Polaris 325 MAGNUM 4X4 HDS A00CD32FA Parts Manual Download Page 18

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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

Ref. Part No.

Qty.

Description

Ref. Part No.

Qty.

Description

1 1380119

2 Asm., CV Housing w/Sleeve

2 5222299

1 Sleeve, Drive Shaft Seal

3 3260115

1 Clamp, CV Joint, Large

4 7670091

1 Circlip

5 5411106

1 Boot, CV Joint

6 1380094

1 Shaft Replacement (Incl. 4)

7 1380092

1 Cardan Replacement (Incl. 4,6,8,9)

8 2200771

1 Kit - Cross and Bearing

9 3260130

1 Yoke, Splined

10 7661913

1 Pin, Spring

11 7080627

1 Clamp, Small Band

12 2200773

1 Kit - Boot Replacement, CV Joint

(Incl. 3,5,11)

13 2200961

1 Kit - Drive Shaft w/Sleeve

11/98

Summary of Contents for 325 MAGNUM 4X4 HDS A00CD32FA

Page 1: ...TS MANUAL PN 9914940 and MICROFICHE PN 9916574 3 00 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...

Page 2: ...C8 FRONT RACK and BUMPER MOUNTING A9 FRONT STRUT B6 FRONT WHEEL B7 FUEL PUMP D13 FUEL TANK A14 G GEAR SELECTOR C12 G GEARCASE SELECTOR MOUNTING C13 H HANDLEBAR B12 I INTAKE and EXHAUST D6 M MAGNETO D...

Page 3: ...r Titan 24x8 12 24x11 5 10 N A 4 3 N A ENGINE Engine Model Number Engine Type Lubrication Type Bore Stroke mm Displacement cc s Compression Ratio Cooling Alternator Output watts Elec Start w Recoil Ba...

Page 4: ...OFICHE ASSEMBLY INSTRUCTIONS Magnum 325 4X4 A00CD32AA 9915299 9914939 9914940 9916574 9914942 Magnum 325 4X4 A00CD32CA 9915299 9914939 9914940 9916574 9914942 325 Magnum 325 4X4 HDS A00CD32FA 9915299...

Page 5: ...AGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 28 27 2 7 3 6 9 10 14 13 15 16 17 42 41 12 19 20 21 36 5 33 44 45 1 43 39 11 4 40 18 3 35 37 34 8 30 26 38...

Page 6: ...e Small 18 5410414 8 Bumper Rubber 19 7517599 2 Screw and Washer 20 5431787 1 Cover Tool Box 21 5410896 1 Cap Drain 22 5243188 067 1 Guard Clutch 23 7661637 4 Rivet 24 7621509 2 Rivet 25 5243829 067 1...

Page 7: ...f built before 3 20 00 Asm Panel w Foam LH E B Green If built after 3 20 00 Asm Panel w Foil RH E B Green 2 7512232 12 Screw 3 5432088 195 1 Cover Front E B Green 4 7670085 2 Clip Spring 5 2632144 195...

Page 8: ...cription Ref Part No Qty Description 1 7517685 2 Screw 2 7517686 4 Screw 3 2670174 1 Asm Rack Rear Incl Ref 4 and Warning Decal 4 2670070 2 Reflector Red 5 1040490 067 1 Support Rear Rack 6 7542324 8...

Page 9: ...211 067 1 1 1 1 Support Front Rack LH If built before 11 15 99 Support Front Rack RH If built before 11 15 99 Support Front Rack LH If built after 11 15 99 Support Front Rack RH If built after 11 15 9...

Page 10: ...35 1 Decal Warning AWD Switch 7 7078315 7078465 1 1 Logo 45th Anniversary If built before 1 01 00 Logo Polaris Star If built after 1 01 00 8 7074220 1 Decal Macpherson Strut 9 7078354 1 Decal Discreti...

Page 11: ...Mount Rubber 3 5242924 067 2 Bracket Cooling Fan 4 7542122 10 Nut Nylok 5 7080474 2 Clamp Hose 6 5411813 1 Hose Cooler Inlet 7 7670111 4 U Clip 8 5433353 1 Shroud Fan 9 4010274 1 Thermister 10 751515...

Page 12: ...7080474 2 Clamp Hose 2 5411813 1 Hose Inlet 3 7542122 4 Nut 4 5243783 067 1 Bracket Top 5 7080869 1 Clamp Rubber Coated 6 7515158 8 Screw 7 7517659 4 Screw 8 2410157 1 Motor Fan 9 7670111 4 U Clip 10...

Page 13: ...790 1 1 Dampener Vib If built before 7 01 99 Dampener Vib If built after 7 01 99 7 7515316 7515339 7515394 1 1 1 Bolt Carriage If built before 7 01 99 Bolt If built after 7 01 99 Screw Carriage If bui...

Page 14: ...Washer 8 7558301 2 Washer 9 5222154 067 5222155 067 1 1 Bracket Mounting Rear LH Bracket Mounting Rear RH 10 5811796 1 Foam Intake Splash 11 5332457 5333936 2 2 Spacer If built before 1 17 00 Spacer...

Page 15: ...CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 34 21 30 12 24 8 15 2 33 16 17 1 32 26 27 28 29 18 4 36 3 37 11 10 23 6 35 9 7 22 13 32 32 33 3...

Page 16: ...nt 9 7552901 2 Washer 10 7512315 2 Bolt 11 7512232 1 Screw 12 4010132 1 Cable Ground Engine 13 7555823 1 Washer 14 3110068 1 Mount Rubber Rear 15 5411721 1 Boot Clutch Intake 16 7080511 1 Clamp Narrow...

Page 17: ...5433396 1 Cap End 9 7080699 2 Clamp Hose 10 5830128 1 Gasket Duct 11 5433180 1 Duct Carburetor Inlet 12 7080413 2 Clamp 13 5411588 1 Boot Carb 14 7080511 1 Clamp 15 7080694 1 Clamp Hose 16 5411746 541...

Page 18: ...19 2 Asm CV Housing w Sleeve 2 5222299 1 Sleeve Drive Shaft Seal 3 3260115 1 Clamp CV Joint Large 4 7670091 1 Circlip 5 5411106 1 Boot CV Joint 6 1380094 1 Shaft Replacement Incl 4 7 1380092 1 Cardan...

Page 19: ...325 MAGNUM 4X4 HDS II A00CD32FB 1 2 3 4 5 6 Ref Part No Qty Description Ref Part No Qty Description 1380138 1 Asm Prop Shaft Incl 1 4 1 3260133 1 Yoke Gear Case Front 2 3260104 2 Kit Cross and Bearin...

Page 20: ...ng Wire 9 1 Asm Front Brake Caliper RH See Front Brake Pg B8 for Details 10 3554509 4 Bearing Tapered Roller 11 3554507 4 Bearing Tapered Roller Cup 12 5222193 2 Sleeve Hubstrut Seal 13 7080306 2 Fitt...

Page 21: ...ture 5 1520281 2 Clutch Front Hub Elec Mech 6 3554506 4 Bearing Tapered Roller Cone 7 3554507 4 Bearing Tapered Roller Cup 8 7515523 8 Stud 9 1520243 2 Asm Hub w Bearing Race Incl 3 7 8 10 3250028 2 C...

Page 22: ...t Set 3 5131115 5131116 1930642 1 1 1 Caliper Brake LH Caliper Brake RH Kit Front Brake Boot 4 1930665 1 Kit Piston and Insulator Seal Incl 5 7 5 5410779 1 Ring Molded Square 094 6 5410780 1 Ring Mold...

Page 23: ...ription Ref Part No Qty Description 1 5432721 5433806 1 1 Cover Throttle Control If built before 11 22 99 Cover Throttle Control If built after 11 22 99 2 5410193 1 O Ring 3 5411439 1 O Ring 4 7080709...

Page 24: ...930799 1 Asm Master Cylinder Piston 6 1930804 1 Rivet 7 2201034 1 Kit Brake Lever w Parking Latch Incl 6 9 8 1 Spring Flat 9 2201090 1 Kit Park Brake Lever Incl 6 8 10 1930806 1 Nut 11 1930792 2 Bolt...

Page 25: ...f built before 7 12 99 Bushing Console If built after 7 12 99 3 7080424 1 Fitting Lubrication 4 7515321 2 Bolt 5 7555878 3 Washer 6 5410772 2 O Ring 7 5431571 1 Spacer Steering Post 8 7543203 1 Nut 9...

Page 26: ...1 Plug Hole 12 7517625 1 Screw 13 5224715 067 1 Tube Handlebar 14 5132382 1 Cap Hall Sensor FA FB 15 4010298 1 Sensor Hall Effect FA FB 16 7517658 1 Screw FA FB 17 5630629 4 Block Handlebar 18 7542122...

Page 27: ...d End LH If Built before 8 16 99 Rod End LH If Built after 8 16 99 10 5411920 1 Boot Seal Rod End 11 7517674 2 Bolt If Built after 8 16 99 12 7555806 7556099 4 4 Washer Flat If Built before 8 16 99 Wa...

Page 28: ...her Multilube 4 1321457 3 Roller and Bushing 5 5431936 6 Button Clutch 6 5210752 5242981 5210753 5210754 AR AR AR AR Spacer 020 Spacer 025 Spacer 032 Spacer 050 7 5630279 3 Weight Shift 16 8 7512266 3...

Page 29: ...1 Spacer 4 7541906 3 Nut FLEXLOC 5 5431936 6 Button Clutch Stemless 6 5020422 3 Pin Roller 7 3585712 1 Bearing 8 7547130 1 Nut Jam 9 3576510 1 Cover Bearing 10 7552801 Washer Spring Lock 11 7512176 6...

Page 30: ...A CA 6 3211077 1 Belt Drive 7 5430766 3 Button Ramp 8 7511854 3 Bolt 9 7710448 1 Ring Retaining 10 5210752 1 Spacer 11 5132344 5131447 1 1 Ramp Stationary If built before 4 01 00 Ramp Stationary If bu...

Page 31: ...2 13 99 Cover Clutch Outer If built before 1 03 00 Cover Clutch Outer If built after 1 03 00 10 7670051 1 Clip Clutch Cover 11 7512093 7512094 5 5 Screw If built before 1 03 00 Screw If built after 1...

Page 32: ...4030043 1 Bulb Taillight 8 4032045 1 Gasket Taillight 9 4032064 1 Backing Taillight Brake Light 10 7670054 2 Nut Speed 11 7541925 4 Nut Nylok 12 7571602 4 Washer 13 7512027 2 Screw 14 5810290 3 Pad Ba...

Page 33: ...X4 A00CD32AA and MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 29 3 25 11 24 9 28 8 7 10 12 27 18 1 6 5 17 13 20 23 2 4 30 16 19 5 7 13 5 18 17 24 27 22...

Page 34: ...iper DH2P Rear Kit Caliper Seal 5 5410988 6 Seal 6 1910286 1 Line Brake Front Hand 7 1910288 1 Line Brake Rear Foot 8 7080573 1 Clamp 9 7517386 2 Screw 10 7080762 3 Clip Brake Line 11 7661048 2 Rivet...

Page 35: ...11 1 12 4 8 2 3 5 9 Ref Part No Qty Description Ref Part No Qty Description 1 7661404 2 Pin Cotter 2 7542714 8 Nut 3 5131777 2 Hub Wheel Rear 4 7512673 8 Bolt 5 7670081 8 Pushnut 6 5411710 2 Tire 24x1...

Page 36: ...ew 3 3233573 1 Cover Gearcase 4 3233588 1 O Ring 5 3233574 1 Nut 6 3233589 1 Bearing Ball 7 3233590 1 Shaft Input Front Housing 8 3233591 1 Bushing 9 7080756 1 Clip 10 8450003 1525 AR Line Vent 11 323...

Page 37: ...UM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 44 50 5 49 53 10 11 18 52 12 13 14 16 15 61 62 59 63 56 57 22 24 27 30 31 47 35 8 7 19 64 32 33 34 2 55 5 66 17 60 54 4 9 17 51 4 1 21 20 26 25...

Page 38: ...1 1 Gear AA CA FB Gear 36T FA 27 3233103 2 Bearing Needle 28 3233602 1 Fork Shift H R 29 3233598 3233761 1 1 Shaft Reverse AA CA FB Shaft Reverse FA 30 3233012 2 Washer Thrust 31 3233014 1 Bearing Ne...

Page 39: ...6 3233587 1 O Ring 7 3233581 1 Shim 8 3233268 2 Bearing Ball 9 3233580 1 Shaft Rear Axle 10 3233579 3233740 1 1 Gear Bevel 31T Rear For Gearcase 1341254 and 1341309 Gear Bevel 31T Rear For Gearcase 13...

Page 40: ...1 16 FA 1 3233195 3233767 1 1 Asm Knob AA CA FB Asm Knob FA 2 7512024 1 Screw 3 3233649 4 Screw 4 3233131 1 Strap Wire 5 3233648 1 Cover Gear Selector Boot 6 3233658 3233766 1 1 Handle Gear Selector A...

Page 41: ...3 5 7 13 2 2 6 6 2 9 10 8 Ref Part No Qty Description Ref Part No Qty Description 1 7061013 2 Rod End LH 2 7546707 4 Nut FLEXLOC 3 7546702 2 Nut LH 4 5020974 1 Rod Low 5 7546701 2 Nut 6 7061014 2 Rod...

Page 42: ...72 2 Seal Swing Arm Pivot 13 3554506 2 Bearing Tapered Roller Cone 14 3554507 2 Bearing Tapered Roller Cup 15 5411602 2 Seal Swing Arm Pivot 16 1541323 1 Asm Swing Arm Incl 14 15 17 5132201 7080433 1...

Page 43: ...3 7515415 1 Screw 4 5132022 1 Tube If built before 6 21 99 5 5241147 1 Retainer Shock 6 7041777 067 7041849 067 7041815 067 1 1 1 Spring For 7041774 If built before 6 21 99 Spring For 7041890 If built...

Page 44: ...f Part No Qty Description Ref Part No Qty Description 1 Asm Main Gearcase See Main Gearcase Pg C10 for Details 1 7515417 2 Screw 2 7547108 6 Nut 3 7515398 2 Screw 4 7542321 2 Nut 5 7555976 3 Washer 6...

Page 45: ...Crankcase Incl 1 5 7 8 12 18 21 22 If built after 3 1 99 4 3086395 1 Bearing Ball 5 3084840 2 Pin Dowel 6 3084205 3 Screw and Washer 7 3084839 1 Seal Oil 8 3085850 1 Pipe 9 3086404 3086794 1 1 Gauge...

Page 46: ...3084798 3 Fin Damper A 10 3084859 1 Seal Exhaust Valve 11 3086418 4 Bolt and Washer 12 3086408 3086796 1 1 Asm Cylinder Head Incl 3 4 6 10 12 14 26 If built before 3 1 99 Asm Cylinder Head Incl 3 4 6...

Page 47: ...ore 3 1 99 use above Set Piston Set STD Incl 3 4 If built after 3 1 99 use Set below Piston Set 0 25 O S Incl 3 4 Piston Set 0 50 O S Incl 3 4 3 3086846 1 Pin Piston 4 3084167 2 Clip 5 3086425 2 Bolt...

Page 48: ...Valve 7 3084907 2 Retainer Spring 8 3084906 2 Spring Valve 9 3086439 1 Lever Release 10 3086440 3086804 1 1 Spring Return If built before 3 1 99 Spring Return If built after 3 1 99 11 3086438 3086803...

Page 49: ...y Description 1 3084822 1 Reel 2 3083463 1 Spring Return 3 3083378 1 Ratchet 4 3083379 1 Spring Friction 5 3084744 1 Plate Friction 6 3085266 1 Bolt and Washer 7 3083453 2 Plug 8 3082956 2 Gasket 9 30...

Page 50: ...Part No Qty Description 1 3083453 1 Plug 2 3082956 1 Gasket 3 3086455 1 Spring 4 3086222 1 Valve Relief 5 3083568 1 Bolt Flange 6 3086454 3087015 1 1 Strainer Oil Strainer Oil For Engine Serial Num b...

Page 51: ...MAGNUM 325 4X4 A00CD32CA and 325 MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 48 38 35 9 51 5 50 1 2 4 6 42 43 39 37 12 36 13 12 14 15 21 19 27 30 29 26 11 10 3 22 20 16 24 18 25 41 23...

Page 52: ...1 Asm Float Body 21 3130521 1 Screw 22 3130529 1 Asm Float 23 3130591 2 Screw 24 3130531 1 Valve Needle 1 5 25 3130533 1 O Ring 26 3131132 1 Jet Pilot 50 27 3130522 1 O Ring 28 3130523 1 Washer 29 31...

Page 53: ...l 1 2 Ignition Coil If built before 3 1 99 Ignition Coil If built after 3 1 99 2 3086463 1 Cap Spark Plug 3 3084997 1 Plug Spark 4 3084978 1 O Ring 5 3086460 1 Bearing Dry 6 3086458 1 Asm Plate Incl 5...

Page 54: ...rting Incl 1 5 7 11 1 3084982 1 Washer Set 2 3085353 1 Armature 3 3084406 1 Brush Carbon 4 3083649 2 Nut Flange 5 3084408 3 O Ring 6 3082038 2 Bolt and Washer 7 3085034 1 Bracket Rear 8 3085033 1 Asm...

Page 55: ...MAGNUM 4X4 HDS A00CD32FA and 325 MAGNUM 4X4 HDS II A00CD32FB 4 1 3 2 2 4 Ref Part No Qty Description Ref Part No Qty Description 3085275 1 Asm Fuel Pump Incl 1 4 1 3084999 1 Screw and Washer 2 3085000...

Page 56: ...Incl 4 16 20 21 23 If built after 3 1 99 Box Breather Incl 1 4 16 4 3085525 1 Pipe Air Breather 5 3084085 4 Clamp 6 3086476 1 Pipe 1 Rubber 7 3083568 4 Bolt Flange Use 3 if built after 3 1 99 8 308649...

Page 57: ...1 Kit Tool Incl 2 7 1 2870725 1 Gauge Tire Pressure 2 3085001 1 Wrench Open 8 10mm 3 3085002 1 Wrench Open 12 14mm 4 3085567 1 Wrench Box 5 3085569 1 Puller Spark Plug Wrench Handle 6 3082657 1 Screwd...

Page 58: ...PRINTED IN THE USA PARTS MANUAL PN 9914940 and MICROFICHE PN 9916574 3 00...

Page 59: ...Changed pages in 9914940 1 2 3 4 5 6 7 8 9 10 11 12 13 14 A cover toc B C x x D E F G 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

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Polaris 325 MAGNUM 4X4 HDS A00CD32FA, Parts Manual

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