MAGNUM 325 2X4 Model #A00CB32AA Model #A00CB32CA Rev. 01

Transcription

1 MAGNUM X Model #A00CBAA Model #A00CBCA Rev. 0 PARTS MANUAL PN and MICROFICHE PN /

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3 TABLE OF CONTENTS Magnum x A00CBAA and Magnum x A00CBCA Parts Manual A A-ARM/STRUT MOUNTING B A A-ARM/STRUT MOUNTING B AIR BOX B B BREATHER BOX D C CARBURETOR D- CLUTCH COVER B CONTROLS - MASTER CYLINDER/BRAKE LINE B CONTROLS - THROTTLE ASM./CABLE..... B CRANKCASE C CRANKSHAFT and PISTON C CYLINDER C D DECALS A0 DRIVE CLUTCH B DRIVEN CLUTCH B E ELECTRICAL/TAILLIGHT B ENGINE MOUNTING A EXHAUST SYSTEM A F FRONT BRAKE B FRONT CAB A FRONT RACK and BUMPER MOUNTING.... A FRONT WHEEL B FUEL PUMP D FUEL TANK B G GEAR SELECTOR C GEARCASE SELECTOR MOUNTING C H HANDLEBAR B0 I INTAKE and EXHAUST D M MAGNETO D MAIN GEARCASE C MAIN GEARCASE C O OIL COOLING A OIL PUMP and OIL FILTER D P PART NUMBER INDEX D-E R REAR BRAKE C- REAR CAB and SEAT A- REAR HOUSING C REAR RACK MOUNTING A REAR WHEEL DRIVE C RECOIL STARTER D S SHOCK MOUNTING C0 STARTING MOTOR D STEERING POST B STRUT B SWING ARM/REAR GEARCASE MOUNTING. C T TOOL KIT D0 TRANSMISSION MOUNTING C The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

4 Type - Front Type - Rear Type - Auxiliary Type - Parking BRAKES CAPACITIES Fuel Tank (gallon) Gearcase Oil (ounces) Engine Oil (quarts) 0W0 Engine Counter Balance Oil (quarts) Injector Rack, Front (pounds) Rack, Rear (pounds) Tongue Weight Tow Hitch Tow Weight Type DRIVE TRAIN DRIVE CLUTCH Drive System Type Center Distance (inches) Clutch Offset (inches) Clutch Weight (grams) Spring Color DRIVEN CLUTCH Helix Angle Outside Diameter (inches) Spring Position DIMENSIONAL FEATURES Approx. Turning Radius (inches) Box, Tool Volume (Cu. Inches) Box Dimensions (inches) Ground Clearance (inches) Height (inches) Length (inches) Seat Height (inches) Weight (dry) Wheel Base (inches) Width (inches) GEARCASE Trans. Number and Type Shift Type Gear Reduction - Low Gear Reduction - Reverse Gear Reduction - High Front Drive (ratio) Final Drive (ratio) Center Drive (ratio) Axle to Axle Chain Type TIRES & WHEELS Tire Manufacturer Tire Size - Front Tire Size - Rear Tire Size - Center Tire Pressure - Front Tire Pressure - Rear Tire Pressure - Center 000 MAGNUM x SPECIFICATIONS ENGINE Hydraulic Disc Hydraulic Disc Hydraulic Disc Hydraulic Lock, All Wheel. 00 (ml). N/A N/A Standard 0 Shaft Ride System PVT 0 / Blue/Green Compound. Black - N/A.. PRD Side Lever./././ N/A./ N/A N/A N/A Titan x- x.-0 N/A N/A Engine Model Number Engine Type Lubrication Type Bore & Stroke (mm) Displacement (cc s) Compression Ratio Cooling Alternator Output (watts) Elec. Start w/recoil Back Up Carburetors (no. of/size) Main Jet Pilot Jet Needle Jet Cut Away Pilot Screw Jet Needle Ignition Ignition (Type & Deg. BTDC) Spark Plug Gap (inches) Spark Plug (Type) Exhaust GRAPHICS Bumper Caps/Polyprop. Cargo Box or Bed Fender, Front Fender, Rear Footwell Frame/Steel Front Cover Handlebar Cover Headlight/Dash Pod Rack, Front Rack, Rear Rims Seat Vinyl Side Panel Spring, Front Spring, Rear Tank Cover Tool Box Cover w/lettering Color ELECTRICAL Headlight - Handlebar(watts) Headlight - Front Hood (watts) Headlight - Grill (watts) Taillight (watts) Brake Light (watts) Indicator Bulb Battery SUSPENSION Front Type - Front Travel (inches) Rear Type - Rear Travel (inches) Shock Adjustment ESPFE0 Stroke, Single Cylinder Wet Sump x : Air w/fan assisted oil cooler 00 Standard /BST (CV Type). 0 P-0() N/A F- CDI 0@00.0 NGKBKRE USFS Appr. Pending N/A N/A Bonnie Blue Bonnie Blue Black Black Bonnie Blue Black Black Black Black Aluminum Steel Gray Bonnie Blue Bonnie Blue Bonnie Blue N/A N/A N/A N/A Single Beam 0 W V/. W V/. W V/.0 W V/ AH MacPherson Strut. Progressive Rate Swing Arm. Gas Charged Monotube Cam Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its products without notice.

5 000 ATV PUBLICATION NUMBERS MODEL MODEL NO. OWNER S MANUAL Magnum X A00CBAA A00CBCA OWNER S MANUAL SUPPLEMENT PARTS MANUAL PARTS MICROFICHE ASSEMBLY INSTRUCTIONS

6 REAR CAB and SEAT MAGNUM X A00CBAA and MAGNUM X A00CBCA A

7 REAR CAB and SEAT MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 0 Rivet 0 Bolt Washer 0 Foil, Rear Cab, Rear - Cab, Rear, Bonnie Blue Nut, Nylok Retainer, Seat Latch 0 Foil, Tape, Rear Cab Screw 0 Washer 0 Screw Box, Tool 0 Rivet 0 Bracket, Lever Retainer 00 Latch, Seat 00 Spring, Latch Seat, Steel Gray Covering, Seat, Steel Gray Foil, Seat Base, Large Foil, Seat Base, Small 0 Bumper, Rubber Bolt and Washer 0 Cover, Tool Box 0 Cap, Drain -0 Guard, Clutch Rivet Rivet -0 Strap, Fuel Pump Guard, Rock 0 Washer Screw 0 Washer 0 Nut Mount, Rubber Screw 0-0 Frame, Main Footwell, LH, Black Footwell, RH, Black Foil, Foam, Rear Fender 0 Foil, Rear Cab, Front 0 Decal - Carb Information 0 Decal - Filter Element 0 Foil, Foam 0 00 Nut, U-Type Speed Guard, Mud, Rear, LH Guard, Mud, Rear, RH / A

8 FRONT CAB MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0-0- Asm., Panel w/foam, LH Asm., Panel w/foil, RH Screw 0- Cover, Front, Bonnie Blue 00 Clip, Spring 0- Cab, Front, Bonnie Blue w/warning Decals 00 0 Nut, U-Type Speed 000 Nut, Push-on Rivet Guard, Mud, Front, LH Guard, Mud, Front, RH 0 Nut, Nylok Washer 0 Screw Washer Nut, Nylok 00 Clip, Dart Shield, Deflector / A

9 REAR RACK MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Screw 0 Asm., Rack, Rear (Incl. Ref. and Warning Decal) 000 Reflector, Red Support, Rear Rack Nut 00 Nut, Chimney Bolt Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH 0 0 Washer -0 Spacer Screw / A

10 FRONT RACK and BUMPER MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 00 Reflector, Amber 00 Asm., Front Rack (Incl. Reflector & Decal) Screw Screw 00 Mount, Front Rack 00-0 Support, Front Rack, LH -00 Panel, Grill Screw -00 Bumper, Front 0 Screw 00-0 Bumper Mount 0 Screw Nut, Nylok 00-0 Support, Front Rack, RH Support, Front Rack, LH Support, Front Rack, RH Screw Bolt 0 Washer 0 Headlight, 0/0 Watt, LH 0 Headlight, 0/0 Watt, RH 000 Bulb, 0/0 Watt Replacement Extension, Frame, RH Extension, Frame, LH 0 Plug, Frame Nut, Nylok 00-0 Brushguard 0 Nut, U-Type -0 Grill, Front Bumper 0 Nut Screw Shroud, LH Shroud, RH Screw 0-0 Hitch, U-Bolt -0 Plate, Back Mount Screw A /

11 DECALS MAGNUM X A00CBAA and MAGNUM X A00CBCA RH 0 LH Ref. Part Qty. Description Ref. Part Qty. Description 0 Decal - Rack/Warning 00 Decal - Load Distribution, W 0 Decal - x, RH 00 Decal - POLARIS Side Panel 00 Decal - Tank Side, RH 0 Logo, th Anniversary 00 Decal -, Stroke, Front Cover 0 Decal - Discretionary Warning, ATV 0 Decal - Drain Recoil 0 00 Decal - CE Regulation 0 Decal - Override Switch, AWD 00 Decal - Tank Side, LH 0 Decal - Age Warning, ATV 00 Decal - Passenger Warning 00 Decal - Tire Pressure 0 Decal - x, LH 0 Decal - Warning, General, CPSC / A0

12 OIL COOLING MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok 00 Mount, Rubber -0 Bracket, Cooling Fan 0 Washer Hose, Oil Cooler Inlet 0 U-Clip Shroud, Fan Screw 00 Cooler, Oil 0-0 Mount, Oil Cooler 000 Mount, Rubber 0 Motor, Fan Screw 00 Clamp Hose, Oil Cooler Outlet 000 Valve, Thermo Hose, Engine Return 00 Clamp Hose, Valve Inlet Clamp / A

13 EXHAUST SYSTEM MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok Washer 0 Washer, Rubber Washer 00 Bushing 0 Dampener, Vibration Screw 0-0 Silencer Bolt 0 00 Mount, Torque Stop 0 Nut 00 Spring, Exhaust 00 Spring, Exhaust 0-0 Headpipe 00-0 Manifold Seal, Exhaust 0 Spring, Exhaust / A

14 ENGINE MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA A

15 ENGINE MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 000- AR Line, Fuel 00 Fitting, Tee 0-0 Bracket, Carburetor 00 Screw and Washer 0 Nut 0 Washer -0 Bracket, Motor Mount 0 Washer Bolt 0 Screw 00 Cable, Ground Engine Washer 00 Mount, Rubber, Top 0 Decal - Drain Recoil Boot, Clutch Intake 00 Clamp, Narrow Band AR Line, Fuel 00-0 Mount, Engine, Rear Nut 0 Screw 00 Mount, Rubber, Front Washer Screw -0 Mount, Lower Front 0 Bushing 0 Washer 0 Washer Bolt 000 Cable, Battery/Engine 0 00 T-Clip AR Line, Fuel 0000 Clamp, Hose 000 Filter 0 Nut, Nylok 00 Mount, Rubber 0 Washer Screw / A

16 FUEL TANK MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cap, Gas Tank 0 Gasket, Fuel Cap 0 Seal, Foam AR Line, Fuel 0 Vent, Tank Bolt 0 Washer 0 Washer -0-0 Bracket, Mounting, Rear, LH Bracket, Mounting, Rear, RH 0 Spacer 0 Nutsert 0 Pad, Fuel Tank Bracket 0 Screw Knob, Fuel Valve Nut, Fuel Valve 0 Valve, -Way AR Line, Fuel 0000 Clamp, Hose, Red 0 Fitting, Fuel Outlet, Reserve 0 0 Fitting, Fuel Outlet, Main 0 Asm., Fuel Tank (Incl.,,0) / B

17 AIR BOX MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Duct, Inlet Gasket, Intake Cover, Air Box Seal, Cover 0 Screw 0 Washer 00 Clamp Cap, End 0 0 Gasket, Duct 0 Duct, Carburetor Inlet 00 Clamp Boot, Carb 00 Clamp 00 Clamp, Hose Hose, Breather Box, Air Insulator 0 Foil, Air Box 0 Plug 00-0 AR Line, Fuel 000 Clamp, Hose Clip 0 Collar, Carburetor Inlet 00 Filter, Air Intake Filter, Precleaner Sleeve / B

18 FRONT WHEEL MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description Support, Strut & Spindle (See Strut Pg. B, Ref. ) 000 Seal, Front Hub Bearing, Ball Disc, Brake 00 Hub, Wheel 0 Tire (x-) 0- Rim, Front 0 Valve, Rim 00 Spacer, Hub, Front 0 Washer Nut 0 Pin, Cotter 0 Cap, Hub 00 O-Ring Nut Stud Bolt / B

19 FRONT BRAKE MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Front Brake Caliper, LH (Incl. -,0,) 0 Asm., Front Brake Caliper, RH (Incl. -,0,) 00 Screw, Bleeder Screw, Socket Set 0 Caliper, Brake, LH Caliper, Brake, RH Kit - Front Brake Boot 0 Kit - Piston and Insulator Seal (Incl. -) 0 Ring, Molded Square (.0) 00 Ring, Molded Square (.0 x.) 000 Piston, Caliper 00 Insulator, Caliper Mount, Caliper 0 Boot, Bushing 0 Boot, Pin Seal Screw Kit - Front Brake Pad, General Duty Kit - Front Brake Pad, Severe Duty Kit - Front Brake Pad, Soft Duty / B

20 CONTROLS THROTTLE ASM./CABLE MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description Cover, Throttle Control 0 O-Ring O-Ring 000 Cable, Throttle Control 00 Asm., Throttle Control (Incl.,,) 00 Asm., Throttle Clamp /0 B

21 A ARM/STRUT MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut, FLEXLOC Bushing Boot, Seal, Rod End 00 Rod End, RH Nut 00 Tie Rod 0 Nut, LH 00 Rod End, LH 0 Asm., Tie Rod (Incl. -) 0 0 Washer 0 Nut 0 Cotter Pin 0 Bracket, Ball Joint Bolt Nut, Castle 0 Boot, Rubber 00 Ball Joint Asm., Hubstrut (See Strut Pg. B, Ref. ) Bushing, A-Arm, Long 0 00 Bushing 00 Fitting, Lubrication Shaft, A-Arm Bolt 0 Washer, Spring Lock Bolt Kit, A-Frame, LH (Incl. -,,) Kit, A-Frame, RH (Incl. -,,) / B

22 STRUT MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Nut Washer 0 Spacer, Rubber 00 Pivot Ball, Top 00 Pivot Ball, Bottom 0 Spacer Retainer, Spring 0-0 Spring, Coil 0 Bumper B 0 0 Strut, Front 00 Clamp, Rubber Coated 0 Nut, FLEXLOC 0 Washer 000 Fitting, Lubrication Bolt 0 00 Support, Strut & Spindle, LH Support, Strut & Spindle, RH Washer, Spring Retainer /

23 CONTROLS MASTER CYLINDER/BRAKE LINE MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 000 Asm., Master Cylinder (Incl. -) 000 Kit - Master Cylinder Reservoir (Incl. -,) 0 Bolt, Cap 0 Cap, Reservoir 0 Diaphragm 000 Kit - Master Cylinder Clamp 0 Asm., Master Cylinder Piston 00 Rivet 00 Kit - Brake Lever w/parking Latch (Incl. -) Spring, Flat 000 Kit - Park Brake Lever (Incl.,) 0 00 Nut 0 Bolt 00 Bolt Ring, Square, Reservoir Boot, Rubber Brake Line 0 Seal 0 Switch 0 Line, Hand Brake, Front Rivet 00 Clamp, Nylon 0 0 Line, Brake, Left Front w/fittings 0 Screw 0 Line, Brake, Right Front w/fittings 0 Fitting, Cross 0 Line, Brake 0 Bolt, Banjo / B

24 STEERING POST MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Steering Post (Incl.,) Bushing, Console Steering 00 Fitting, Lubrication Bolt Washer 0 O-Ring Spacer, Steering Post 0 Nut B Pin, Cotter 0 0 Bushing, Steering, Lower Rivet Plug, Steering Grease 00 Fitting, Lubrication Bushing, Console Steering -0 Bracket, Steering Bushing, Upper Nut, Nylok /

25 HANDLEBAR MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description -00 Cover, Logo 0 Screw -00 Panel, Instrument Screw -0 Bracket, Instrument Panel Asm., Master Cylinder (See Control - Master Cyl./Brake Line Pg. B for Details) Cable, Choke w/adjuster Kit - Choke Lever Spacer, Switch, LH 00 Switch, Hi/Low/Rev. Override 0 00 Grip, Handlebar Plug, Hole Screw B0-0 Tube, Handlebar 0 Block, Handlebar Nut, Nylok 00 Clip, Cable Retaining Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. B, Ref. ) 0 Harness, Control Panel 000 Indicator, Neutral/Reverse Indicator, Hot Temperature 0 Plug, Indicator Hole 0 Switch, Ignition (Incl. Key) NOTE: Ignition Key may be ordered by using the four digit number on the key. Cover, Key 00 Nut, Choke Slide /

26 DRIVE CLUTCH MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description Bolt 0 Washer 0 Cover, Bearing 0 Spring, Clutch, 0 Washer, Multilube Roller and Bushing 0 Button, Guide AR AR AR AR Spacer (.00) Spacer (.0) Spacer (.0) Spacer (.00) 0 Weight, Shift, 0 Bolt, Shoulder 0 Nut, FLEXLOC 0 Bearing, Moveable, / 00 Pin, Spider Asm., Drive Clutch, ATV-0 (Incl. All Less,) / B

27 DRIVEN CLUTCH MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 AR Bushing 0 Belt, Drive Asm., Driven Clutch, Angle (Incl. -) 0 Washer, Domed 0 Washer Bolt AR Washer (.00 mm) 0 AR Washer (.0mm) 0 AR Washer (.0mm) 0 0 Bearing, Moveable (/ ) Bearing, Moveable ( ) 0 Spring Ramp, Stationary 0 Spacer 0 Ring, Retaining Bolt 0 Button, Ramp / B

28 CLUTCH COVER MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Screw Foam Foil Plate, Backing 0 Kit - Inner Clutch Cover (Incl.,,) Duct, Inlet, Down Tube 0 Bolt and Washer 00 Clamp, Narrow Band 0 Seal, Clutch Cover 0 Cover, Clutch, Outer 00 Clip, Clutch Cover 0 Screw 0 Decal - Clutch Cover 0 Decal - Engine/Clutch Modification 0 Decal - Automatic Transmission 0 Screw Boot, Duct 00 Cable Tie Duct, Air Outlet 0 Screw and Washer (See Crankcase Pg. C, Ref. ) 00-0 Bracket, Retainer, Seal 0 Seal, Cover Case Stopper, Inner Clutch Cover 0 Seal, Cover Case / B

29 ELECTRICAL/TAILLIGHT MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 0 Harness, Main Wire 00 Kit - Circuit Breaker, 0 AMP 0 Asm., Taillight w/brake Light (Incl. -) 00 Lens, Taillight 00 Screw, Taillight 000 Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 00 Nut, Speed 0 Nut, Nylok 0 Washer 0 Screw 00 Pad, Battery 00 Kit - Battery Bolt, Short 000 Cable, Battery/Engine 000 Hook, Battery Strap 0 Strap, Battery Holddown 0 AR Tube, Battery Vent 000 Battery 0 Cover, Battery 000 Cable, Battery/Solenoid 000 Cable, Solenoid/Starter 00 Bolt 00 Cable Tie 0 Pigtail, Power 00 Plug, Power, V Sink, Heat 00 Switch, Thermister LR-0 0 Screw 0 00 Rectifier, Regulator, LR 00 Limiter, RPM LR - 0 Screw 00 Clip, Rosebud 00 Clip, Routing / B

30 REAR BRAKE MAGNUM X A00CBAA and MAGNUM X A00CBCA C

31 REAR BRAKE MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 0 Kit - Brake Pads (Incl. Spacer and Pin) 0 Screw 0 Washer 00 Asm., Brake Caliper, Rear 0 Seal 0 Line, Hand Brake, Front 0 Line, Foot Brake, Rear 00 Clamp Screw 0 00 Clip, Brake Line 0 Rivet 00 T-Clip, Dual 0 Bolt, Banjo 0 Nut Nut, Nylok 0 Reservoir, Brake, Rear 0000 Clamp, Hose 0 Hose, Reservoir 0 Bolt Pivot, Brake Mount, Rear Nut, Nylok 0 Washer 0-0 Rod, Brake Washer 0 Pin, Cotter 00 Washer Bushing, Pedal Pivot Screw 0 Master Cylinder, Foot 0 00 Spring, Torsion / C

32 REAR WHEEL DRIVE MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Pin, Cotter Nut Hub, Wheel, Rear Bolt 00 Pushnut 0 Tire, x.-0 0 Valve, Rim 0- Rim, Rear, Silver Washer 0 Washer 00 Nut Hub, Dust Cover / C

33 MAIN GEARCASE MAGNUM X A00CBAA and MAGNUM X A00CBCA C

34 MAIN GEARCASE MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gearcase, Main (Incl. -) 0 Bearing, Ball 0 Shaft, Input, T 0 Chain, Silent 0 Gear, T w/t Spline 0 Bearing, Ball 0 Nut, FLEXLOC 0 Washer, Flat Bellcrank 0 Ring, Retaining 0 00 Washer Plug, Vent Cap 0 Tube, Vent Screw Switch, Position Gearcase, RH Plug Seal Washer Deflector, Oil 0 0 Screw Shaft, Shift, H/R Shim Pipe, Knock Plug, Drain Washer Screw Cover, Front, Gearcase Shim Button, Thrust 0 Shaft, Rear Output Gear, Spiral, Bevel, T Washer, Thrust O-Ring Ring, Retaining Shaft, Shift, Low Switch, Position 0 Shaft, 0T, Spiral Bevel 0 Bearing, Ball 0 Ring, Retaining 0 0 Cover, Bearing, Center 0 Screw 0 Gear, T 0 Fork, Shift, Low Washer Engagement Dog, Low 0 Ring, Retaining Gear 0 Bearing, Needle 0 Fork, Shift, H/R 0 Shaft, Reverse 0 Washer, Thrust 0 Bearing, Needle Sprocket, T 0 Ring, Retaining Engagement Dog, H/R, HLR 00 Gear, 0T Spacer 0 Gear, T 0 Gearcase, LH 0 0 Bracket, Interlock 0 Spring, Shifting, Interlock 0 Pin, Interlock / C

35 REAR HOUSING MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gearcase, Rear (Incl. -0, -) (For Machines Built Before --) 0 Asm., Gearcase, Rear (Incl. -0, -) (For Machines Built After --) Screw Seal 0 Screw Cover, Gearcase, Output Pipe, Knock O-Ring Shim Bearing, Ball 0 Shaft, Rear Axle 0 Gear, Bevel, T, Rear 00 Clip 000- AR Line, Vent C 000 Clamp,Hose Tube, Vent Gearcase, Rear Housing Plug Washer Bushing 0 Shaft, Pinion, 0T, Bevel, Rear (For Gearcase ) Shaft, Pinion, 0T, Bevel, Rear (For Gearcase 0) 0 Bearing, Ball Nut, Lock O-Ring Gearcase, Cover, Input Seal, Oil Button, Thrust Shim /

36 GEAR SELECTOR MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Gear Selector (Incl. -) Asm., Knob 0 Screw Screw Strap, Wire Cover, Gear Selector Boot Handle, Gear Selector Sphere, Plastic Pin, Groove Pin, Dowel 0 Spring, Detent 00 Bullet, Detent 0 O-Ring Slide, Low 0 Slide, High/Reverse Body, Gear Selector Spring, Centering / C

37 GEARCASE SELECTOR MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Rod End, LH 0 Nut, FLEXLOC 0 Nut, LH 00 Rod, Low 0 Nut 00 Rod End, RH 0-0 Bracket, Shifter Bolt Washer 0 Nut, Nylok Screw 00 Rod, High, Rev / C

38 SWING ARM/REAR GEARCASE MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description Hub, Brake Disc Asm., Rear Brake Caliper (See Rear Brake Pg C, Ref. ) Bearing, Ball Shield, Brake Line, Rear 0 Bolt 0 Screw Washer 0 Nut, FLEXLOC Cap, Swing Arm Pivot 0 Nut Pivot, Threaded 00 Seal, Swing Arm Pivot 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup 0 Seal, Swing Arm Pivot Asm., Swing Arm (Incl.,) 0 O-Ring Asm., Prop Shaft, Rear 0 Bolt Coupling, Prop Shaft, Greased Fitting, Lubrication C O-Ring 0 Ring, Retaining 0 Collar, Rear Axle Axle, Rear Screw 0-0 Asm., Skid Plate Plate, Rear Housing Skid Pad, Rubber Asm., Gearcase, Rear (See Rear Housing Pg. C for Details) 0 O-Ring 0 Decal - Hitch 0 Pin 0 Washer 00-0 Tube, Axle, LH Screw 0 Spacer, Bearing 0 Ring, Retaining 00 Seal, Axle, Rear Disc, Brake O-Ring /

39 SHOCK MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description Nut, Nylok Bushing Screw 0 Tube Retainer, Shock 0-0 Spring 0 Shock 0 Cam, Adjuster 0 Tube 0 Bushing Screw / C0

40 TRANSMISSION MOUNTING MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Main Gearcase (See Main Gearcase Pg. C for Details) Screw 0 Nut Screw Nut Washer -0 Mount, Rear Transmission Screw 0 Washer Bolt Mount, Transmission 00-0 Mount, Engine, Rear / C

41 CRANKCASE MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Bushing, Starter 000 Pin, Dowel 0 0 Asm., Crankcase (Incl. -,,,,,,)(If built before //) Asm., Crankcase (Incl. -,,,,,,)(If built after //) 0 Bearing, Ball 00 Pin, Dowel 00 Screw and Washer 0 Seal, Oil 00 Pipe O-Ring Gauge, Oil (If built before //) Gauge, Oil (If built after //) C 0 Pin, Straight 0 Plug 0 Union 000 Gasket, Oil Cooler 00 Union 00 Adapter, Oil Cooler (Incl.,) 00 Connector, Oil Cooler 0 Bolt, Flange 0 Plug 0 0 Gasket 0 Bolt, Flange 0 Bolt, Flange /

42 CYLINDER MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Cover, Valve 0 O-Ring 0 Bolt, Flange 0 Bolt, Flange 0 Plug, Cylinder Block 00 Pin, Straight 0 Seal, Intake Valve 0 Guide, Valve 0 Fin Damper A 0 0 Seal, Exhaust Valve 0 Bolt and Washer 00 Asm., Cylinder Head (Incl.,,-0,,,)(If built before //) 0 Asm., Cylinder Head (Incl.,,-0,,,)(If built after //) 0 Gasket, Exhaust 0 Stud 000 Washer 00 Nut 0 Pin, Straight 00 Gasket, Cylinder 00 0 Cylinder (If built before //) Cylinder (If built after //) 0 0 Gasket, Head 0 Gasket, Cam 00 Adapter 0 Asm., Adapter Band (Incl. ) 0 Screw 00 Bolt 0 Cover, Rocker (If built before // only) 0 Bolt, Flange / C

43 CRANKSHAFT and PISTON MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description Piston Ring Set (STD) Piston Ring Set (0. O/S) Piston Ring Set (0.0 O/S) Piston Set (STD)(Incl.,) Piston Set (0. O/S)(Incl.,) Piston Set (0.0 O/S)(Incl.,)(If built before // use above Set) Piston Set (STD)(Incl.,)(If built after // use Set below) Piston Set (0. O/S)(Incl.,) Piston Set (0.0 O/S)(Incl.,) Pin, Piston 0 Clip 0 Bolt 0 Asm., Connecting Rod (Incl.,) Crankshaft, Complete (Incl. ) Crankshaft (If built before //) Crankshaft (If built after //) 0 Key, Woodruff 0 Spacer 0 Spacer 0 Spacer 0 Spacer 0 0 Sprocket 0 Nut 00 Washer 00 Nut Nut 0 Bearing, Ball Bearing (STD) Bearing (0.0 U/S)(If built after //) Bearing (0. U/S)(If built after //) / C

44 INTAKE and EXHAUST MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Screw, Adjusting 0 Nut 00 Asm., Rocker Arm (Incl.,) 0 Shaft, Rocker 0 Washer 00 Collet, Valve 00 Retainer, Spring 00 Spring, Valve 0 Lever, Release 0 00 Spring, Return (If built before //) Spring, Return (If built after //) Camshaft (Incl.,0,)(If built before //) Camshaft (Incl.,0,)(If built after //) D 0 Pin, Dowel 0 Valve, Intake 0 Valve, Exhaust 0 Guide, Chain 0 Chain, Timing 0 Gasket, Tensioner 0 Tensioner 0 Bolt, Flange 0 0 Sprocket 0 Washer 0 Bolt, Flange 0 Lever 0 Bolt, Pivot /

45 RECOIL STARTER MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Reel 0 Spring, Return 0 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Bolt and Washer 0 Plug 0 Gasket D 0 Bushing, Starter 0 0 Spring, Spiral 00 Bushing 0 Gasket, Recoil 0 Bolt, Flange 0 0 Asm., Recoil (Incl. -,-,,) Starter Case (Incl. ) 00 Rope /

46 CARBURETOR MAGNUM X A00CBAA and MAGNUM X A00CBCA D

47 CARBURETOR MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 00 Ring 00 E-Ring 00 Needle, Jet 0 Ring 0 Diaphragm 0 Jet, Needle (P-0M) 0 Screw 00 Washer, Spring Asm., Jet Block 0 00 Washer Seal 0 Packing 0 E-Ring 0 Cap 0 Pin, Float 0 Plate 0 O-Ring 00 Screw 0 00 Asm., Float Body 0 Screw 0 Asm., Float 0 Screw 0 Valve, Needle (.) 0 O-Ring Jet, Pilot (#0) 0 O-Ring Jet, Main (#.)(If built before //) Jet, Main (#)(If built after //) 0 Washer 0 Spring 0 Adjuster 00 Plug (If built before // only) 0 Screw, Adjust 0 Ring 0 Spring Valve, Throttle (0) 0 Spring 0 Ring 00 Screw 0 Asm., Throttle Shaft 0 0 Guide, Cable 0 Screw 0 Cover 0 O-Ring 0 Holder, Guide 0 Spring 0 Asm., Plunger Jet, Air (#) Asm., Carburetor (Incl. -,-) (If built before //) Asm., Carburetor (Incl. -,-) (If built after //) 00 Screw and Washer 0 Spring Asm., Cover 0 Screw / D

48 OIL PUMP and OIL FILTER MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Plug 0 Gasket 0 Spring 0 Valve, Relief 0 Bolt, Flange 0 Strainer, Oil 0 Filter, Oil 0 00 Screw (If built before //) Screw (If built after //) 00 Cover, Oil Pump 0 0 Rotor, Inner 0 Rotor, Outer / D

49 MAGNETO MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description Asm., Ignition Coil (Incl.,) Ignition Coil (If built before //) Ignition Coil (If built after //) 0 Cap, Spark Plug 0 Plug, Spark 0 O-Ring 00 Bearing, Dry 0 Asm., Plate (Incl.,)(Incl. if built before // only) D 0 Bolt and Washer 0 Seal, Oil 0 Screw and Washer (If built before // only) 0 0 CDI System 00 Nut 000 Washer, Spring 0 Switch, Magnetic 0 Flywheel w/ring Gear /

50 STARTING MOTOR MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Motor, Starting (Incl. -,-) 0 Washer Set 0 Armature 00 Brush, Carbon 0 Nut, Flange 00 O-Ring 00 Bolt and Washer 00 Bracket, Rear 00 Asm., Front Bracket (Incl. ) D 0 O-Ring 0 0 Asm., Set Bolt (Incl. ) 00 Ring, Rubber 0 Washer, Gear Shaft 0 Clip 0 Spring, Weight 00 Spring, Return 00 Clip 0 Asm., Gear Shaft (Incl. -) /

51 FUEL PUMP MAGNUM X A00CBAA and MAGNUM X A00CBCA Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Fuel Pump (Incl. -) 0 Screw and Washer 0000 Screw and Washer 0 Screw 0 Diaphragm Gasket Set / D

52 BREATHER BOX MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 0 Ref. Part Qty. Description Ref. Part Qty. Description 00 Pipe 0 Bolt, Flange 0 00 Asm., Breather Box (Incl.,-0, -)(If built before //) Asm., Breather Box (Incl.,-0, -)(If built after //) Box, Breather (Incl.,,) 0 0 Pipe, Air Breather 00 Clamp 0 Pipe, Rubber 0 Bolt, Flange (Use if built after //) 0 Pipe 0 Pipe, Rubber 0 0 Bolt, Banjo D 0 Gasket 0 Pipe 0 Clamp, Hose 0 Band, Wire (Use if built after //) 00 Pipe, Rubber 0 Pipe, Pulse 00 Gasket, Breather Plate 0 Plate, Breather 0 Bracket 0 0 Bolt, Flange 00 Screw 0 Plate, Breather Box 0 Gasket, Plate /

53 TOOL KIT MAGNUM X A00CBAA and MAGNUM X A00CBCA 0 Ref. Part Qty. Description Ref. Part Qty. Description 0 Asm., Tool Kit (Incl. -) 0 Gauge, Tire Pressure 000 Wrench, Open -0mm 000 Wrench, Open -mm 0 Wrench, Box 0 Screwdriver 00 Pouch, Tool Kit D0 Lube, U-Joint, oz., Case Owner s Manual, 00 ATV Supplement, Owner s Manual, 00 Magnum x 0-0 Wrench, Spanner, Cam 0 0 Pigtail, Power /

54 Part Ref. Grid C C C A C C A.. C A A A A A A A A A A A A A A A A B B B C... C C C C C C B B... C C B B B B C B B... C C C C B B B... C Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA Ref. D Grid B B B B B B B B B B B C B B B B B B B B B B B B B B B C B B A A A B B 0.. D B B B A A A A A A A A A A D D D D0 Part Ref. Grid D C C C D D C C D D D D C... D... D D C D D 0... D D D D C... D... D D D... D D D C... D D D C C D C A.. C... D D D D D D D D D D D C

55 Part Ref. Grid D D C.. C C C C C C C C D D D D D D D D D D D D D D D D C D D D D D D D D D D D C D D D D C C C C D C D C... D Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA Ref. D Grid D D D C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C D D D D D D D D D D D D Part Ref. Grid D D D D D D D D D D D D D D D D D D D D D D D C C D D D D D C C C C C C C C C C D D D D D D C A A A A A A D

56 Part Ref. Grid D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D D B Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA Ref. D Grid C C C C C C C C C C C C C C C C C C C C C C... C C C C C C C C C C C... C C C... C C C C C C C C C C C C... C C... C C C Part Ref. Grid C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C C... C C C D C B C C

57 Part Ref. Grid C B 0.. B B B B C C B B A.. B A B B B B B A B B B B B B B B B B A B B B B B B C C B B B B B B C C C C C C C B C Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA Ref. D Grid C C B A B.. B B B A B A A C B B B B B A B B B C A B A A C C C A B A A A B A A A B A B A B B A A B A B B B B Part Ref. Grid B B B B A B... C C C B B B B B B C C C A B C B C A A A A C B C A B B A B B B B B B B B B B B B B B B B B A A A

58 Part Ref. Grid A A A A B B B A A A B B A B B B B B B B B B B B B B C C C A A B B A A B B B B C B B B B A B A A A A A A A Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA E Ref. Grid B A B B A C B B B B B B A B C B C C B A A A A B B B B C C B B C A A A B B A A0.. A A A B A A A A A A A A A A0 Part Ref. Grid A A A... B... C B B C B B B B... B... C A A B A... B.. B B B... C B B B B B B B B B C A A C B A B B B0.. B... C B B... C A... A B B C A B

59 Part Ref. Grid A... A 0.. A.. B C A A B B A B A B A A C A... C B A A A... A A B B B A A C A C C A.. C C C B C B A B A A.. C A... C... C A B B B B Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA E Ref. Grid B A C A B C C A B A B A 0... A 0.. B A A... A... A.. A.. B0... C 0... C C A B C A.. A... B A A... B... C B C A... B C B B C C B A C C C B B B B C Part Ref. Grid B.. C A B.. B A.. B C A B... C C B A... A C A 0... B... C A A C A A B B C A C A B C B B A.. A... B... B... C A... A... B B A A A B C B C C B B B

60 Part Ref. Grid A A... A C A B B A... A C Part PART NUMBER INDEX MAGNUM X A00CBAA and A00CBCA Ref. Grid A A A C B A A B C C Part Ref. Grid A B A... C A... B B D D0 E

61 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

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63 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

64 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN

65 In order to better serve you, this postage-paid mailer is provided for your convenience to report an error or relay a suggestion relative to any Polaris Publication. or FAX your report to: --0 POLARIS PUBLICATIONS REPORT Publication Machine Publ. Date Page Report of Error Suggestion Name Company Address City, State, Zip Phone ( ) Date Thank you for your help! Mailing Instructions Please fold the top portion down first then fold the bottom portion up second so the open edge is located at the top. Tape the open edge. / Rev. 0

66 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS PERMIT NO. ROSEAU, MINNESOTA POSTAGE WILL BE PAID BE ADDRESSEE ATTN: TECHNICAL PUBLICATIONS POLARIS SALES INC. 0 TH AVE. S.W. ROSEAU, MN

67

68 PRINTED IN THE USA PARTS MANUAL PN and MICROFICHE PN /