, Hi/Lo/Rev. Override 5433733 1 Nut, Ignition
10 5431030 2 Grip, Handlebar 5431964 1 Cover, Key
11 5432952 1 Plug, Hole 26 7080229 1 Nut, Choke Slide
12 7517625 1 Screw 27 3280337 1 Speedometer (FB)
13 5224715-067 1 Tube, Handlebar 3280345 1 Speedometer (FA)
28 7512024 2 Screw (FA)(FB)
14 5132382 1 Cap, Hall Sensor (FA)(FB)
15 4010298 1 Sensor, Hall Effect (FA)(FB) 29 3280201 1 Clamp (FA)(FB)
30 5630633 1 Block, Riser (FA)(FB)
16 7517658 1 Screw (FA)(FB)
17 5630629 4 Block, Handlebar 31 7541933 2 Nut, Brass (FA)(FB)
18 7542122 4 Nut, Nylok 32 7558212 2 Washer, Flat (FA)(FB)
19 7080631 1 Clip, Cable Retaining 33 7555868 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
6
4
2
7

8
9
3 10

31 30 11
9

12
29 28

13
14

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

21 14

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

1 7542403 2 Nut, FLEXLOC 16 5211121 2 Bracket, Ball Joint

2 5333367 1 Bushing 17 7512284 4 Screw
3 1820567 2 Asm., Tie Rod 18 5410548 2 Boot, Rubber
(Incl. 4-9)(If Built before 8/16/99) 19 7542438 2 Nut, Castle
1820805 2 Asm., Tie Rod 20 5431150 1 Shield, CV Joint, LH
(Incl. 4-9)(If Built after 8/16/99) 5431149 1 Shield, CV Joint, RH
4 5411291 2 Boot, Seal, Rod End 21 7517756 6 Screw
5 7061034 2 Rod End 22 5433066 4 Bushing, A-Arm, Long
6 7542711 2 Nut 23 5020677 4 Bushing
7 5020926 2 Tie Rod 24 5020681 2 Shaft, A-Arm
8 7547028 2 Nut, LH 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 2 Fitting, Lubrication
10 5411920 1 Boot, Seal, Rod End 27 -------- 1 Asm., Heavy Hubstrut
11 7517674 2 Bolt (If Built after 8/16/99) (See Front Strut Pg. B6, Ref. 15)
12 7555806 4 Washer, Flat (If Built before 8/16/99) 28 7512492 4 Screw
7556099 4 Washer, Flat (If Built after 8/16/99) 29 7552603 4 Washer, Spring Lock
13 7546904 2 Nut 30 7517527 1 Bolt
14 7661203 4 Pin, Cotter 31 7515415 1 Screw
15 7080927 2 Joint, Ball
10/00

B13
 DRIVE CLUTCH
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA

5 8
3 4 7
1 2
6

13 12 10
11
9
5

14

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

1 7512176 6 Bolt 7 5630279 3 Weight, Shift, 16

2 7552801 6 Washer 8 7512266 3 Bolt, Shoulder
3 5430945 6 Washer, Multilube 9 7541906 3 Nut, FLEXLOC
4 1321457 3 Roller and Bushing 10 3576504 1 Bearing, Moveable (1/2I)
5 5431936 6 Button, Clutch 11 5020422 3 Pin, Roller
6 5210752 AR Spacer (.020) 12 7041157 1 Spring, Clutch
5242981 AR Spacer (.025) 13 3576510 1 Cover, Bearing
5210753 AR Spacer (.032)
5210754 AR Spacer (.050) 14 1321632 1 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
4 6

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 1 Clutch, One Way Drive 11 7512176 6 Bolt

2 7556009 1 Washer 12 7041157 1 Spring, Clutch
3 5131646 1 Spacer 13 1321457 3 Roller and Bushing
4 7541906 3 Nut, FLEXLOC 14 5430945 6 Washer, Multilube
5 5431936 6 Button, Clutch, Stemless 15 7512266 3 Bolt, Shoulder
6 5020422 3 Pin, Roller 16 5630279 3 Weight, Shift, 16 MH
7 3585712 1 Bearing 17 1321706 1 Asm., Drive Clutch, Braking
8 7547130 1 Nut, Jam (Incl. All Less 12,7)
9 3576510 1 Cover, Bearing 18 7556008 1 Washer
10 7552801 Washer, Spring Lock
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 3
4

10
11 5
12
13

14
5 15
16
1
A00CD32FA
A00CD23FB
17
18
21 2
3
4
9 10 22 20 19
26
25
13 23
24

20

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

1 7556120 AR Bushing 14 3576504 1 Bearing, Moveable (1/2”)

2 5220646 1 Washer, Domed 15 7556804 AR Washer (.030”)
3 7552901 1 Washer, Spring Lock 16 7555898 AR Washer, Spacer (.020”)
4 7515382 1 Bolt 7556076 AR Washer, Spacer (.025”)
5 1321855 1 Asm., Driven Clutch, 3 Angle, Heavy 17 7556013 1 Washer
(Incl. 7-16)(AA)(CA) 18 7556010 1 Bushing
6 3211077 1 Belt, Drive 19 7710461 1 Ring, Retaining
7 5430766 3 Button, Ramp 20 1322184 1 Asm., Driven Clutch, Braking (Incl.
8 7511854 3 Bolt 2,9,10,13,18,19,23-26)(FA)(FB)
9 7710448 1 Ring, Retaining 21 3211069 1 Belt, Drive
10 5210752 1 Spacer 22 7517323 3 Screw
11 5132344 1 Ramp, Stationary (If built before 4/01/00) 23 3585710 1 Bearing
5131447 1 Ramp, Stationary (If built after 4/01/00) 24 5211115 1 Washer
12 7041782 1 Spring, Clutch 25 7041635 1 Spring
13 3576511 1 Bearing, Moveable (1”) 26 5131674 1 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 6
3 5
9 10
7 11

8
25
12

13
24

23
22 21

20 14
15

18
19
17
16

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

1 7512232 2 Screw 12 7074946 1 Decal - Clutch Cover

2 2632116 1 Foam, Clutch Air Inlet (If built before 10/04/99)
7078689 1 Decal - Warning, Clutch Cover
3 5433453 1 Plate, Backing (If built after 10/04/99)
4 2201520 1 Kit - Inner Clutch Cover (Incl. 8,11,15) 13 7077377 1 Decal - Engine/Clutch Modification
(If built before 1/03/00)
2201676 1 Kit - Clutch Cover, Inner 14 7074782 1 Decal - “Automatic Transmission”
(If built after 1/03/00) (AA)(AC)
7077666 1 Decal - “Automatic/EBS’ (FA)(FB)
5 5433363 1 Duct, Inlet, Down Tube
15 7512094 9 Screw
6 7517601 3 Bolt and Washer (If built before
7517599 5 1/03/00) 16 5411489 1 Boot, Duct
Bolt and Washer (If built after 1/03/00) 17 7080761 2 Cable Tie
7 7080909 1 Clamp, Narrow Band 18 7558301 2 Washer, Flat
8 5521301 1 Seal, Clutch Cover 19 7517386 2 Screw
9 5432849 1 Cover, Clutch, Outer 20 5433172 1 Duct, Air Outlet (If built before 11/05/99)
(If built before 2/13/99) 5433744 1 Duct, Air Outlet (If built after 11/05/99)
5433540 1 Cover, Clutch, Outer 21 - - - - - - - 3 Screw and Washer
(If built before 1/03/00) (See Crankcase Pg. D3, Ref. 6)
5433451-328 1 Cover, Clutch, Outer 22 5240409-067 1 Bracket, Retainer, Seal
(If built after 1/03/00) 23 5410575 1 Seal, Cover Case
10 7670051 1 Clip, Clutch Cover 24 5411795 1 Stopper, Inner Clutch Cover
11 7512093 5 Screw (If built before 1/03/00) 25 5410489 1 Seal, Cover Case (If built before 1/03/00)
7512094 5 Screw (If built after 1/03/00) 1 Seal, Clutch Cover (If built after 1/03/00)
5411901
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

5 18
4
1
3
6

2 7 14
8 19 20
9 21
10 13
38 22
12

11
37 11 28 23
12
29 27
30 24
25

36
26
35

34
33
31
32
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2460737 1 Harness, Main Wire (AA)(CA) 18 5810317 1 Pad
(If built before 8/01/99) 19 2200361 1 Kit - Battery Bolt, Short
2460821 1 Harness, Main Wire (AA)(CA)
(If built after 8/01/99) 20 4010095 1 Cable, Battery/Engine
2460833 1 Harness, Main Wire (FA) 21 7010032 2 Hook, Battery Strap
2460834 1 Harness, Main Wire (FB) 22 5410424 1 Strap, Battery Holddown
2 2200593 1 Kit - Circuit Breaker, 20 AMP 23 5432077 AR Tube, Battery Vent
3 2201795 1 Kit - Circuit Breaker, 10 AMP 24 4140006 1 Battery
4 2432034 1 Asm., Taillight w/Brake Light (Incl. 25 7511876 2 Screw
5-10) 26 4010354 1 Limiter, Speed (FA)(FB)
5 4032046 1 Lens, Taillight 27 5431769 1 Cover, Battery
6 4032029 2 Screw, Taillight 28 4010094 1 Cable, Battery/Solenoid
7 4030043 1 Bulb, Taillight
29 4010093 1 Cable, Solenoid/Starter
8 4032045 1 Gasket, Taillight
30 7512007 2 Bolt
9 4032064 1 Backing, Taillight/Brake Light 31 5132214 1 Sink, Heat
10 7670054 2 Nut, Speed 32 4010249 1 Switch, Thermister LR-60
11 7541925 4 Nut, Nylok
33 7512018 5 Screw
12 7571602 4 Washer
34 4060191 1 Rectifier, Regulator, LR 35
13 7512027 2 Screw 35 4010195 1 Limiter, RPM LR 83-3 (AA)(CA)
14 5810290 3 Pad, Battery
36 7512017 2 Screw
15 4010311 1 Switch, Horn 37 4020149 7 Clip, Rosebud
16 4010310 1 Horn 38 7670109 3 Clip, Routing
17 7517386 1 Screw
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 9
6 10
3
5
8 11
4
7
12

13
5
14

15

16

19
17
18
7

13
18 19
17
22
5 21 20

30
24
28 27
29
21
27 22
26

19
9
24
25 23

C5
 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

1 2201189 1 Kit - Brake Pad (Incl. Spacer and Pin) 13 1930674 3 Bolt, Banjo
1910339 1 Pad, Spacer 14 7542403 2 Nut
1930860 1 Pin
15 7542153 1 Nut, Nylok
2 7515406 2 Screw
16 1930854 1 Reservoir, Brake, Rear
3 7555806 2 Washer
17 7080003 2 Clamp, Hose
4 1910270 1 Asm., Brake Caliper, Rear
(If built before 2/09/99) 18 1910331 1 Hose, Reservoir
1910367 1 Asm., Brake Caliper 19 7512240 3 Bolt
(If built after 2/09/99) 20 1012753-067 1 Pivot, Brake Mount, Rear
2201428 1 Kit, Bleeder Replacement 21 7542122 2 Nut, Nylok
2201467 1 Piston, Caliper, DH2P, Rear
2201385 1 Kit, Caliper Seal 22 7558301 2 Washer
5 5410988 6 Seal 23 1012752-067 1 Rod, Brake
6 1910286 1 Line, Brake, Front Hand 24 7555919 2 Washer
7 1910288 1 Line, Brake, Rear Foot 25 7661401 1 Pin, Cotter
8 7080573 1 Clamp 26 7556090 1 Washer
9 7517386 2 Screw 27 5433189 2 Bushing, Pedal Pivot
10 7080762 3 Clip, Brake Line 28 7515158 2 Screw
11 7661048 2 Rivet 29 1910311 1 Master Cylinder, Foot
12 7080816 1 T-Clip, Dual 30 7041750 1 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

4
5
1

9
10
8
11 6
7
12

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

1 7661404 2 Pin, Cotter 7 1525017 2 Valve, Rim

2 7542714 8 Nut 8 1520183-117 2 Rim, Rear, Silver
3 5131777 2 Hub, Wheel, Rear 9 7555745 2 Washer
4 7512673 8 Bolt 10 7555796 2 Washer
5 7670081 8 Pushnut 11 7543005 2 Nut
6 5411710 2 Tire, 24x11.5-10 12 5411164 2 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 21 2
14 20
12 16 19
15 17 18
13
22
1

8 12 24 23
7 11

5
4

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

1341253 1 Asm., Front Gearcase (Incl. 1-24) 13 3233524 1 Tube, Vent

1 3233319 2 Seal, Oil 14 3233592 1 Housing, Front, Gearcase
2 3233252 11 Screw 15 3233593 1 Bushing
3 3233573 1 Cover, Gearcase 16 3233594 1 Gear, 37T, Bevel
4 3233588 1 O-Ring 17 3233595 1 Shaft, Output, Front
5 3233574 1 Nut 18 3233020 1 Bearing
6 3233589 1 Bearing, Ball 19 3233554 1 Shim
7 3233590 1 Shaft, Input, Front Housing 20 3233596 1 O-Ring
8 3233591 1 Bushing 21 3233597 1 Cover, Output, Front Housing
9 7080756 1 Clip 22 3233248 1 Seal
10 8450003-1525 AR Line, Vent 23 3233583 1 Shim
11 3233253 2 Plug, Drain 24 3233582 1 Button, Thrust
12 3233254 2 Washer
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

9
6 38
37
40
36 39
7
35
8
9 25 27 41

34 24
33
30
32 9
31
42
30
10 28 43
11
29
12 44
45
13 27
14 26 46
15
47
16 25
48
23 24
17 22 17
18 9
49
54 55 2
19 5 25 51 52 53
50 5

1 56

20
21 58
4 57
66 65 1
64 63
62 61 60 59 5

C9
 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. Qty. Description Ref. Part No. Qty. Description

1341296 1 Asm., Gearcase, Main 31 3233014 1 Bearing, Needle

(Incl. all less 11)(AA)(CA)(FB) 32 3233599 1 Sprocket, 24T
1341336 1 Asm., Gearcase, Main
(Incl. 1-48,50-66)(FA) 33 3233029 1 Ring, Retaining
1 3233248 3 Seal (FA) 34 3233533 1 Engagement Dog, H/R, HLR
3233788 3 Seal (AA)(CA)(FB) 35 3233600 1 Gear, 30T
2 3233252 17 Screw 36 3233613 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 4 Pipe, Knock 38 3233309 1 Bracket, Interlock
5 3233019 4 Bearing, Ball 39 3233032 1 Spring, Shifting, Interlock
6 3233604 1 Shaft, Input, 31T (AA)(CA)(FB) 40 3233308 2 Pin, Interlock
3233756 1 Shaft, Input, 31T (FA) 41 3233747 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 4 Screw (Qty. 8 for FA)
9 3233018 4 Bearing, Ball 44 3233609 1 Cover, Bearing, Center
10 3233055 2 Nut, FLEXLOC (FA) 45 3233106 1 Ring, Retaining
3233961 2 Nut, Lock (AA)(CA)(FB)
46 3233607 1 Bearing, Ball
11 3233054 2 Washer, Flat (FA)
47 3233606 1 Shaft, 10T, Spiral Bevel
12 3233153 2 Bellcrank
48 3233605 1 Fork, Shift, Low (AA)(CA)(FB)
13 3233045 2 Ring, Retaining 3233759 1 Fork, Shift, Low/Park (FA)
14 3233040 2 Washer 49 3233617 1 Switch, 2 Position (AA)(CA)(FB)
15 8360009-600 AR Line, Vent 50 3233620 1 Sprocket, 12T w/18T Spline
16 3233037 1 Tube, Vent 51 3233621 1 Gear, Spiral, Bevel, 31T
17 3233749 8 Screw 52 3233622 1 Shaft, Rear Output
18 3233615 1 Switch, 3 Position (Qty. 2 for FA) 53 3233582 1 Button, Thrust
19 3233902 1 Gearcase, Main (AA)(CA)(FB) 54 3233583 1 Shim
3233765 1 Gearcase, RH (FA)
55 3233623 1 Cover, Output (FA)
20 3233711 1 Plug 3233781 1 Cover, Output (AA)(CA)(FB)
21 3233324 1 Washer 56 3233253 1 Plug, Drain (FA)
22 3233628 1 Washer 3233777 1 Plug, Drain (AA)(CA)(FB)
23 3233629 1 Engagement Dog, Low (AA)(CA)(FB) 57 3233254 1 Washer
3233758 1 Engagement Dog, Low/Park (FA) 58 3233611 1 Shim
24 3233306 2 Ring, Retaining 59 3233625 1 Shaft, Front Output
25 3233619 3 Washer, Thrust 60 3233093 1 Sprocket, 12T
26 3233631 1 Gear (AA)(CA)(FB) 61 3233626 1 Chain, Roller
3233760 1 Gear, 36T (FA)
62 3233552 1 Bushing, Garlock
27 3233103 2 Bearing, Needle
63 3233624 1 Shaft, Shift, Low
28 3233602 1 Fork, Shift, H/R
64 3233627 1 Shaft, Shift, H/R
29 3233598 1 Shaft, Reverse (AA)(CA)(FB)
3233761 1 Shaft, Reverse (FA) 65 3233548 2 O-Ring
30 3233012 2 Washer, Thrust 66 3233618 2 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

4
5
6

7
26
8
25
9

10
11
12
13 8
16 15 14
24 23
17
3
17
16
18 19 20 21 2 22

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

1341254 1 Asm., Gearcase, Rear (Incl. 1-10, 13 7080307 1 Clamp,Hose

14-26) (If built before 2-21-99) 14 3233524 1 Tube, Vent
1341309 1 Asm., Gearcase, Rear (Incl. 1-10, 15 3233586 1 Gearcase, Rear Housing
14-26) (If built before 7-01-99) (For Gearcase 1341254 and 1341309)
1341321 1 Asm., Gearcase, Rear (Incl. 1-10, 3233739 1 Gearcase, Rear Housing
14-26) (If built after 7-01-99) (For Gearcase 1341321)
1 3233585 2 Screw 16 3233711 2 Plug
2 3233252 10 Screw 17 3233324 2 Washer
3 3233256 2 Seal 18 3233577 1 Bushing
4 3233584 1 Cover, Gearcase, Output 19 3233576 1 Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341254 and 1341309) (For Gearcase 1341254)
3233741 1 Cover, Gearcase, Output 3233707 1 Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341321) (For Gearcase 1341309)
5 3233529 1 Pipe, Knock 3233738 1 Shaft, Pinion, 10T, Bevel, Rear
(For Gearcase 1341254 and 1341309) (For Gearcase 1341321)
6 3233587 1 O-Ring 20 3233575 1 Bearing, Ball
7 3233581 1 Shim (For Gearcase 1341254 and 1341309)
8 3233268 2 Bearing, Ball 3233714 1 Bearing, Ball
9 3233580 1 Shaft, Rear Axle (For Gearcase 1341321)
10 3233579 1 Gear, Bevel, 31T, Rear 21 3233588 1 O-Ring
(For Gearcase 1341254 and 1341309) 22 3233319 1 Seal, Oil
3233740 1 Gear, Bevel, 31T, Rear 23 3233573 1 Gearcase, Cover, Input
(For Gearcase 1341321) 24 3233574 1 Nut, Lock
11 7670102 3 Clip 25 3233582 1 Button, Thrust
12 8450003-1525 AR Line, Vent 26 3233583 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

6
10
16 11
7

15
9
10
11
14

12
13

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

1341271 1 Asm., Gear Selector 7 3233646 1 Sphere, Plastic

(Incl. 1-16)(AA)(CA)(FB) 8 3233754 1 Pin, Groove
1341337 1 Asm., Gear Selector (Incl. 1-16)(FA)
9 3233644 1 Pin, Dowel
1 3233195 1 Asm., Knob (AA)(CA)(FB) 10 3233642 2 Spring, Detent
3233767 1 Asm., Knob (FA)
2 7512024 1 Screw 11 3233060 2 Bullet, Detent
3 3233649 4 Screw 12 3233076 2 O-Ring
4 3233131 1 Strap, Wire 13 3233639 1 Slide, Low (AA)(CA)(FB)
5 3233648 1 Cover, Gear Selector Boot 14 3233640 1 Slide, High/Reverse (FA use Qty. 2)
6 3233658 1 Handle, Gear Selector (AA)(CA)(FB) 15 3233641 1 Body, Gear Selector
3233766 1 Handle, Gear Selector (FA) 16 3233643 1 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

6
5
2
2 8
13 7

6 9

2
12
9
10

11

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

1 7061013 2 Rod End, LH 8 7512130 2 Screw

2 7546707 4 Nut, FLEXLOC 9 7542122 4 Nut, Nylok
3 7546702 2 Nut, LH 10 7555827 2 Washer
4 5020974 1 Rod, Low 11 7512126 2 Bolt
5 7546701 2 Nut 12 7517386 4 Screw
6 7061014 2 Rod End, RH 13 5020973 1 Rod, High, Rev
7 1012822-067 1 Bracket, Shifter
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
10 11
1 12 19
2 13 14
15 18
4 16 17
3
6
5 7 15
8 14 13
38 12 10
36 11
37 9
35
34 20
33 5 21

32 20
28
31
30 29
23 22
25 24
26

27

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

1 5132152 1 Hub, Brake Disc 21 7517585 8 Bolt

2 ------- 1 Asm., Rear Brake Caliper 22 5131862 1 Axle, Rear
(See Rear Brake Pg C6, Ref. 4) 23 7710482 1 Ring, Retaining
3 3513523 2 Bearing, Ball 24 7517612 3 Screw
4 5411653 1 Shield, Brake Line, Rear 25 1012881 1 Asm., Skid Plate
5 7517604 3 Bolt 5242851-067 1 Plate, Rear Housing Skid,
6 7512084 2 Screw 5811716 1 Pad, Rubber
7 7555721 3 Washer 26 - - - - - - - 1 Asm., Gearcase, Rear (See Rear
8 7542703 3 Nut, FLEXLOC Housing Pg. C11 for Details)
9 5411532 2 Cap, Swing Arm Pivot 27 5411531 1 O-Ring
10 5131863 2 Nut 28 5131930 1 Collar, Rear Axle
11 5131864 2 Pivot, Threaded 29 5411707 1 O-Ring
12 3610072 2 Seal, Swing Arm Pivot 30 7072533 1 Decal - Hitch
13 3554506 2 Bearing, Tapered Roller Cone 31 7661913 1 Pin
14 3554507 2 Bearing, Tapered Roller Cup 32 1012740-067 1 Tube, Axle, LH
15 5411602 2 Seal, Swing Arm Pivot 33 7515481 3 Screw
16 1541323 1 Asm., Swing Arm (Incl. 14,15) 34 7710471 1 Ring, Retaining
17 5132201 1 Coupling, Prop Shaft, Greased 35 5132075 1 Spacer, Bearing
7080433 1 Fitting, Lubricating 36 3610071 1 Seal, Axle, Rear
18 5411092 1 O-Ring 37 5211849 1 Disc, Brake
19 1380137 1 Asm., Prop Shaft, Rear 38 5411092 1 O-Ring
20 7553201 8 Washer
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

4
5

7
11

9
10

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

1 7542439 2 Nut, Nylok 7 7041774 1 Shock (If built before 6/21/99)

2 5433213 2 Bushing (If built before 6/21/99) 7041890 1 Shock (If built after 6/21/99)
3 7515415 1 Screw 8 5630921 1 Cam, Adjuster
(For 7041774)(If built before 6/21/99)
4 5132022 1 Tube (If built before 6/21/99) 5630551 1 Cam, Adjuster
5 5241147 1 Retainer, Shock (For 7041890)(If built after 6/21/99)
6 7041777-067 1 Spring 9 5132021 1 Tube
(For 7041774)(If built before 6/21/99) 10 5433212 2 Bushing
7041849-067 1 Spring
(For 7041890)(If built after 6/21/99) 11 7515438 1 Screw
7041815-067 1 Spring (FA)(FB)
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

1 2

4
3

5
1

8 5 6
9

7 7

8
11
9
2

10
2

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

------- 1 Asm., Main Gearcase (See Main 7 7517289 4 Screw

Gearcase Pg. C10 for Details) 8 7552603 4 Washer
1 7515417 2 Screw 9 7515522 4 Bolt
2 7547108 6 Nut 10 5242820-067 1 Mount, Transmission
3 7515398 2 Screw 11 ------- 1 Mount, Engine,Rear
4 7542321 2 Nut (See Engine Mounting Pg. B2, Ref.
5 7555976 3 Washer 18)

6 5242819-067 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

5
7
8

3
4

9
2
1

10

11

12
22

21
20
19
13

18
14
15

16
17

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

1 3083669 1 Bushing, Starter 11 3084838 2 Pin, Straight

2 3080103 2 Pin, Dowel 12 3086397 1 Plug
3 3086394 1 Asm., Crankcase (Incl. 1-5,7,8,12, 13 3084842 1 Union
18,21,22)(If built before 3/1/99) 14 3086400 1 Gasket, Oil Cooler
3086793 1 Asm., Crankcase (Incl. 1-5,7,8,12, 15 3086403 1 Union
18,21,22)(If built after 3/1/99)
4 3086395 1 Bearing, Ball 16 3086402 1 Adapter, Oil Cooler (Incl. 13,15)
5 3084840 2 Pin, Dowel 17 3086401 1 Connector, Oil Cooler
6 3084205 3 Screw and Washer 18 3084841 8 Bolt, Flange
7 3084839 1 Seal, Oil 19 3083453 1 Plug
8 3085850 1 Pipe 20 3082956 1 Gasket
9 3086404 1 Gauge, Oil (If built before 3/1/99) 21 3086398 2 Bolt, Flange
3086794 1 Gauge, Oil (If built after 3/1/99) 22 3086399 1 Bolt, Flange
10 3086405 1 O-Ring
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
6 9 11
7 10
25 8 8
21

12 9
24 22
23
13
14
15
9

14 16
15
20

17

19

18

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

1 3086413 2 Cover, Valve 15 3080530 2 Washer

2 3086414 2 O-Ring 16 3080285 2 Nut
3 3086412 4 Bolt, Flange 17 3084838 2 Pin, Straight
4 3084874 6 Bolt, Flange 18 3086407 1 Gasket, Cylinder
5 3086417 1 Plug, Cylinder Block 19 3086406 1 Cylinder (If built before 3/1/99)
6 3086410 2 Pin, Straight 3086795 1 Cylinder (If built after 3/1/99)
7 3084858 1 Seal, Intake Valve 20 3086415 1 Gasket, Head
21 3086416 1 Gasket, Cam
8 3084994 2 Guide, Valve
22 3086420 1 Adapter
9 3084798 3 Fin Damper A
10 3084859 1 Seal, Exhaust Valve 23 3083166 1 Asm., Adapter Band (Incl. 24)
24 3081497 1 Screw
11 3086418 4 Bolt and Washer
12 3086408 1 Asm., Cylinder Head (Incl. 3,4,6-10, 25 3081330 2 Bolt
12,14,26)(If built before 3/1/99) 26 3086491 1 Cover, Rocker (If built before 3/1/99
3086796 1 Asm., Cylinder Head (Incl. 3,4,6-10, only)
12,14,26)(If built after 3/1/99) 27 3086419 2 Bolt, Flange
13 3086421 1 Gasket, Exhaust
14 3085326 2 Stud
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

4
2

3
4

5 5

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 1 Piston Ring Set (STD) 8 3240168 2 Key, Woodruff

3085775 1 Piston Ring Set (0.25 O/S) 9 3086434 1 Spacer
3085776 1 Piston Ring Set (0.50 O/S) 3086435 1 Spacer
2 3086431 1 Piston Set (STD)(Incl. 3,4) 3086436 1 Spacer
3086432 1 Piston Set (0.25 O/S)(Incl. 3,4) 3086437 1 Spacer
3086433 1 Piston Set (0.50 O/S)(Incl. 3,4)(If built 10 3086492 1 Sprocket 1
before 3/1/99 use above Set) 11 3085528 1 Nut
3086800 1 Piston Set (STD)(Incl. 3,4)(If built after
3/1/99 use Set below) 12 3083904 1 Washer
3086801 1 Piston Set (0.25 O/S)(Incl. 3,4) 13 3083905 1 Nut
3086802 1 Piston Set (0.50 O/S)(Incl. 3,4) 14 3086427 2 Bearing (STD)
3 3086846 1 Pin, Piston 3086798 2 Bearing (0.05 U/S)(If built after 3/1/99)
4 3084167 2 Clip 3086799 2 Bearing (0.25 U/S)(If built after 3/1/99)
5 3086425 2 Bolt 15 3086426 2 Nut
6 3086424 1 Asm., Connecting Rod (Incl. 5,15) 16 3085815 2 Bearing, Ball
7 3086422 1 Crankshaft, Complete (Incl. 16)
3086423 1 Crankshaft (If built before 3/1/99)
3086797 1 Crankshaft (If built after 3/1/99)
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

1 3
2 4
1
2

5 6
6 7 10
7 9
8
11
8
12

19 18
17

20

21
22
16

13
23
14
24

15

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

1 3084911 2 Screw, Adjusting 12 3084899 1 Pin, Dowel

2 3084912 2 Nut 13 3085778 1 Valve, Intake
3 3084910 2 Asm., Rocker Arm (Incl. 1,2) 14 3086441 1 Valve, Exhaust
4 3086442 1 Shaft, Rocker 15 3086445 1 Guide, Chain
5 3085836 1 Washer 16 3086444 1 Chain, Timing
6 3084908 4 Collet, Valve 17 3086448 1 Gasket, Tensioner
7 3084907 2 Retainer, Spring 18 3086493 1 Tensioner
8 3084906 2 Spring, Valve 19 3083361 2 Bolt, Flange
9 3086439 1 Lever, Release 20 3086443 1 Sprocket 2
10 3086440 1 Spring, Return (If built before 3/1/99) 21 3083663 1 Washer
3086804 1 Spring, Return (If built after 3/1/99) 22 3086449 1 Bolt, Flange
11 3086438 1 Camshaft (Incl. 9,10,12)(If built before 23 3086446 1 Lever
3/1/99)
3086803 1 Camshaft (Incl. 9,10,12)(If built after 24 3084924 1 Bolt, Pivot
3/1/99)
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

5
4
3
1 2
6

7
8

15

11
10

12
14

8 13
7

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

1 3084822 1 Reel 9 3083669 1 Bushing, Starter

2 3083463 1 Spring, Return 10 3083185 1 Spring, Spiral
3 3083378 1 Ratchet 11 3084750 1 Bushing
4 3083379 1 Spring, Friction 12 3084933 1 Gasket, Recoil
5 3084744 1 Plate, Friction 13 3084877 9 Bolt, Flange
6 3085266 1 Bolt and Washer 14 3085856 1 Asm., Recoil (Incl. 1-6,9-11,14,15)
7 3083453 2 Plug 3085943 1 Starter Case (Incl. 11)
8 3082956 2 Gasket 15 3085083 1 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

6
11

10
9

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

1 3083453 1 Plug 7 3084963 1 Filter, Oil

2 3082956 1 Gasket 8 3086451 5 Screw (If built before 3/1/99)
3 3086455 1 Spring 3086805 5 Screw (If built after 3/1/99)
4 3086222 1 Valve, Relief 9 3086450 1 Cover, Oil Pump
5 3083568 1 Bolt, Flange 10 3086452 1 Rotor, Inner
6 3086454 1 Strainer, Oil 11 3086453 1 Rotor, Outer
3087015 1 Strainer, Oil (For Engine Serial Num-
bers 35878-39057 Only)
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

6 7
8
44
45
46
47
9 49 42
48 43
41

10 40
11
39

37
12 36 38
13 12
14
15 35
26
34
27
16 25 33
28
29
24 32
30
31

17
23 22

18

21

20

19

D9
 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 1 Ring 28 3130523 1 Washer

2 3130508 1 E-Ring 29 3130525 1 Spring
3 3130730 1 Needle, Jet 30 3131131 1 Adjuster
4 3130752 1 Ring 31 3130905 1 Plug (If built before 3/1/99 only)
5 3130732 1 Diaphragm 32 3130546 1 Screw, Adjust
6 3131130 1 Jet, Needle (P-0M) 33 3130545 1 Ring
7 3130541 2 Screw 34 3130544 1 Spring
8 3130540 2 Washer, Spring 35 3131126 1 Valve, Throttle (120)
9 3131128 1 Asm., Jet Block 36 3130589 1 Spring
10 3130014 1 Washer 37 3130514 1 Ring
11 3130566 1 Jet, Main (#142.5)(If built before 38 3130501 2 Screw
3130567 1 3/1/99) 39 3130513 1 Asm., Throttle Shaft
Jet, Main (#145)(If built after 3/1/99) 40 3130543 1 Guide, Cable
12 3130515 2 Seal 41 3130535 4 Screw
13 3130517 1 Packing 42 3130511 1 Cover
14 3130518 1 E-Ring 43 3130512 1 O-Ring
15 3130519 1 Cap 44 3130199 1 Holder, Guide
16 3130361 1 Pin, Float 45 3130538 1 Spring
17 3130594 1 Plate 46 3130593 1 Asm., Plunger
18 3130532 1 O-Ring 47 3131133 1 Jet, Air (#175)
19 3130520 4 Screw 48 3131125 1 Asm., Carburetor (Incl. 1-39,44-52)
20 3130590 1 Asm., Float Body (If built before 3/1/99)
21 3130521 1 Screw 3131147 1 Asm., Carburetor (Incl. 1-39,44-52)
22 3130529 1 Asm., Float (If built after 3/1/99)
23 3130591 2 Screw 49 3084205 2 Screw and Washer
24 3130531 1 Valve, Needle (1.5) 50 3131129 1 Spring
25 3130533 1 O-Ring 51 3131127 1 Asm., Cover
26 3131132 1 Jet, Pilot (#50) 52 3130592 4 Screw
27 3130522 1 O-Ring
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

10
9
11 4
12
13 6

14
7
8

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

1 3086483 1 Asm., Ignition Coil (Incl. 1,2) 7 3081657 5 Bolt and Washer
3086484 1 Ignition Coil (If built before 3/1/99) 8 3084973 1 Seal, Oil
3086807 1 Ignition Coil (If built after 3/1/99)
9 3081256 1 Screw and Washer
2 3086463 1 Cap, Spark Plug (If built before 3/1/99 only)
3 3084997 1 Plug, Spark 10 3086464 1 CDI System
4 3084978 1 O-Ring 11 3083073 2 Nut
5 3086460 1 Bearing, Dry 12 3080077 2 Washer, Spring
6 3086458 1 Asm., Plate (Incl. 5,8)(Incl. 9 if built 13 3085521 1 Switch, Magnetic
before 3/1/99 only) 14 3086457 1 Flywheel w/Ring Gear
6/99
D11
 STARTING MOTOR
MAGNUM 325 4X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB

3
5

1
2
6
7

11

8
11

12

13
10
14
9

15

17
16

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

3084981 1 Motor, Starting (Incl. 1-5,7-11) 9 3240114 1 O-Ring

1 3084982 1 Washer Set 10 3084983 2 Asm., Set Bolt (Incl. 5)
2 3085353 1 Armature 11 3084405 2 Ring, Rubber
3 3084406 1 Brush, Carbon 12 3083737 1 Washer, Gear Shaft
4 3083649 2 Nut, Flange 13 3084412 1 Clip
5 3084408 3 O-Ring 14 3084411 1 Spring, Weight
6 3082038 2 Bolt and Washer 15 3084410 1 Spring, Return
7 3085034 1 Bracket, Rear 16 3084409 1 Clip
8 3085033 1 Asm., Front Bracket (Incl. 9) 17 3085394 1 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

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

3085275 1 Asm., Fuel Pump (Incl. 1-4) 3 3084591 4 Screw

1 3084999 1 Screw and Washer 4 3084998 1 Diaphragm Gasket Set
2 3085000 2 Screw and Washer
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

6
5
2 4
5
3

1 7
16 13
8
15

17
14

18
5

7 14

9
23

5
19

22
20
21 13
12

10

11

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

1 3085850 1 Pipe 11 3082719 2 Gasket

2 3086481 3 Bolt, Flange 12 3086496 1 Pipe 2
3 3086486 1 Asm., Breather Box (Incl. 4,16-20, 13 3083418 2 Clamp, Hose
21-23)(If built before 3/1/99) 14 3084823 3 Band, Wire (Use 2 if built after 3/1/99)
3086808 1 Asm., Breather Box (Incl. 4,16-20,
21-23)(If built after 3/1/99) 15 3086809 1 Pipe 2, Rubber
3086487 1 Box, Breather (Incl. 1,4,16) 16 3083798 1 Pipe, Pulse
4 3085525 1 Pipe, Air Breather 17 3086470 1 Gasket, Breather Plate
5 3084085 4 Clamp 18 3086468 1 Plate, Breather
6 3086476 1 Pipe 1, Rubber 19 3086494 1 Bracket 1
7 3083568 4 Bolt, Flange (Use 3 if built after 20 3083361 1 Bolt, Flange
3/1/99) 21 3081180 4 Screw
8 3086495 1 Pipe 1 22 3086467 1 Plate, Breather Box
9 3086478 1 Pipe 3, Rubber 23 3086469 1 Gasket, Plate
10 3086482 1 Bolt, Banjo
3/99
D14
 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
4

10
6

11
7

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

3086485 1 Kit - Tool (Incl. 2-7) 7 2682572 1 Pouch, Tool Kit

1 2870725 1 Gauge, Tire Pressure 8 2871515 1 Lube, U-Joint, 3 oz., Case
2 3085001 1 Wrench, Open 8-10mm 9 9915299 1 Owner’s Manual, ‘00 ATV
3 3085002 1 Wrench, Open 12-14mm 9914939 1 Supplement, Owner’s Manual, ’00
4 3085567 1 Wrench, Box Magnum 325 4x4
5 3085569 1 Puller, Spark Plug (Wrench Handle) 10 2871095-067 1 Wrench, Spanner, Cam
6 3082657 1 Screwdriver 11 2460442 1 Pigtail, Power

2/00

E1
PRINTED IN THE USA PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3/00
Changed pages in 9914940
1 2 3 4 5 6 7 8 9 10 11 12 13 14

A cover toc

C x x

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