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2002 Polaris Magnum 325 2x4 Parts Manual

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🏷️ Basic Information Identification Make: Polaris Model: Magnum 325 2x4 Model Variant: HDS Codes Oem Code 1: A02CB32AA Oem Code 2: A02CB32AB Oem Code 3: A02CB32FC 👋 Introduction Market Position Atv Segment: Entry-to-mid-level utility ATV, popular for recreational riding and light farm/ranch work. Competitive Analysis Competitors: Honda FourTrax 300/350, Yamaha Wolverine 350, Suzuki QuadRunner 300/300F, Kawasaki Bayou 300. Key Features Ease Of Maintenance: Designed with simpler construction, making it accessible for DIY maintenance and repairs. Part Availability: The availability of specific parts manuals ensures access to correct OEM components for repairs. Value Proposition Cost Savings: Empowers owners to perform their own maintenance and repairs, significantly reducing labor costs from authorized service centers. 📋 Manual Details Coverage Areas Manual Type: Parts Manual Coverage Focus: Component identification and assembly for routine maintenance and repair. Page Count Total Pages: 54 Language Language: English Format File Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Powertrain: Engine Mounting, Cooling System, Exhaust System, Fuel Tank, Oil Tank, Air Box, Carburetor, Oil Pump, Magneto, Starting Motor, Piston and Crankshaft, Crankcase and Cylinder, Recoil Starter, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase/Brake and Chain Cover Mounting, Rear Wheel Drive. Chassis & Suspension: Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, A-Arm/Strut Mounting, Center Tightener, Swing Arm/Shock Mounting, Front Drive, Front Tightener, Front Strut, CV Joint – BTB, Front Wheel. Braking System: Front Brake, Rear Brake, Controls -- Master Cylinder/Brake Line. Controls & Electrical: Controls -- Throttle Asm./Cable, Steering Post, Handlebar and Headlight Pod, Electrical/Taillight. Bodywork & Aesthetics: Decals. Procedures Included Component Identification: Detailed exploded diagrams for every component group with associated part numbers. Parts Procurement: Facilitates ordering correct replacement parts by providing OEM part numbers. Assembly/Disassembly Reference: Visual guides for understanding component relationships and installation order. Technical Depth Depth Level: Comprehensive parts cataloging for repair and maintenance purposes. Diagram Detail: Exploded diagrams offering clear visual representation of assemblies and individual parts. 📊 Manual Specifications File Format Print Quality Support: Printable pages, allowing users to print specific sections or the entire document. Searchability: Likely text-searchable PDF for quick information retrieval. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Liquid-Cooled, SOHC Displacement: 325 cc Bore X Stroke: Details not explicitly provided in the product description but available within the manual. Performance Horsepower: Estimated around 18-20 HP, typical for this class of ATV. Specific figures would be in the manual. Torque: Torque figures are model-specific and would be detailed in the manual. Fuel System Fuel Delivery: Carbureted (specific carburetor model expected within the manual). Cooling System Cooling Method: Liquid-cooled, requiring a specific coolant mixture. The manual covers the cooling system components. Lubrication Oil Type: Specific oil viscosity and API classification for the engine and potentially transmission/final drive would be detailed. SAE 10W-40 is a common specification. Ignition Ignition System: CDI (Capacitor Discharge Ignition) with a Magneto ignition source, detailed in the manual. 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) with High/Low range and Reverse. Optional Optional Transmissions: N/A for this model. Features Drive Clutches: Primary (Drive) and Secondary (Driven) clutch systems, covered extensively in the manual with part numbers. Gearcase: Includes components for final drive and potentially integrated transmission elements, detailed in the 'Gearcase/Brake and Chain Cover Mounting' and 'Gearcase' sections. Fluid Type Gearcase Oil Type: Specific gearcase lubricant type and capacity would be detailed in the manual. Often a dedicated gear oil or engine oil blend. 📐 Dimensions Exterior Length: Approx. 78 inches (198 cm). Specific dimensions are best confirmed in the manual or OEM specifications. Width: Approx. 45.5 inches (115.5 cm). Specific dimensions are best confirmed in the manual or OEM specifications. Height: Approx. 45 inches (114 cm). Specific dimensions are best confirmed in the manual or OEM specifications. Weights Dry Weight: Approx. 540 lbs (245 kg). Specific weights are best confirmed in the manual or OEM specifications. Ground Clearance: Typically around 7-8 inches (17.8-20.3 cm). Detailed measurements would be in the manual. Cargo Rack Capacity Front: Specific weight capacity for front rack would be listed in the manual. Rack Capacity Rear: Specific weight capacity for rear rack would be listed in the manual. 🛡️ Safety Features Ratings Safety Standards: ATVs are subject to specific safety regulations and standards (e.g., ANSI). The manual focuses on mechanical safety through correct part usage. Active Features Braking System: Hydraulic disc brakes on all wheels (front) and potentially drum or disc (rear, depending on specific variant), covered by the manual's brake sections. Passive Features Handlebar Design: Ergonomic handlebar and control layout for stable operation. Lighting: Headlights and taillight for visibility, with components detailed in the Electrical/Taillight section. 💡 Technology Features Infotainment Infotainment System: Basic dashboard with indicator lights (neutral, reverse, oil). No advanced infotainment features. Driver Assistance Driver Assistance...
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Type: Atv
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Sku: 25721
Collections: ALL ATV Powersports

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2002 Polaris Magnum 325 2x4 Parts Manual2002 Polaris Magnum 325 2x4 Parts Manual2002 Polaris Magnum 325 2x4 Parts Manual2002 Polaris Magnum 325 2x4 Parts Manual
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Magnum 325 2x4
Model Variant:
HDS
Codes
Oem Code 1:
A02CB32AA
Oem Code 2:
A02CB32AB
Oem Code 3:
A02CB32FC
👋 Introduction
Market Position
Atv Segment:
Entry-to-mid-level utility ATV, popular for recreational riding and light farm/ranch work.
Competitive Analysis
Competitors:
Honda FourTrax 300/350, Yamaha Wolverine 350, Suzuki QuadRunner 300/300F, Kawasaki Bayou 300.
Key Features
Ease Of Maintenance:
Designed with simpler construction, making it accessible for DIY maintenance and repairs.
Part Availability:
The availability of specific parts manuals ensures access to correct OEM components for repairs.
Value Proposition
Cost Savings:
Empowers owners to perform their own maintenance and repairs, significantly reducing labor costs from authorized service centers.
📋 Manual Details
Coverage Areas
Manual Type:
Parts Manual
Coverage Focus:
Component identification and assembly for routine maintenance and repair.
Page Count
Total Pages:
54
Language
Language:
English
Format
File Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine Mounting, Cooling System, Exhaust System, Fuel Tank, Oil Tank, Air Box, Carburetor, Oil Pump, Magneto, Starting Motor, Piston and Crankshaft, Crankcase and Cylinder, Recoil Starter, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase/Brake and Chain Cover Mounting, Rear Wheel Drive.
Chassis & Suspension:
Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, A-Arm/Strut Mounting, Center Tightener, Swing Arm/Shock Mounting, Front Drive, Front Tightener, Front Strut, CV Joint – BTB, Front Wheel.
Braking System:
Front Brake, Rear Brake, Controls -- Master Cylinder/Brake Line.
Controls & Electrical:
Controls -- Throttle Asm./Cable, Steering Post, Handlebar and Headlight Pod, Electrical/Taillight.
Bodywork & Aesthetics:
Decals.
Procedures Included
Component Identification:
Detailed exploded diagrams for every component group with associated part numbers.
Parts Procurement:
Facilitates ordering correct replacement parts by providing OEM part numbers.
Assembly/Disassembly Reference:
Visual guides for understanding component relationships and installation order.
Technical Depth
Depth Level:
Comprehensive parts cataloging for repair and maintenance purposes.
Diagram Detail:
Exploded diagrams offering clear visual representation of assemblies and individual parts.
📊 Manual Specifications
File Format
Print Quality Support:
Printable pages, allowing users to print specific sections or the entire document.
Searchability:
Likely text-searchable PDF for quick information retrieval.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, Liquid-Cooled, SOHC
Displacement:
325 cc
Bore X Stroke:
Details not explicitly provided in the product description but available within the manual.
Performance
Horsepower:
Estimated around 18-20 HP, typical for this class of ATV. Specific figures would be in the manual.
Torque:
Torque figures are model-specific and would be detailed in the manual.
Fuel System
Fuel Delivery:
Carbureted (specific carburetor model expected within the manual).
Cooling System
Cooling Method:
Liquid-cooled, requiring a specific coolant mixture. The manual covers the cooling system components.
Lubrication
Oil Type:
Specific oil viscosity and API classification for the engine and potentially transmission/final drive would be detailed. SAE 10W-40 is a common specification.
Ignition
Ignition System:
CDI (Capacitor Discharge Ignition) with a Magneto ignition source, detailed in the manual.
🔧 Transmission
Standard
Transmission Type:
Automatic (PVT - Polaris Variable Transmission) with High/Low range and Reverse.
Optional
Optional Transmissions:
N/A for this model.
Features
Drive Clutches:
Primary (Drive) and Secondary (Driven) clutch systems, covered extensively in the manual with part numbers.
Gearcase:
Includes components for final drive and potentially integrated transmission elements, detailed in the 'Gearcase/Brake and Chain Cover Mounting' and 'Gearcase' sections.
Fluid Type
Gearcase Oil Type:
Specific gearcase lubricant type and capacity would be detailed in the manual. Often a dedicated gear oil or engine oil blend.
📐 Dimensions
Exterior
Length:
Approx. 78 inches (198 cm). Specific dimensions are best confirmed in the manual or OEM specifications.
Width:
Approx. 45.5 inches (115.5 cm). Specific dimensions are best confirmed in the manual or OEM specifications.
Height:
Approx. 45 inches (114 cm). Specific dimensions are best confirmed in the manual or OEM specifications.
Weights
Dry Weight:
Approx. 540 lbs (245 kg). Specific weights are best confirmed in the manual or OEM specifications.
Ground Clearance:
Typically around 7-8 inches (17.8-20.3 cm). Detailed measurements would be in the manual.
Cargo
Rack Capacity Front:
Specific weight capacity for front rack would be listed in the manual.
Rack Capacity Rear:
Specific weight capacity for rear rack would be listed in the manual.
🛡️ Safety Features
Ratings
Safety Standards:
ATVs are subject to specific safety regulations and standards (e.g., ANSI). The manual focuses on mechanical safety through correct part usage.
Active Features
Braking System:
Hydraulic disc brakes on all wheels (front) and potentially drum or disc (rear, depending on specific variant), covered by the manual's brake sections.
Passive Features
Handlebar Design:
Ergonomic handlebar and control layout for stable operation.
Lighting:
Headlights and taillight for visibility, with components detailed in the Electrical/Taillight section.
💡 Technology Features
Infotainment
Infotainment System:
Basic dashboard with indicator lights (neutral, reverse, oil). No advanced infotainment features.
Driver Assistance
Driver Assistance Features:
None typical for this era and class of ATV.
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 100-200 operating hours or annually. The manual would provide the exact interval and procedure.
Air Filter Maintenance:
Regular inspection and cleaning/replacement, especially in dusty conditions. Covered in the Air Box section.
Spark Plug Replacement:
Periodic replacement based on hours or mileage. Specific spark plug part number and gap would be in the manual.
Fluid Specifications
Engine Oil Capacity:
Specific oil capacity would be detailed in the manual, usually around 1.5-2 quarts.
Coolant Type:
A 50/50 mixture of antifreeze and distilled water is standard. Specific type might be mentioned.
Known Issues
Clutch Wear:
As with many belt-driven ATVs, clutch wear and belt degradation can occur over time. The manual details clutch components and replacement.
Carburetor Cleaning:
Carburetors can require periodic cleaning due to fuel varnish or debris, particularly if the ATV sits for extended periods. The Carburetor section is crucial here.
Drive Line Maintenance:
CV joints and drive shafts require inspection for boot integrity to prevent contamination and premature wear.
📚 Vehicle History
Brand Heritage
Polaris Atv History:
Polaris has a long history in powersports, particularly with ATVs, establishing itself as a major manufacturer known for innovation and ruggedness.
Model Evolution
Magnum Series:
The Magnum series was a popular line of Polaris ATVs, known for their blend of power and utility in the late 1990s and early 2000s. The 325cc engine offered a good balance for its time.
Production
Model Year:
2002
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific awards for the 2002 Magnum 325 are not widely publicized, but Polaris ATVs of this era generally received positive reviews for performance and value in their segments.
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