MAGNUM 325 4X4 Model #A02CD32AA MAGNUM 325 4X4 Model #A02CD32AB 325 MAGNUM 4X4 HDS Model #A02CD32FB MAGNUM 325 4X4 FREEDOM Model #A02CD32AC Rev.
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1 MAGNUM X Model #A0CDAA MAGNUM X Model #A0CDAB MAGNUM X HDS Model #A0CDFB MAGNUM X FREEDOM Model #A0CDAC Rev. 0 E 00 Polaris Sales Inc. PARTS MANUAL PN 0 and MICROFICHE PN 0 /0
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3 TABLE OF CONTENTS Magnum X A0CDAA and Magnum X A0CDAB and Magnum X HDS A0CDFB and Magnum X Freedom A0CDAC Parts Manual A G A- ARM/STRUT MOUNTING... C AIR BOX... B C CARBURETOR... D- CARBURETOR MOUNTING... B- CLUTCH COVER... C CONTROLS - MASTER CYLINDER/BRAKE LINE.. A CONTROLS - THROTTLE ASM./CABLE... C CRANKCASE... D CRANKSHAFT and PISTON... D CYLINDER... D D DECALS (AA)(AB)(FB)... A DECALS (AC)... E DRIVE CLUTCH... C DRIVE SHAFT... B- DRIVEN CLUTCH... C- E ELECTRICAL/TAILLIGHT... C ENGINE MOUNTING... B- EXHAUST SYSTEM... B F GEAR SELECTOR... GEARCASE SELECTOR MOUNTING... HANDLEBAR... INTAKE and EXHAUST... FRONT BRAKE... A FRONT CAB... A SHOCK MOUNTING... FRONT HOUSING... C STARTING MOTOR... FRONT PROP SHAFT... B-0 STEERING POST... FRONT RACK and BUMPER MOUNTING... A SWING ARM/REAR/GEARCASE MOUNTING... FRONT STRUT... B- FRONT WHEEL... B- T FUEL PUMP... E TOOL KIT... FUEL TANK... B- TRANSMISSION MOUNTING... The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly. H I M MAGNETO... MAIN GEARCASE... MAIN GEARCASE... OIL COOLING... OIL PUMP and OIL FILTER... O R D D C D D C C A D REAR BRAKE... A-0 REAR CAB and SEAT... A- REAR HOUSING... C REAR RACK MOUNTING... A REAR WHEEL DRIVE... C0 RECOIL STARTER... D0 S D E C D E D
4 REAR CAB and SEAT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC E 00 Polaris Sales Inc A
5 REAR CAB and SEAT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 Rivet (AA)(AB)AC) 0 Bolt Washer 0 Foil, Rear Cab, Rear - -A - Cab, Rear, Gunmetal (AA)(FB) Cab, Rear, Camo (AB) Cab, Rear, Blue (AC) Nut, Nylok Retainer, Seat Latch 0 Foil, Tape, Rear Cab Screw 0 Washer, Flat 0 Screw Box, Tool 0 Rivet 0 Bracket, Lever Retainer 00 Latch, Seat 00 Spring, Latch Seat, Black (AA)(AB)(FB) Seat (AC) Covering, Seat, Black (AA)(AB)(FB) Cover, Seat (AC) Foil, Seat Base, Large Foil, Seat Base, Small 0 Bumper, Rubber Screw and Washer 0 Cover, Tool Box 0 Cap, Drain -0 Guard, Clutch Rivet Asm., Front Gearcase (See Front Housing Pg. C for Details) 0 Washer, Spring Lock Screw Guard, Rock 0 Washer Screw 0 0 Washer, Flat Screw Nut, Nylok Mount, Rubber Screw 00-0 Frame, Main Footwell, LH, Black Footwell, RH, Black Foil, Foam, Rear Fender 0 Foil, Rear Cab, Front 000 Decal, Stroke Carb/Filter 0 0 Foil, Foam 00 Nut, U-Type Speed Guard, Mud, Rear, LH (AA)(AB)(AC) Guard, Mud, Rear, RH (AA)(AB)(AC) Kit, Mud Skirt, Full Set (FB) /0 A
6 FRONT CAB MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Foil, Side Panel, Gen IV, RH 0 Foil, Foam, Side Panel Asm., Panel w/foam, LH, Gunmetal (AA) Asm., Panel w/foam, LH, Camo (AB) Asm., Panel w/foam, LH, Gunmetal (FB) Asm., Panel w/foam, LH, Blue (AC) Asm., Panel w/foil, RH, Gunmetal (AA)(FB) Asm., Panel w/foil, RH, Camo (AB) Asm., Panel w/foil, RH, Blue (AC) Foam, LH Foam, RH 0 Screw 0 Foam, Cab, Front 0-0-A 0- Cover, Front, Gunmetal (AA)(FB) Cover, Front, Camo (AB) Cover, Front, Red (AC) 00 Clip, Spring Cab, Front, Genmetal (Incl. Warning Decals)(AA)(FB) Cab, Front, Camo (Incl. Warning Decals)(AB) Cab, Front, Red (Incl. Warning Decals)(AC) Nut, Speed, U-Type -0-0 Shield, Splash, LH Shield, Splash, RH Screw 0 Rivet, Plastic Shield, Deflector 0 Nut, Speed (AA)(AB)(AC) Rivet, T-Lock Screw Guard, Mud, Front, LH (AA)(AB)AC) Guard, Mud, Front, RH (AA)(AB)(AC) Kit, Mud Skirt, Full Set (FB)(See Rear Cab and Seat Pg.A Ref. ) Nut, Nylok 0 Washer 0 Screw Nut, Nylok Washer, Flat A /0
7 REAR RACK MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Kit, Rack Extender, Rear (Incl. )(AC) Screw Screw 0-00 Asm., Rack, Rear (Incl. Ref. and Warning Decal) 0 Decal, Reflector, Red Nut, Nylok -0 Bumper, Rear (AC) 0 Cap, Bumper, End (AC) Bolt (AC) 0 Bolt 0 Washer, Flat 00 Nut, Chimney Mount, Front, Rear Rack, LH Mount, Front, Rear Rack, RH -0 Spacer Screw Support, Rear Rack (AC) Support, Rear Rack (AA)(AB)(FB) 0 Screw (AC) /0 A
8 FRONT RACK and BUMPER MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Screw Asm., Front Rack (Incl. Ref. and Warning Decal) 0 Decal, Reflector, Amber Screw 00 Kit, Front Rack Mount Nut, Nylok -00 Bumper Screw 0 Screw 0 Washer Support, Front Rack, LH Support, Front Rack, RH Screw Bolt Headlight, LH Headlight, RH Bulb, Replacement, W 0 Washer, Flat 0 Plug, Frame -0 Guard, Brush 0-0 Grill, Brush Guard 0 Rivet 0 0 Cap, End, Bumper (AC) -0 Bumper, Front (AC) 0 Washer (AC) 0 Screw 00 Nut, U-Type Shield, Radiator Side, LH Shield, Radiator Side, RH 0 Nutsert Extension, Frame, LH Extension, Frame, RH 0 Screw (AC) 00-0 Extender, Front Rack, Low (AC) /0 A
9 CONTROLS - MASTER CYLINDER/BRAKE LINE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 00 Asm., Master Cylinder Boot, Brake Line, Rubber 0 Seal 0 Switch 0 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 0 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) 0 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 0 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) 0 Line, Brake Rivet 0 00 Clamp, Nylon 00-0 AR Conduit 0 Line, Brake, Left Front w/fittings 00 Cable Tie 0 Screw 0 Line, Brake, Right Front Stainless Steel 0 Fitting, Cross 0 Line, Brake, Stainless Steel 0 Bolt, Banjo /0 A
10 REAR BRAKE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC,,,,, 0 0 A
11 REAR BRAKE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 Asm., Rear Caliper 0 Kit, Anvil Body 00 Kit, Slide Bolt 0 Kit -Seal 0 Kit, Piston and Seal 0 Kit, Bracket Pad (Incl. Spacer and Pin) 0 Kit, Brake Pad 0 Screw 0 Clamp, Brake Line Nut, Flanged 0 0 Reservoir, Brake, Rear 0000 Clamp, Hose 0 Hose, Reservoir Screw 0 Washer, Flat 0-0 Pivot, Mount, Brake, Rear Nut, Nylok 0 Bolt Screw 0-0 Rod, Brake 0 00 Spring Washer Bushing, Pedal Pivot 00 Washer, Spring 0 Pin, Cotter 0 Master Cylinder, Foot 0 Line, Foot Brake, Rear, Master Cyl. 0 Seal 0 Bolt, Banjo /0 A0
12 FRONT BRAKE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X FREEDOM A0CDAC 0 0 Asm., Front Brake Caliper, LH (Incl. -,-0) 0 Asm., Front Brake Caliper, RH (Incl. -,-0) 00 Screw, Bleeder Screw, Socket Set 0 0 Caliper,Brake,LH Caliper,Brake,RH Kit, Front Brake Boot 0 Boot, Pin Seal 0 Boot, Bushing 0 Kit, Piston and Seals (Incl. -) 0 Square Ring, Molded (.0) 00 Square Ring, Molded (.0 x.) Piston, Long 0 0 Mount, Caliper 0 Kit, Front Brake Pad 0 0 Screw Washer Washer, Lock 0/00 A
13 FRONT BRAKE MAGNUM X HDS A0CDFB 0 0 Asm., Brake Caliper, LH (Incl. -,0,) 00 Asm., Brake Caliper, RH (Incl. -,0,) Screw, Socket Set 0 0 Caliper,Brake,LH Caliper,Brake,RH Kit, Front Brake Boot 0 Boot, Pin Seal 0 Kit, Piston and Seal (Incl. -) 0 Ring, Molded Square (.0) 00 Ring, Molded Square (.0 x.) Piston, Brake, Long 0 Kit, Front Brake Pad 0 Mount, Caliper 0 0 Boot, Bushing 00 Screw, Bleeder 0/00 A
14 DECALS MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 RH LH 00 Decal, Warning, Front and Rear Rack Decal, x, Shaft Ride Sys., LH Decal, x, Shaft Ride Sys., RH (AA)(FB) Decal, x, Shaft Ride Sys., RH (AB) 0 Decal, POLARIS Side Panel 0 Decal, Age Warning, ATV 00 Decal, Ignition Decal, Tank Side, LH (AA) Decal, Tank Side, LH (AB) Decal, Tank Side, LH (FB) Decal, Tank Side, RH (AA) Decal, Tank Side, RH (AB) Decal, Tank Side, RH (FB) Decal, Warning, AWD Switch (AA)(AB) Decal, DHB, Low Range 0 Logo, Polaris Star 0 0 Decal, POLARIS Front Cover (AA)(AB)(FB) Decal, Mossy Oak, Front Cover (AB) 0 00 Decal, MacPherson Strut 0 Decal, Drain Recoil 00 Decal, Warning, Override, AWD 00 Decal, Warning, General, CPSC 00 Decal, Discretionary Warning, ATV 00 Decal, Passenger Warning 00 Decal, Tire Pressure 0 Decal, POLARIS, Rear 00 Decal, Load Distribution, W /0 A
15 OIL COOLING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Hose, Inlet 00 Clamp, Hose Nut, Nylok -0 Bracket, Oil Cooler, Top 00 P-Clamp, Cushioned 0 Screw Screw 0 Motor, Fan 0 U-Clip 0 Shroud 00 Thermister 0 Washer, Flat 00 Cooler, Oil Mount, Rubber 0 Asm.. Bracket, Lower /0 A
16 EXHAUST SYSTEM MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Nut, Nylok Washer, Flat 0 Washer, Rubber 0 Dampener, Vibration Screw, Carriage 00 Spring, Exhaust 0-0 Silencer Bolt 00 Mount, Torque Stop 0 0 Nut 0 Spring, Exhaust Seal, Exhaust 00 Spring, Exhaust 0-0 Headpipe 00-0 Manifold, Black 0 Gasket, Exhaust /00 B
17 AIR BOX MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Screw Washer, Flat 0 Seal, Intake 0 Duct, Inlet 0 Pad, Fuel Tank Bracket Cover, Air Box Seal, Air Box Cover 0 Clip 0 Collar, Carb Inlet 0 00 Clamp, Hose 0 Cap, Rubber Hose, Breather 00 Clamp, Narrow Band Boot, Carburetor 00 Clamp, Narrow Band 0 Duct, Carb Inlet 0 Gasket, Carb Inlet Box, Air Intake, Stroke Plug, Trap 0 Foil, Air Box, RH 000 Clamp, Hose 0 Cap, Rubber Asm., Filter /0 B
18 ENGINE MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC B
19 ENGINE MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 000- AR Line, Fuel 00 Fitting, Tee 0 Asm., Engine 0 Nut, Flange Lock -0 Bracket, Motor Mount 0 Washer, Spring Lock Bolt Screw 00 Cable, Ground Engine 0 Washer, Flat 00 Mount, Rubber Rear Boot, Clutch Intake 00 Clamp, Narrow Band AR Line, Fuel 0-0 Mount, Engine, Rear Screw 0 Mount, Rubber, Rear Washer Screw 0-0 Mount, Lower Front 0 Mount, Rubber, Engine 0 Bushing 0 Washer, Flat 0 Washer, Interlock Bolt 000 Cable, Battery/Engine 00 T-Clip AR Line, Fuel 0000 Clamp, Hose Filter 0 Nut, Nylok /0 B
20 FUEL TANK and CARBURETOR MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC B
21 FUEL TANK and CARBURETOR MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Cap, Gas Tank (Includes Gasket) Gasket Seal, Foam AR Line, Fuel 0 Asm., Fuel Tank (Incl.,,) 0 Nut 0 Washer, Split Lock Washer, Flat -0 Bracket, Carburetor Support 0 0 Nutsert 0 Screw Knob, Fuel Valve Nut, Fuel Valve 0 Valve, -Way Rivet 0-0 Bracket, Fuel Valve 0 Fitting, Fuel Outlet, Main 0 Fitting, Fuel Outlet, Reserve 0000 Clamp, Hose, Red AR Line, Fuel 00 Screw and Washer -0 Mount, Carburetor 000 Mount, Carburetor Screw 0 Vent, Tank -0-0 Bracket, Fuel Cover Mount, Rear, LH Bracket, Fuel Cover Mount, Rear, RH 0 Washer Screw /0 B
22 DRIVE SHAFT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X FREEDOM A0CDAC BTB 0 0 Asm., CV Housing w/sleeve Sleeve, Drive Shaft Seal 0 Clamp, CV Joint, Large 00 Circlip 0 Boot, CV Joint 00 Shaft Replacement (Incl. ) 00 Cardan Replacement (Incl.,,,) 00 Kit, Cross and Bearing 00 Yoke, Splined 0 Pin, Spring 00 Clamp, Small Band 00 Kit, Boot Replacement, CV Joint (Incl.,,) 00 Kit, Drive Shaft w/sleeve / B
23 DRIVE SHAFT MAGNUM X HDS A0CDFB Asm., Drive Shaft, LH Asm., Drive Shaft, RH 00 CV-Joint 00 Clamp, Large 00 Grease 0 Boot 00 Clamp, Small 00 Clamp, Small 00 Boot 00 Grease 000 Clamp, Large 0 00 Joint, Plunging (Incl. ) 00 Ring, Spring 0 Kit, Boot (Gear Side)(Incl. -) 00 Kit, Boot (Wheel Side)(Incl. -) /00 B
24 FRONT PROP SHAFT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X FREEDOM A0CDAC 0 Asm.,PropShaft(Incl.-) 0 Yoke, Gear Case, Front 00 Kit, Cross and Bearing 00 Shaft, Prop, Front 0 Yoke 0 O-Ring Pin, Spring / B
25 FRONT PROP SHAFT MAGNUM X HDS A0CDFB 0 Asm., Prop Shaft 000 End, Yoke 00 Pack, Unit 00 Shaft, Bar 00 Slip, Yoke 0 O-Ring 00 Fitting /00 B0
26 FRONT STRUT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X FREEDOM A0CDAC Bumper 0 Asm., Hubstrut, LH (mm) 0 Strut, Front (Incl.,-,) 0 Asm., Hubstrut, RH (mm) Washer (Incl.,-,) 0 Washer, Flat 0-0 Spring, Compression 00 Clamp, Rubber Coated Retainer, Spring Nut, Nylok Ball, Pivot, Bottom Screw Bolt 0 Retainer, Strut Casting Wire 0 0 Spacer Asm., Front Brake Caliper, RH (See Front Brake Pg. A for Details) 0 0 Bearing, Tapered Roller Bearing, Tapered Roller Cup Sleeve, Hubstrut Seal 000 Fitting, Lubrication 0 Coil, Magnetic B 00 Seal, Hubstrut Ball, Pivot, Top 0 Spacer, Rubber Washer 0 Nut, Nylok, This Kit, Drive Shaft w/sleeve (See CV Joint - BTB Pg. B, Ref. )(AA)(AB) Asm., Drive Shaft (See Drive Shaft Pg. B for Details)(FB) 0/00
27 FRONT STRUT MAGNUM X HDS A0CDFB Nut, Nylok Washer 0 Spacer, Rubber Ball, Pivot, Top 0 Spacer Ball, Pivot, Bottom Retainer, Spring 0-0 Spring, Compression Bolt Washer, Flat 0 0 Hubstrut, LH Hubstrut, RH Bearing, Hubstrut 00 Ring, Retaining Asm., Front Brake Caliper, LH (See Front Brake Pg. A for Details) 000 Fitting, Lubrication 0 Washer, Spring Lock Screw Nut, Nylok 00 Clamp, Rubber Coated 0 Washer 0 Strut, Front 0 Bumper 0/00 B
28 FRONT WHEEL MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X FREEDOM A0CDAC 0 0 Bolt Disc, Brake 00 Seal, Front Hub Plate, Armature 0 Clutch, Front Hub, Elec./Mech. 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup Stud 0 Asm., Hub w/bearing Race (Incl.,,) 0 00 Cage, Roll 000 Roll 00 Spring, Garter Spacer 000 Cam 00 Plug, Magnetic Drain 0 Tire (x-) 00 Washer 0 Nut, Slotted 0 Pin, Cotter 0 00 O-Ring Cap, Hub 0 Screw Nut, Flange Lock Rim, Front (AA) Rin, Front (AB) 0 Valve, Rim /00 B
29 FRONT WHEEL MAGNUM X HDS A0CDFB 0 Bolt Disc, Brake Stud Hub 0- Rim, Front 0 Tire (x -) Nut 00 Washer 0 Nut, Slotted 0 Cover, Dust 0 Pin, Cotter 0 Valve, Rim 0/00 B
30 CONTROLS - THROTTLE ASM./CABLE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Cover, Throttle Control 0 O-Ring O-Ring Cable, Throttle (AA)(AB) Cable, Throttle (FB) Asm., Throttle Control (Incl.)(AA)(AB) Asm., Throttle Control (Incl.)(FB) Bracket, Throttle Stop (FB) 0 Screw (FB) 00 Asm., Throttle Clamp 0/00 C
31 STEERING POST MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 Nut, Nylok 00 Fitting, Lubrication Bushing, Steering, Upper Post Steering (AA)(AB) Post, Steering (FB) Bracket, Steering Post Bolt, Carriage Bushing Flangette Bearing 0 Nut Pin, Cotter /0 C
32 HANDLEBAR MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC A0CBFB 0 0 A0CBFB 0 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. -00 Cover, Logo (AA)(AB) 0 Screw 0 Cover, Screw Panel, Instrument (AA)(AB) Panel, Instrument (FB) Screw (AA)(AB) Screw (FB) -0-0 Bracket, Instrument Panel (AA)(AB) Bracket, Instrument Panel (FB) Asm., Master Cylinder (See Control - Master Cyl./Brake Line Pg. A for Details) 000 Cable, Choke 0 Spacer, Switch, LH 0 00 Switch, Handlebar, Hi/Lo/Rev. Override -00 Grip, Handlebar Plug, Hole Screw -0-0 Tube, Handlebar (AA)(AB) Tube, Handlebar (FB) Cap, Hall Sensor (FB) 00 Sensor, Hall Effect (FB) Screw (FB) 0 Block, Handlebar Nut, Nylok 0 00 Clip, Cable Retaining C Asm., Throttle Control (See Controls - Throttle Asm./Cable Pg. C, Ref. ) 0 0 Harness, Control Panel (AA)(AB) Harness, Control Panel (FB) 000 Indicator, Neutral/Reverse 000 Indicator, Hot Temperature 0 00 Plug, Indicator Hole(AA)(AB) Indicator, P, Park (FB) Switch, Ignition Cover, Key Blank, Key, Series 000, 00, 00 NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. 00 Blank, Key, Series 00, 00, 00, 00. NOTE: Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. Nut, Ignition 00 Nut, Choke 0 Speedometer (FB) 0 00 Clamp (FB) 0 Block, Riser (FB) Nut (FB) Washer,Flat(FB) Washer, Lock (FB) /0
33 A-ARM/STRUT MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC E 00 Polaris Sales Inc Nut, FLEXLOC 00 Asm., Tie Rod (Incl. -) Boot, Seal, Rod End 00 Rod End Nut 00 Tie Rod 0 Nut, Jam, LH Bolt 00 Rod End, LH 0 0 Boot, Seal, Rod End 0 Washer, Flat 0 Nut 0 Pin, Cotter 00 Joint, Ball Bracket, Ball Joint Screw 0 Boot, Rubber Nut, Castle C Shield, CV Joint, LH (AA)(AB) Shield, CV Joint, RH (AA)(AB) Shield, CV Joint, LH (FB) Shield, CV Joint, RH (FB) 0 0 Screw (FB uses Qty. ) 0 Bushing, A-Arm, Long (If built before 0/0/0) Bushing, A-Arm, Long (If built after 0/0/0) 00 Bushing 00 Shaft, A-Arm Kit, A-Frame, LH Kit, A-Frame, RH 00 Fitting, Lubrication Asm., Heavy Hubstrut (See Front Strut Pg. B, Ref. ) Screw 0 Washer, Spring Lock Screw /0
34 DRIVE CLUTCH MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC A0CDAA and A0CDAB and A0CDAC 0 A0CDFB 0 Asm., Drive Clutch, ATV-0 Bolt, Shoulder (Incl. All Less,)(AA)(AB)(AC) 0 Nut, FLEXLOC 0 Asm., Drive Clutch, Braking (Incl. All Less,)(FB) Bolt 0 Washer, Spring Lock 0 Washer, Multilube Roller and Bushing Button, Clutch AR AR AR AR Spacer (.00)(AA)(AB)(AC) Spacer (.0)(AA)(AB)(AC) Spacer (.0)(AA)(AB)(AC) Spacer (.00)(AA)(AB)(AC) Weight, Shift, (AA)(AB)(AC) Weight, Shift, 0 MH (FB) 0 0 Bearing, Moveable (/I)(AA)(AB)(AC) Bearing (FB) 00 Pin, Roller 0 Spring, Clutch 0 Cover, Bearing 00 Washer (FB) 0 Clutch, One Way Drive (FB) 00 Washer (FB) Spacer (FB) 0 Nut, Jam (FB) /0 C
35 DRIVEN CLUTCH MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X FREEDOM A0CDAC 0 0 AR Bushing 0 Washer, Domed 0 Washer, Spring Lock Bolt Asm., Driven Clutch (Incl. -) 0 Belt, Drive 0 Button, Ramp Bolt 0 Ring, Retaining 0 Spacer Ramp, Stationary 0 Spring, Clutch Bearing, Moveable ( ) 0 Bearing, Moveable (/ ) 0 AR Washer (.00 ) 0 AR AR Washer (.00 ) Washer (.0 ) /00 C
36 DRIVEN CLUTCH MAGNUM X HDS A0CDFB 0 0 AR Bushing Asm., Driven Clutch, Braking (Incl.-,-) 0 Washer 00 Bushing 0 Ring, Retaining 0 Washer, Domed 0 Washer, Spring Lock Bolt 0 Belt, Drive 0 Screw Roller, Taper 0 Bearing Washer Bearing, Moveable, 0 Spring Ramp, Stationary 0 Spacer 0 Ring, Retaining 0/00 C
37 CLUTCH COVER MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Screw 0 Foam, Clutch Air Inlet Plate, Backing 0 0 Kit, Inner Clutch Cover Duct, Inlet Bolt and Washer 000 Clamp, Narrow Band 0 Seal, Clutch Cover -00 Cover, Clutch, Outer 0 0 Screw 0 Decal, Warning, Clutch Cover Decal, Automatic Transmission (AA)(AB) Decal, Automatic/EBS, Clutch (FB) Boot, Duct 000 Clamp, Narrow Band 0 Washer, Flat Duct, Air Outlet Screw and Washer (See Crankcase Pg. D, Ref. ) 0-0 Bracket, Clutch Seal 0 Seal, Cover Case 0 Stopper, Inner Clutch Cover 0 Seal, Cover Case /0 C
38 ELECTRICAL/TAILLIGHT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Harness, Main (AA)(AB) Harness, Jumper (FB) 00 Kit, Circuit Breaker, 0 AMP 0 Kit, Circuit Breaker, Fan 0 Asm., Taillight w/brake Light (Incl. -0) 00 Lens, Taillight 00 Screw, Taillight 000 Bulb, Taillight 00 Gasket, Taillight 00 Backing, Taillight/Brake Light 0 00 Nut, Speed Nut, Nylok 0 Washer 0 Screw 00 Pad, Battery 0 Pad, Fuel Tank (FB) 000 Horn (FB) 00 Switch, Horn (FB) Screw (FB) 00 Kit, Battery Bolt, Short Cable, Battery/Engine 000 Hook, Battery Strap 0 Strap, Battery Holddown 0 AR Tube, Battery Vent 000 Battery Cover, Battery 000 Cable, Battery/Solenoid 000 Cable, Solenoid/Starter 00 Bolt Limiter, RPM LR - (AA)(AB) Liniter, Speed (FB) 0 0 Screw Sink, Heat 000 Switch, Thermister LR- 0 Screw 00 Rectifier, Regulator, LR 00 Clip, Rosebud 00 Clip, Routing /0 C
39 REAR WHEEL DRIVE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to the Electronic Catalog, which is updated monthly. 0 Pin, Cotter Nut, Flange Lock -0 Hub, Wheel, Rear Stud Tire, x- 0 Valve, Rim 00- Rim, Rear, Silver Washer, Cone 00 Nut, Castle 0 Cover, Dust, Hub /0 C0
40 FRONT HOUSING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 A0CDAA and A0CDAB and A0CDAC 0 A0CDFB Asm., Front Gearcase (Incl. -)(AA)(AB)(AC) Asm., Front Gearcase (FB) Housing, Front Gearcase (AA)(AB)(AC) Housing, Front Gearcase (FB) Bushing (AA)(AB)(AC) Seal, Oil (AA)(AB)(AC) Gear, T, Bevel (AA)(AB)(AC) Seal, Triple Lip (FB) Shaft, Output, Front (AA)(AB)(AC) Screw (Qty. for FB) 00 Bearing (AA)(AB)(AC) Cover, Gearcase (AA)(AB)(AC) 0 Bearing (FB) Cover, Gearcase (FB) Shim O-Ring 0 O-Ring (AA)(AB)(AC) Nut (AA)(AB)(AC) Cover, Output, Front Housing Bearing, Ball (AA)(AB)(AC) 0 Bushing 00 Clip AR Line Shaft, Input, Front Housing (AA)(AB)(AC) Pinion, 0T (FB) Plug, Drain (AA)(AB)(AC) Plug (FB) Washer (Qty. for FB) Tube, Vent C CoverOutput, Front Housing (FB) Seal (AA)(AB)(AC) Seal (FB) Shim (AA)(AB)(AC) Button, Thrust (AA)(AB)(AC) Gear, T (FB) Differential (FB) Plug (FB) Pipe, Knock (FB) /0
41 REAR HOUSING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Asm., Gearcase, Rear (Incl. -, -) Screw 0 Screw Seal Cover, Gearcase, Output Pipe, Knock O-Ring AR Shim Bearing, Ball 0 Gear, Bevel, T, Rear 0 00 Clip 000- AR Line, Vent 000 Clamp,Hose Tube, Vent Gearcase, Rear Housing Plug Washer Bushing Shaft, Pinion, 0T, Bevel, Rear Bearing, Ball 0 O-Ring Seal, Oil Gearcase, Cover, Input Ring, Retaining Button, Thrust AR Shim /00 C
42 MAIN GEARCASE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC C
43 MAIN GEARCASE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Asm., Gearcase, Main (AA)(AB)(AC) Asm., Gearcase (FB) Screw Seal 0 Bearing, Ball Shaft, Front Output 0 Sprocket, T (AA)(AB)(AC) Sprocket, T/T Spline (FB) Gear, Spiral Bevel, T Bushing Pipe, Knock Screw Tapping 0 Switch, Position (AA)(AB)(AC) Washer Plug Bellcrank, HLR Nut, Lock, Hex Flange Switch, Position (Qty. for FB) 0 Ring, Retaining 00 Washer Plug, Vent Cap (AA)(AB)(AC) 0 Tube, Vent 0 0 Gearcase, RH (AA)(AB)(AC) Gearcase, RH (FB) Plate (FB) 0 Screw (Qty. for FB) 0 Bearing, Ball Washer Engagement Dog, Low (AA)(AB)(AC) Engagement Dog, Low/Park (FB) 0 Ring, Retaining Washer, Thrust 0 Gear, T (AA)(AB)(AC) Gear, T (FB) Ring, Retaining 0 Shift, Shaft, H/R 0 Fork, Shift, H/R 0 Bearing, Needle Shaft, Reverse (AA)(AB)(AC) Shaft, Reverse (FB) 0 Washer, Thrust 0 Bearing, Needle 0 Chain, Silent 0 Gear, T, wt Spline (AA)(AB)(AC) Gear, /T (FB) Shaft, Input, T 00 Gear, 0T 0 Spacer 0 Gear, T (AA)(AB)(AC) Gear T (FB) 0 Gearcase, LH (AA)(AB)(AC) Cover, LH (FB) 0 Pin Srew, Tapping 0 Bracket, Interlock 0 Spring Engagement Dog, H/R, HLR 0 Ring, Retaining Sprocket, T 0 0 Gear, T (AA)(AB)(AC) Gear, 0T (FB) 0 Cover, Bearing 0 Ring, Retaining 0 Bearing, Ball 0 Shaft, 0T 0 Fork, Shift, Low (AA)(AB)(AC) Fork, Shift Low/Park (FB) Shift, Shaft, Low O-Ring Chain, Roller (AA)(AB)(AC) Chain (FB) 0 Sprocket, T, w/t Spline (AA)(AB)(AC) Sprocket T/T Spline (FB) 0 Shaft, Rear Output AR Shim Button, Thrust Shim Cover, Output Washer Plug /0 C
44 GEAR SELECTOR MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Asm., Gear Selector (Incl. -)(AA)(AB)(AC) Asm., Gear Selector (Incl. -)(FB) Asm., Knob (AA)(AB)(AC) Asm., Knob (FB) 0 Screw Screw Strap, Wire Cover, Gear Selector Boot Handle, Gear Selector (AA)(AB)(AC) Handle, Gear Selector (FB) Sphere, Plastic Pin, Groove Pin, Dowel 0 Spring, Detent 00 Bullet, Detent 0 O-Ring Slide, Low (AA)(AB)(AC) 0 Slide, High/Reverse (FB use Qty. ) Body, Gear Selector Spring, Centering /0 D
45 GEARCASE SELECTOR MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 00 Rod End, LH 0 Nut, FLEXLOC 0 Nut, LH 00 Rod, Low 0 Nut 00 Rod End, RH 0-0 Bracket, Shifter Bolt Nut, Nylok 0 0 Screw Washer Screw 00 Rod, High, Rev /00 D
46 SWING ARM/REAR/GEARCASE MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC O-Ring Hub, Wheel, WD Stud Disc, Brake Asm., Brake Caliper (See Rear Brake Pg. A0 for Details) Screw Washer, Spring Lock 0 Bolt Washer 0 Nut, FLEXLOC Cap, Pivot, Swing Arm 0 Nut, Jam Pivot, Threaded 00 Seal, Pivot, Swing Arm 0 Bearing, Tapered Roller Cone 0 Bearing, Tapered Roller Cup 0 Seal, Pivot, Swing Arm Asm., Swing Arm (Incl.,) 0 00 Coupling, Prop Shaft, Greased Fitting, Lubrication 0 O-Ring D 0 Asm., Prop Shaft, Rear 0 Pivot, Swing Arm 0 Washer, Split Lock Bolt Axle, Rear Screw O-Ring Asm., Gearcase, Rear (See Rear Housing Pg. C for Details) 0-0 Asm., Skid Plate, Rear Plate, Skid, Rear Housing Pad, Rubber Collar, Rear Axle 0 O-Ring 0 0 Decal, Hitch Pin, Spring 00 Clamp, Brake Line, Rear 0 Screw 0-0 Tube, Axle, LH Bearing Hubstrut 00 Ring, Retaining Bolt 0/00
47 SHOCK MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Nut, Nylok Screw Retainer, Shock Spring, Compression (AA)(AB)(AC) Spring, Compression (FB) 0 Shock 0 Cam, Adjuster 0 Tube Bushing Screw /0 D
48 TRANSMISSION MOUNTING MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Asm., Main Gearcase (See Main Gearcase Pg. C for Details) Screw 0 Nut, Flange Lock Screw Nut, Flange Washer, Flat -0 Mount, Rear Transmission Screw 0 Washer, Spring Lock Bolt Mount, Transmission Mount, Engine,Rear (See Engine Mounting Pg. B, Ref. ) / D
49 CRANKCASE MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Bushing, Starter 0 Pin, Dowel 0 Asm., Crankcase (Incl. -,,,,,) 0 Pin, Dowel 0 Bearing, Ball 0 Pin, Straight 00 Screw and Washer 0 Seal, Oil 00 Gauge, Oil 0 00 O-Ring 00 Union 0 Plug 00 Union 0 Union, Oil Pump 0 Bolt, Flange 0 Plug 0 Gasket 0 Bolt, Flange 0 Bolt, Flange /00 D
50 CYLINDER MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Cover, Valve 0 O-Ring 0 Bolt, Flange 0 Bolt, Flange 0 Plug, Cylinder Block 00 Cover, Breather 00 Pipe 00 Gasket 0 Seal, Intake Valve 0 0 Guide, Valve 0 Fin Damper A 0 Seal, Exhaust Valve 0 Bolt and Washer 0 Asm., Cylinder Head (Incl.,,0-,,) D 0 Gasket, Exhaust 0 Stud 000 Washer 00 Nut 0 Pin, Straight 0 00 Gasket, Cylinder 0 Cylinder 0 Gasket, Head 0 Gasket, Cam 000 Adapter 0 Asm., Adapter Band (Incl. ) 0 Screw 0 Bolt 0 Bolt, Flange /0
51 CRANKSHAFT and PISTON MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 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.,) 0 Pin, Piston 0 Clip 0 Bolt 0 Asm., Connecting Rod (Incl.,) 0 Crankshaft, Complete (Incl. ) 0 Key, Woodruff Spacer Spacer Spacer Spacer 0 0 Sprocket 0 Nut 0 Washer 00 Nut, Lock Nut 0 Bearing, Ball Bearing (STD) Bearing (0.0 U/S)(If built after //) Bearing (0. U/S)(If built after //) /0 D
52 INTAKE and EXHAUST MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC Screw, Adjusting 0 Nut 00 Asm., Rocker Arm (Incl.,) 00 Shaft, Rocker 0 Washer, Wave 00 Collet, Valve 0 Retainer, Spring 0 Spring, Valve 0 Lever, Release 0 00 Spring, Return 00 Camshaft (Incl.,0,) 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 /0 D
53 RECOIL STARTER MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Reel 0 Spring, Return 0 Ratchet 0 Spring, Friction 0 Plate, Friction 0 Bolt and Washer 0 Plug 0 Gasket 0 Bushing, Starter 0 0 Spring, Spiral 00 Bushing 0 Gasket, Recoil 0 Bolt, Flange Asm., Recoil (Incl. -,-,,) Starter Case (Incl. ) 00 Rope /0 D0
54 CARBURETOR MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC D
55 CARBURETOR MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 00 Ring 00 E-Ring 00 Needle, Jet 0 Ring 0 Diaphragm 0 Jet, Needle 0 Screw 00 Washer, Spring Asm., Jet Block 0 00 Washer 0 Jet, Main (#) 0 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 0 Washer 0 Spring 0 Adjuster 0 Screw, Adjust 0 Ring 0 Spring Valve, Throttle (0) 0 Spring 0 Ring 00 Screw 0 Asm., Throttle Shaft 0 Guide, Cable 0 0 Screw 0 Cover 0 O-Ring 0 Holder, Guide 0 Spring 0 Asm., Plunger Jet, Air (#) Asm., Carburetor (Incl. -,-) 00 Screw and Washer Spring 0 Asm., Cover 0 Screw /0 D
56 OIL PUMP and OIL FILTER MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Plug 0 Gasket 0 Spring 0 Valve, Relief 00 Bolt, Flange 0 Strainer, Oil 0 Filter, Oil 00 Screw 00 Cover, Oil Pump 0 0 Rotor, Inner 0 Rotor, Outer /0 D
57 MAGNETO MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Coil, Ignition 00 Cap, Spark Plug 0 Plug, Spark 0 O-Ring 00 Asm., Plate 0 Bolt and Washer 0 CDI System 00 Nut 000 Washer, Spring 0 0 Switch, Magnetic 0 Flywheel w/ring Gear /00 D
58 STARTING MOTOR MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 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.,FrontBracket(Incl.) E 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 000 Asm., Gear Shaft (Incl. -) /00
59 FUEL PUMP MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 Asm., Fuel Pump (Incl. -) 0 Screw and Washer 0000 Screw and Washer 0 Screw 0 Diaphragm Gasket Set / E
60 TOOL KIT MAGNUM X A0CDAA and MAGNUM X A0CDAB and MAGNUM X HDS A0CDFB and MAGNUM X FREEDOM A0CDAC 0 0 Kit, Tool (Incl. -) 0 Gauge, Tire Pressure 000 Wrench, Open -0mm 000 Wrench, Open -mm 0 Wrench, Box 0 Puller, Spark Plug (Wrench Handle) 0 Screwdriver E Pouch, Tool Kit Lube, U-Joint, oz., Case 0 Owner s Manual, 0 ATV Supplement, Owner s Manual, 0 Magnum x (AA)(AB)(AC) Suplement, Owner s Manual, 0 Magnum x HDS (FB) 0 Wrench, Torx /0
61 DECALS MAGNUM X FREEDOM A0CDAC Decal, Warning, Front/Rear Rack 0 Urocal, X on Demand True WD 0 0 Decal,, Flag, Side Panel, LH Decal,, Flag, Side Panel, RH 0 Decal, Age Warning, ATV 00 Decal, Ignition 00 Decal, Warning, AWD Switch 0 Logo, Polaris Star 0 Decal, POLARIS, Front Cover 00 Decal, MacPherson Strut 0 0 Decal, Drain Recoil 0 Decal, Reflector, Red 0 Urocal, Freedom Series 00 Decal, Warning, Override, AWD 0 0 Decal, Tank Side, Flag, LH Decal, Tank Side, Flag, RH 0 Urocal, Magnum 00 Decal, Passenger Warning 00 Decal, Tire Pressure 0 Decal, POLARIS, Rear 00 Decal, Discretionary Warning 0 00 Decal, Warning, General, CPSC 0 Decal, Reflector, Amber /0 E
62 This page left blank intentionally.
63 PRINTED IN THE USA PARTS MANUAL PN 0 and MICROFICHE PN 0 /0
Page 1 of 1
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