2005 Polaris Magnum 330 4×4 Parts Manual – PDF DOWNLOAD

PARTS MANUAL PN 9919490 and MICROFICHE PN 9919491 7/04

MAGNUM 330 4X4 Model #A05CD32AA Model #A05CD32AB Model #A05CD32AC

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TABLE OF CONTENTS MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Parts Manual

A

G

A- ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14 AIR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C8

CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARBURETOR MOUNTING . . . . . . . . . . . . . . . . . .

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROLS - MASTER CYLINDER/BRAKE LINE . .

CONTROLS - THROTTLE ASM./CABLE . . . . . . . .

CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT and PISTON . . . . . . . . . . . . . . . . .

CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D1-2 B3-4 C3 A8 B11 C14 D4 D3

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . B13

DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE SHAFT, FRONT . . . . . . . . . . . . . . . . . . . . .

DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . .

A13 C1 B7 C2

C

D

E ELECTRICAL/TAILLIGHT . . . . . . . . . . . . . . . . . . . C4 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . B1-2 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . B5

F

FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . .

FRONT PROP SHAFT . . . . . . . . . . . . . . . . . . . . . .

FRONT RACK and BUMPER MOUNTING . . . . . . . .

FRONT STORAGE BOX . . . . . . . . . . . . . . . . . . . .

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G

A10 A5 C6 B8 A7 A9 D10 B3-4

GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . C10

H I

INTAKE and EXHAUST . . . . . . . . . . . . . . . . . . . . . D5

M

MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8

O

OIL COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . A14 OIL PUMP and OIL FILTER . . . . . . . . . . . . . . . . . . D7

R

RACK MOUNTING, REAR . . . . . . . . . . . . . . . . . .

REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR CAB and SEAT . . . . . . . . . . . . . . . . . . . . .

REAR HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . .

RECOIL STARTER . . . . . . . . . . . . . . . . . . . . . . . .

A6 A11-12 A3-4 C9 C5 D6

SHOCK MOUNTING . . . . . . . . . . . . . . . . . . . . . . .

STARTING MOTOR . . . . . . . . . . . . . . . . . . . . . . . .

STEERING POST . . . . . . . . . . . . . . . . . . . . . . . . .

STRUT MOUNTING . . . . . . . . . . . . . . . . . . . . . . . .

STRUT, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . .

SWING ARM/REAR/GEARCASE MOUNTING . . . . .

C12 D9 B12 B14 B9 C11

S

T

TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11 TRANSMISSION MOUNTING . . . . . . . . . . . . . . . . . C13

W

WHEEL, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . B10

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.

REAR CAB and SEAT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

16 6

7

15

5

9 1

18 19

10

13 11

4 3 2

38 39

41

17

14

8

12 37

6

3

21

36 35 40

20

22 34 33

32

23

31 10 30

28 29

24 25 26 27 28

A3

REAR CAB and SEAT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

7661645 7511930 7555792 5811107 5432117-382 5432117-400 5435164-455 7541925 5224592 5811308 7512242 7555859 7512085 7556034 5431786 7621403 5211033 1040387 7041370 2683222-070 2682958-070 7517375 5431787 7515199

Qty.

10 2 4 1 1 1 1 4 1 1 4 14 2 2 1 2 2 1 1 1 1 2 1 3

Description

Rivet Bolt Washer Foil, Rear Cab, Rear Cab, Rear, Silver Vapor Metallic (AA) Cab, Rear, Camo Green Metallic (AB) Cab, Rear, New Break Up (AC) Nut, Nylok Retainer, Seat Latch Foil, Tape, Rear Cab Screw Washer, Flat Screw Washer Box, Tool Rivet Bracket, Lever Retainer Latch, Seat Spring, Latch Asm., Seat, Black Covering, Seat, Black Screw Cover, Tool Box Screw

Ref. Part No.

Qty.

22 1040447-067 23 - - - - - - -

1 Box, Battery 1 Asm., Front Gearcase (See Front Housing Pg. C6 for Details) 4 Washer, Spring Lock 4 Screw 1 Guard, Rock 7 Washer 9 Screw 2 Washer, Flat 8 Nut, Nylok 8 Grommet 8 Screw 1 Frame, Main 1 Footwell, LH, Black 1 Footwell, RH, Black 21 Screw 1 Foil, Rear Fender 1 Foil, Tape 1 Decal, 4 Stroke Carburetor/Filter 1 Foil 12 Nut, U-Type Speed 1 Guard, Mud, Rear, LH 1 Guard, Mud, Rear, RH

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

7552603 7512492 5435005 7556065 7517386 7558301 7542122 5412156 7517987 1014293-067 5432221-070 5433219-070 7512232 5811111 5811322 7170007 5811087 7670057 5431796-070 5431797-070

Description

7/04

A4

FRONT CAB MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

6

1

2

7

4

3

5 14

19

18

8

20 17

16

13

15

9 10

9

11

12

5 21 23 21

22 11

10

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 5811491 2 5812484 3 2632284-177 2632848-455 2632633-382 2632849-455 4 5 6 7

5811797 7512232 5811801 5435110-382 5435110-400 5435166-455 8 2632981-382 2632981-400 2632982-455

Qty.

Description

1 Foil, Side Panel, RH 1 Foil, Side Panel, RH 1 Asm., Panel w/Foam, LH, Black Metallic (AA)(AB) 1 Asm., Panel w/Foam, LH, New Break Up (AC) 1 Asm., Panel w/Foil, RH, Silver Vapor Metallic (AA)(AB) 1 Asm., Panel w/Foil, RH, New Break Up (AC) 1 Foam, Panel, Side, LH 10 Screw 1 Foam, Cab, Front 1 Cover, Front, Silver Vapor Metallic (AA) 1 Cover, Front, Camo Green Metallic (AB) 1 Cover, Front, New Break Up (AC) 1 Asm., Cab, Foam, Front, Silver Vapor Metallic (Incl. Warning Decals)(AA) 1 Asm., Cab, Foam, Front, Camo Green Metallic (Incl. Warning Decals)(AB) 1 Asm., Cab, Front, New Break Up (Incl. Warning Decals)(AC)

Ref. Part No.

9 7670057 10 5245394-067 5246021-067 11 7621509 12 7515158 13 7670135 14 7517312 15 5431798-070 5431799-070 16 7541925 17 7555792 18 5812138 19 7556034 20 7512085 21 7542122 22 7512126 23 7558221

Qty.

12 1 1 2 2 4 2 1 1 2 2 1 2 2 3 1 2

Description

Nut, Speed, U-Type Shield, Splash, LH Guard, Splash, RH Rivet Screw Nut, Speed Screw Guard, Mud, Front, LH Guard, Mud, Front, RH Nut, Nylok Washer Foam, Panel, LH Washer Screw Nut, Nylok Bolt Washer, Flat

7/04

A5

REAR RACK MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 2

3

4

5 6

7 12

8 9 10 11 12

12

8

13

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 7518280 2 7517983 3 2670174-070 4 7079927 5 7517312 6 7555859

Qty. Description

2 Screw 2 Screw 1 Asm., Rack, Rear (Incl. Ref. 4 and Warning Decal) 2 Decal, Reflector, Red 2 Screw 2 Washer, Flat

Ref. Part No.

7 8 9 10 11 12 13

1013724-067 7512329 7558402 5334092 5246394-067 7542324 7512371

Qty. Description

1 6 16 2 2 8 2

Support, Rear Rack Bolt Washer, Flat Spacer Mount, Front, Rear Rack Nut, Nylok Bolt 7/03

A6

FRONT RACK and BUMPER MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 1 2

4

2 4

7

5 6

5

3

7

15 16 7

16

7

4 8

15 14

9

4 6

10

7 13 11

12

4

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 7512232 2 1013744-067 1013746-067 3 5810467 4 7515399 5 1014099-067 1014101-067 6 2431011 2431012 4030061 7 7542324

Qty. Description

6 1 1 1 6 1 1 1 1 2 4

Screw Support, Front Rack, LH Support, Front Rack, RH Plug, Frame Screw Mount, Rack, LH Mount, Rack, RH Asm., Headlight, Side, LH Asm., Headlight, Side, RH Bulb, Headlamp, 30W Nut, Nylok

Ref. Part No.

8 9 10 11 12 13

7517977 5432155-070 1013772-067 7670094 7512097 5433923 5433924 14 5244729-067 5244730-067 15 7512329 16 7558402

Qty. Description

4 1 1 6 6 1 1 1 1 2 2

Screw Bumper Guard, Brush Nut, U-Type Screw Shield, Radiator Side, LH Shield, Radiator Side, RH Extension, Frame, LH Extension, Frame, RH Bolt Washer, Flat 10/03

A7

CONTROLS - MASTER CYLINDER/BRAKE LINE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

20

17 19

21

35

34

22 18

31

32

33 25

30

23

24

26 27 28 29

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

Qty. Description

2010238 17 5410988 18 4110164 19 2202725

1 2 1 1

20 7517899 21 2201836

2 1

22 2201833

1

23 2202410

1

24 2201835

1

Asm., Master Cylinder, LH Seal Switch Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) Screw Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) Kit, Master Cylinder Clamp (Incl. Clamp, Screws) Kit, Piston (Incl. Piston, Seals, Boot, Spring) Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip)

Ref. Part No.

25 26 27 28 29 30 31 32 33 34 35

1910565 7621462 7080539 1910838 7512024 7080138 8360031-34 1910839 7052292 1910470 1910499

Qty. Description

1 1 1 1 2 4 1 1 1 1 1

Line, Brake, JB to Rear Rivet Clamp, Nylon Line, Brake, Left Front Screw Cable Tie Conduit Line, Brake, Right Front Fitting, Cross Line, Brake, Pod Bolt, Banjo 7/04

A8

FRONT STORAGE BOX MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2 3

4 5

4

6 5 7 5

19

8

18 17

9 16

7

10

15 14 13

12

11

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7

1253528 7518216 7081101 5334257 7512076 5521641 7081125 7081145 8 7542324 9 7515399

Qty. Description

1 6 6 2 6 1 1 1 6 6

Asm., Front Cover (Incl. 2-5,8,17) Screw Ring, Tie Down Latch, Wire Screw Seal, Front Compartment Latch, 1/4 Turn, RH Latch, 1/4 Turn, LH Nut, Nylok Screw

Ref. Part No.

10 11 12 13 14 15 16 17 18 19

7555958 5133825 5435073-070 7541925 7555792 7512007 5412352 5246928 7512024 7081124

Qty. Description

4 2 1 2 2 2 3 2 2 2

Washer, Flat Pin, Hinge, Front Base, Front Box w/Decals Nut, Nylok Washer Bolt Plug, Compartment Channel, Lid Screw Cable, Lid, Front 7/03

A9

FRONT BRAKE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

11

5

4 6 7

8

10

9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4

1910841 1910842 7515489 5134639 5134640 1930642 5410494 1930665

Qty. Description

1 1 1 1 1 1 1 1

Asm., Brake Caliper, LH (Incl. 1-7,9,10) Asm., Brake Caliper, RH (Incl. 1-7,9,10) Screw, Socket Set Caliper, Brake, LH Caliper, Brake, RH Kit, Front Brake Boot Boot, Pin Seal Kit, Piston and Seal (Incl. 5-7)

Ref. Part No.

5 6 7 8 9 10 11

5410779 5410780 5132294 2202412 1910411 5410495 7080352

Qty. Description

1 1 1 1 1 1 1

Ring, Molded Square (.094) Ring, Molded Square (.103 x .134) Piston, Brake, Long Kit, Front Brake Pad Mount, Caliper Boot, Bushing Screw, Bleeder 7/04

A10

REAR BRAKE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2 2 1

3, 4

2

5

1

6

1, 2

3, 4 4 7

9

8 19

10 11

30 19

12

28

13 14

27

13 12

15

29 17

26

16

14

25 23 22

24

22

17

21

23 19 20

A11

15

18

15

1

1, 2, 6

REAR BRAKE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1910680 2201873 2201870 2201872 2201869 2201732 2202414 7512018 7080573 7512084 5434041 1930854 7080003 1910675 7515158 7558301

Qty. Description

1 1 1 1 1 1 1 1 1 6 3 1 2 1 2 3

Asm., Caliper Kit, Anvil Body Kit, Slide Bolt Kit -Seal Kit, Piston and Seal Kit, Bracket Pad, Rear Axle Kit, Brake Pad Assembly Screw Clamp, Rubber Coated Screw Clamp, Brake Line Asm., Reservoir, Brake, Rear Clamp, Hose Hose, Reservoir Screw Washer, Flat

Ref. Part No.

16 17 18 19 20 21 22 23 24 25 26 27 28

1012753-067 7542122 7512240 7517386 1014009-067 7041750 7555919 5433189 7661401 1910791 5410988 1910499 1910516

29 7042075 30 7670126

Qty. Description

1 2 2 3 1 1 2 2 1 1 6 3 1

Pivot, Mount, Brake, Rear Nut, Nylok Bolt Screw Rod, Brake Spring, Torsion, Brake Washer Bushing, Pedal Pivot Pin, Cotter Asm., Brake, Master Cylinder, Foot Seal Bolt, Banjo Line, Brake, Foot, Master Cylinder to Rear 1 Spring 1 Clip, Retaining 7/04

A12

DECALS MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

5

4

6

7

8

9

10

11

16

17

14 13

RH

18 19

12

15

25

24

20 21

22

23

LH

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 5435424 7173013 2 7172572 3 7172579 7172580 7172533 7172534 4 7171495 5 7172531 7172532 6 7172559 7 7079780 8 7172576 7172529 7172577 7172530 9 7078465

Qty.

Description

1 Badge, 50 Years (If built before 7/05/04) 1 Urocal, 50th Anniversary (If built after 7/05/04) 2 Decal, Warning, Front and Rear Rack 1 Decal, “AWD”, Side Panel, Lower, LH (AC) 1 Decal, “AWD”, Side Panel, Lower, RH (AC) 1 Decal, “AWD”, Side Panel, Lower, LH (AA)(AB) 1 Decal, “AWD”, Side Panel, Lower, RH (AA)(AB) 1 Decal, Arrow, ATP Container, RH 1 Decal, Side Panel, Upper, LH (AA)(AB) 1 Decal, Side Panel, Upper, RH (AA)(AB) 1 Decal, Age Warning, 16, ATV 1 Decal, Warning, AWD Switch 1 Decal, “Magnum 330”,Tank Side, LH (AC) 1 Decal, “Magnum 330”,Tank Side, LH (AA)(AB) 1 Decal, “Magnum 330”, Tank Side, RH (AC) 1 Decal, “Magnum 330”, Tank Side, RH (AA)(AB) 1 Logo, Polaris Star

Ref. Part No.

Qty.

10 7079916 7079773 7171879 11 7172569 12 7074220 13 7171473 14 7172562 15 7171472 16 7079672 17 7172564 18 7171494 19 7172578 20 7172566 21 7172571 22 7079927 23 7079960 7079959 7172066 24 7172561 25 7172560

1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 1 1 1

Description

Decal, “POLARIS”, Front Cover (AA) Decal, “POLARIS”, Front Cover (AB) Decal, “POLARIS”, Front Cover, Gold (AC) Decal, Warning, Front Rack, 90 lbs Decal, “MacPherson Strut” Decal, Reflector, Amber, RH Decal, Drain Recoil Decal, Reflector, Amber, LH Decal, Foot Brake Decal, Warning, Override, AWD Decal, Arrow, ATP Container, LH Decal, Side Panel, Upper (AC) Decal, Passenger Warning Decal, Tire Pressure Decal, Reflector, Red Decal, “POLARIS”, Rear (AA) Decal, “POLARIS”, Rear (AB) Decal, “POLARIS”, Rear, Gold (AC) Decal, Discretionary Warning, Drum Shift Decal, Warning, General, CPSC 8/04

A13

OIL COOLING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

5 4

6 7

3

2

10 11 12

4

13 8

9 14 15

18

17

Ref. Part No.

1 2 3 4 5 6 7 8

5412355 7512084 7080851 7515133 7547069 5245416-067 7542122 5248139 7542130 9 7555932

16

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Qty. Description Ref. Part No. Qty. Description

2 1 1 4 2 1 4 1 2 4

Hose, Cooler, Threaded 90 Degree Screw Clamp, Hose Bolt Nutsert Bracket, Oil Cooler, Top Nut, Nylok Bracket, Lower Oil Cooler Nut, Rivet Washer, Nylon

10 11 12 13 14 15 16

7517659 2410534 7670111 5433353 4010934 7558301 7512240 7512163 17 1240191 18 7080999

4 1 4 1 1 4 4 4 1 1

Screw Asm., Motor, Fan U-Clip Shroud, Fan Thermister Washer, Flat Bolt (If built before 2/21/04) Bolt (If built after 2/21/04) Cooler, Oil Cable Tie 7/04

A14

ENGINE MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

8

7

1

9

6 5

2

31

4

11

29

4

10

3

27 28 29

27

30

29

12 13 14 26

4

25

23 24

22

18 19

4

17

20

21

15

4

4 16

4

B1

ENGINE MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

8450003-1525 7052075 1202789 7547108 5247341 7552901 7512232 4010132 7512315 5412248 7555823 5411721 7080511 8360009-600 1013133-067 7517289

Qty.

AR 1 1 8 1 2 1 1 2 1 1 1 1 AR 1 2

Description

Ref. Part No.

Line, Fuel Fitting, Tee Engine, ES320PFE103 Nut, Flange Lock Bracket, Motor Mount Washer, Spring Lock Screw Cable, Ground Engine Bolt Mount, Rubber Washer, Flat Boot, Clutch Intake Clamp, Narrow Band Line, Fuel Mount, Engine, Rear Screw

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

3021119 7555815 7515417 5247342 3021181 5430261 5210748 7575202 7512566 4010095 8450103 2530009 7080003 8450040-150 7546601

Qty.

1 2 2 1 1 1 1 1 1 1 AR 1 8 AR 2

Description

Mount, Rubber, Rear Washer Screw Mount, Lower Front Mount, Rubber, Engine Bushing Washer, Flat Washer, Interlock Bolt Cable, Battery/Engine Hose, Fuel Filter Clamp, Hose Line, Fuel Nut, Nylok 7/04

B2

FUEL TANK and CARBURETOR MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4

6

3 5

2 1

8

26

25 18 19

23

24

10 11

22

13

21 20

13

19 18

19 18 17 16 15

7

14

B3

12

9

FUEL TANK and CARBURETOR MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

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

2520409 5812123 2873626 8360009-600 5431053 7512277 7558301 5222154 5222155 5811899 7542105 7552801 5245671-067 7547069

Qty. Description

1 1 1 AR 1 2 2 1 1 1 1 1 1 5

Asm., Tank, Fuel Gasket Kit, Fuel Gauge Hose, Vent Vent, Tank Bolt Washer, Flat Bracket, Fuel, Cover Mount, LH Bracket, Fuel, Cover Mount, RH Seal, Foam Nut, Hex Washer, Spring Lock Bracket, Carburetor Support Nutsert

Ref. Part No.

14 15 16 17 18 19 20 21 22 23 24 25 26

7517505 5432559 5432733 7052161 7080003 8450103 3084205 5245674-067 3110050 7512276 7555859 7515136 7052364

Qty. Description

1 1 1 1 8 AR 2 1 1 2 3 2 1

Screw Knob, Fuel Valve Nut, Fuel Valve Valve, 3-Way Clamp, Hose Line, Fuel Asm., Screw and Washer Mount, Carburetor Mount, Carburetor Bolt Washer, Flat Screw Fitting, Fuel, Duel Outlet 7/04

B4

EXHAUST SYSTEM MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

1

3 7

6

5

4

16 8 9

15

10 11

12 13

10 14 9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8

7542324 7555716 5410436 5412233 5010192 7515316 1261215-029 7512666

Qty. Description

2 2 2 2 2 2 1 1

Nut, Nylok Washer, Flat Washer, Rubber Dampener, Vibration Bushing Bolt, Carriage Silencer, Black Bolt

Ref. Part No.

9 10 11 12 13 14 15 16

7041804 5243517 1261222-029 7041687 7542301 3110064 1260960-029 3086237

Qty. Description

4 2 1 1 2 1 1 1

Spring, Exhaust Seal, Exhaust Headpipe, Black Spring, Exhaust Nut Mount, Torque Stop Manifold, Black Gasket, Exhaust 7/04

B5

AIR BOX MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

5

4

6 3

6

1 2

7 8 9

10 11

26

12

17

13 25 23 24

21

19

20

18 17

22

14 16

15

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

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

7518306 7558301 5812023 5433920 7517317 5810317 5433769 5811482 5242044 5432601 7080699 5433396 5411866

Qty. Description

1 1 1 1 2 2 1 1 6 1 1 1 1

Screw Washer, Flat Seal, Airbox, Intake Duct, Inlet, Airbox Cover Screw Pad Cover, Air Box Seal, Air Box Cover Clip, Air Box Collar, Carburetor Inlet Clamp, Hose Cap, Rubber Hose, Breather

Ref. Part No.

14 15 16 17 18 19 20 21 22 23 24 25 26

7080694 7080511 5411588 7080413 5433180 5830128 5435758 7556091 5435299 5812111 8450059-100 7080650 1253372

Qty. Description

2 1 1 2 1 1 1 2 1 1 AR 1 1

Clamp, Hose, Spring Clamp, Narrow Band Boot, Carburetor Clamp, Narrow Band Duct, Carburetor Inlet Gasket, Carburetor Inlet Box, Air Intake, 4 Stroke Spacer Plug, Trap Foil, Air Box, RH Line, Fuel Clamp, Hose Asm., Filter 7/04

B6

FRONT DRIVE SHAFT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

3

4

5

1

3 6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1332288 1 7670092 2 1590395 3 7710557

Qty. Description

2 2 2 2

Ref. Part No.

Asm., Drive Shaft, Front Circlip Joint (CV, Inner) Circlip

4 2202826 5 2201015 6 1590396

Qty. Description

2 Kit, Boot (Inner)(Incl. Clamps and Grease) 1 Kit, Boot (Outer)(Incl. Clamps and Grease) 1 Joint, CV (Outer) 3/04

B7

FRONT PROP SHAFT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

4

2

5

3

6

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

Qty.

1380229 1 3260133 2 2202015 3 1380188

1 1 2 1

Description

Ref. Part No.

Asm., Front Prop Shaft (Incl. 1-4) Yoke, Gear Case, Front Kit, Cross and Bearing Shaft, Prop

4 5 6 7

3260131 7080424 5411092 7661913

Qty.

1 1 1 1

Description

Yoke, Propshaft, Transmission Fitting, Lubrication O-Ring Pin, Spring 7/03

B8

FRONT STRUT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

5 1 2 3 4

6 7 22 19

20

8 21

18 16 17

9

15 10

14

12

11

13

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8

7547104 7555749 5810291 5432872 5132062 5432871 5243364 7042312-385 7042312-067 9 5411608 10 7518340 11 5134154 5134155

Qty. Description

2 2 2 2 2 2 2 2 2 2 4 1 1

Nut Washer Spacer, Rubber Ball, Pivot, Top Spacer Ball, Pivot, Bottom Retainer, Spring Spring, Compression, Silver (AA) Spring, Compression, Black (AB)(AC) Bumper Bolt, Flange Support, Hubstrut, LH Support, Hubstrut, RH

Ref. Part No.

Qty. Description

12 13 14 15

3514342 7710507 7080306 -------

2 2 2 1

16 17 18 19 20 21 22

7558402 7552901 7512365 7542343 7080367 5211115 7041761

4 4 4 4 2 2 2

Bearing, Hubstrut Ring, Retaining Fitting, Lubrication w/Ball Asm., Brake Caliper (See Front Brake Pg. A10 for Details) Washer, Flat Washer, Spring Lock Screw, Cap Nut, Flange Clamp, Cable Washer Strut, Front 7/04

B9

FRONT WHEEL MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

1

3 4 7

6

5

8

9 11 10

12

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7

7512325 5244314 7515513 5134310 7556004 7542810 7661401

Qty. Description

8 2 8 2 2 2 2

Bolt Disc, Brake, Front Stud Hub, Wheel, AWD Washer Nut, Slotted Pin, Cotter

Ref. Part No.

8 5411164 9 1520269-486 1520269-067 10 7547237 11 5411709 12 1525017

Qty. Description

2 2 2 8 2 2

Hub, Dust Cover Rim, Front, Silver (AA) Rim, Front, Black (AB)(AC) Nut, Flange Tire, Front, 24x8-12 Valve, Rim 7/04

B10

CONTROLS - THROTTLE ASM./CABLE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 2

3

4

5

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 5434113 2 5410193 3 5411439

Qty.

Description

1 Cover, Throttle Control 1 O-Ring 1 O-Ring

Ref. Part No.

4 7081181 5 2010230 6 2010191

Qty.

Description

1 Cable, Throttle 1 Asm., Throttle Control (Incl.6) 1 Asm., Throttle Clamp 7/04

B11

STEERING POST MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

3

1

2 4

5

2

5

11 1

6 7 8

10 6 9

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6

7542324 5433866 1822630-067 5246732 7517428 7556162

Qty.

4 2 1 1 4 2

Description

Ref. Part No.

Nut, Nylok Bushing, Steering, Upper Post Steering Bracket, Upper Steering Bushing Bolt, Carriage Bushing

7 8 9 10 11

5222393 3514352 7547158 7661633 7558402

Qty.

1 1 1 1 2

Description

Flangette Bearing Nut, Slotted Hex Pin, Cotter Washer, Flat 7/04

B12

HANDLEBAR MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

24

4 23 11

5 10 9 21

6 22

7

13 12

8

21

14

15

16

18 20

17 19

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

Qty. Description

1 2 3 4 5 6 7 8

7078465 7518176 7080922 7081176 5435256-070 7515189 5248182 -------

1 2 1 1 1 4 1 1

9 10 11 12 13 14 15

5433903 4010592 5433834-070 5432952 7517625 5334127-067 5132382

1 1 2 1 1 1 1

Logo, Polaris Star Screw Nut, Choke Cable, Choke Panel, Instrument Screw Bracket, Instrument Panel Asm., Master Cylinder (See Control - Master Cyl./Brake Line Pg. A8 for Details) Spacer, Switch, LH Switch, Handlebar, Hi/Lo/Off Grip, Handlebar Plug, Hole Screw, Set Tube, Handlebar Cap, Hall Sensor

Ref. Part No.

Qty. Description

16 4010298 17 7517658 18 5631517 5631516 19 7542122 20 - - - - - - -

1 1 1 1 4 1

21 4011002 5431964 4010278 4010321

1 1 1 1

22 5433733 23 5412138 24 3280450

1 1 1

Sensor, Hall Effect Screw Block, Handlebar, Pegged Block, Handlebar Nut, Nylok Asm., Throttle Control (See Controls Throttle Asm./Cable Pg. B11, Ref. 5) Switch, Ignition Cover, Key Blank, Key, Series 2000, 6700, 6800 Blank, Key, Series 2200, 2300, 2700, 2800. 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 Mount, Rubber Cluster, Instrument 7/04

B13

A-ARM/STRUT MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

25

24

26

27

22

1 2

28

27

23

3

26

22

25

21

4

5

20

6

19 18

8

9

7

17

10

6

16 15

11 13 14 12

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

7080927 5211121 5410548 7512284 7542438 7661203 5435028-070 5435029-070 7512084 7517909 7556099 7547177 5411920 7061054 7547028 5020926

Qty. Description

2 2 2 4 2 4 1 1 6 2 4 2 1 2 2 2

Joint, Ball Bracket, Ball Joint Boot, Rubber Bolt, Socket Nut, Castle Pin, Cotter Shield, CV Joint, Black, LH Shield, CV Joint, Black, RH Screw Bolt Washer Nut, Lock Boot, Seal, Rod End Rod, End, LH Nut, Jam, LH Rod, Tie

Ref. Part No.

16 17 18 19 20 21 22 23

Qty. Description

7542711 7061034 5411291 7515415 1820805 5133806 5434551 2202280 2202281 24 - - - - - - -

2 2 2 2 2 2 4 1 1 1

25 26 27 28

4 4 2 2

7512492 7552603 7555832 7542439

Nut, Jam Rod End, RH Boot, Seal, Rod End Screw Asm., Tie Rod (Incl. 13-18) Shaft, A-Arm Bushing, A-Arm, Long Kit, A-Frame, LH (Incl. 6,21,22,25,26) Kit, A-Frame, RH (Incl. 6,21,22,25,26) Support, Hubstrut (See Front Strut Pg. B9, Ref. 11) Screw Washer, Spring Lock Washer Nut, Nylok 7/04

B14

DRIVE CLUTCH MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2

3

4

6

7

1 5

12

11

10

9 8

4

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1321976 1 2 3 4 5

7518062 5430945 1321457 5431936 5210752 5242981 5210753 5210754

Qty.

Description

1 Asm., Drive Clutch, Wide (Incl. All Less 6,11) 6 Screw 6 Washer, Multilube 3 Asm., Roller and Bushing 6 Button, Clutch AR Spacer, .020 AR Spacer, .025 AR Spacer, .032 AR Spacer, .050

Ref. Part No.

6 7 8 9 10 11 12

5630279 7512266 7541906 3576504 5020422 7041157 3576510

Qty.

3 3 3 1 3 1 1

Description

Weight, Shift, 16 Bolt, Shoulder Nut, FLEXLOC Bearing, Moveable Pin, Roller Spring, Clutch Cover, Bearing

7/04

C1

DRIVEN CLUTCH MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

8

9

7

2

6

3 4

10 5

11 12 13

14 15

16

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8 9

7556120 5220646 7552901 7515382 1322337 3211077 5430766 7511854 7710448

Qty. Description

AR 1 1 1 1 1 3 3 1

Bushing Washer, Domed Washer, Spring Lock Bolt Asm., Driven Clutch (Incl. 7-16) Belt, Drive Button, Ramp Bolt Ring, Retaining

Ref. Part No.

10 11 12 13 14 15 16

5244116 5133701 7041782 3576511 3576504 7556804 7555898 7556076

Qty. Description

1 1 1 1 1 AR AR AR

Spacer Ramp, Stationary Spring, Clutch Bearing, Moveable, 1 Inch Bearing, Moveable, 1/2 Inch Washer, .030 Washer, .020 Washer, .025 7/03

C2

CLUTCH COVER MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 2

3

4 5

6

8

9

7

10

11

21

20

19

18

1 16

13 17

12

9

16 1

15 14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11

7517386 2632513 2201956 5433363 7517599 7080909 5521578 5434255-070 7512094 5410542 5434264

Qty.

3 1 1 1 5 1 1 1 9 1 1

Description

Ref. Part No.

Screw Asm., Foam, Clutch Air Inlet Kit, Inner Clutch Cover Duct, Inlet Asm., Bolt and Washer Clamp, Narrow Band Seal, Outer, Clutch Cover Cover, Clutch, Outer Screw O-Ring Plug, Drain

12 13 14 15 16 17 18

7172746 7172563 5411489 7080707 7558301 5434213 -------

19 5242046 20 5410575 21 5411795

Qty.

Description

1 1 1 2 2 1 3

Decal, “Automatic Transmission” Decal, Warning, Clutch Cover Boot, Duct Clamp, Narrow Band Washer, Flat Duct, Air Outlet Asm., Screw and Washer (See Crankcase Pg. C14, Ref. 8) 1 Bracket, Clutch Seal 1 Seal, Cover Case 1 Stopper, Inner Clutch Cover 7/04

C3

ELECTRICAL/TAILLIGHT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2 4

3

1

5 6 8

17

10

26

20

11

27 25

24

14 15 16

12 11

9

28

13

7

22

21

19

18

23

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

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

2410500 2200593 2410320 4032046 4032029 4030043 4032045 ------7670054 7518287 7571602 7512027 5810290 2202213

Qty.

1 1 1 1 2 1 1 1 2 2 4 2 3 1

Description

Ref. Part No.

Harness, Main Kit, Circuit Breaker, 20 AMP Asm., Taillight (Incl. 4-9) Lens, Taillight Screw, Taillight Bulb, Taillight Gasket, Taillight Backing, Taillight/Brake Light Nut, Speed Nut, Flange Washer Screw Pad, Battery Kit, Battery Bolt

15 16 17 18 19 20 21 22 23 24 25 26 27 28

4010095 7010032 5412499 4010774 5431769 4010094 4010093 7512007 4011088 7512024 7541925 4020139 7080138 7670109

Qty.

1 2 1 1 1 1 1 2 1 2 2 2 9 2

Description

Cable, Battery/Engine Hook, Battery Strap Strap, Battery Holddown Battery Cover, Battery Cable, Battery/Solenoid Cable, Solenoid/Starter Bolt Module, Electronic Control Screw (AA) Nut, Nylok Clip, Rosebud Cable Tie Clip, Routing 7/04

C4

REAR WHEEL DRIVE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

3

4

2

1

8 9 10

7

5

6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6

7661404 7547237 5131649 7515513 5411936 1525017

Qty. Description

2 8 1 8 2 2

Pin, Cotter Nut, Flange Hub, Wheel, Rear (RH Side) Stud Tire, 24x11-12 Valve, Rim

Ref. Part No.

7 1520564-385 1520457-067 8 7555796 9 7543005 10 5411164

Qty. Description

2 2 2 2 2

Rim, Rear (AA) Rim, Rear (AB)(AC) Washer, Cone Nut, Castle Cover, Dust, Hub 7/04

C5

FRONT HOUSING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 2

3 4 5 6

14 13

2

25

7

9

8

10

13 11

24

14

7 12 23

22

18

17

16

15

19

6 21

20

13

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1341497 3233955 1 3234163 2 3234159 3 4 5 6 7 8 9 10

Qty. Description

1 1 1 1

3234164 3234165 3234161 3233926 3233953 3233928 3234166 3234167

1 1 1 2 1 1 1 1

------11 3233957

1 14

Asm., Front Gearcase Kit, Bolt Screw, Set Asm., Cover Plate (Incl. Output Cover, Insert and Coil) Button, Thrust Plate, Thrust Shim, Armature Plate Bearing, Roller Ball Asm., Race/Output Hub (Incl. 22) Pin, Dowel Clutch Housing/Ring Gear Asm., Roll Cage (Incl. Spring and Roll Cage) Spring Kit, Roll

Ref. Part No.

12 3234169 13 3233956 14 15 16 17 18 19 20 21

3233918 3233947 3234112 3233944 ------------3233942 3233951

22 23 24 25

3233929 3234168 3234162 3234160

Qty. Description

1 Bushing 1 Kit, Minor Repair (Incl. O-Rings and Seals) 11 Bolt 1 Cover, Input 1 Bearing, Roller Ball 1 Shaft, Pinion, 11T 1 Bushing 1 Gearcase, LH 1 Plug, Oil Fill 1 Asm., Drain Plug (Incl. Plug and Washer) 1 Bearing, Needle, Roller Thrust 1 Asm., Clutch (Incl. 9-11) 1 Ring, Retaining, Internal 1 Plate Armature 7/03

C6

GEARCASE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

21

20

22

19

18 17

24

16

14

25

15 24 12 9

2 1

3

4

6 7 5

8

26

15

33 31 32 28 30 29 27

28 30 29 33 31 35 34

3 18 62 63 59 58 56 67 65 64 19 61 55 66 60 57

69

23

13

11 10

23

54 53

52

18 51

68

C7

29

15 40 42 41 44 43 45

50 49

48 21 47

15 38 33 36 37

46

9

39

GEARCASE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

Qty.

1341372 3233961 3233906 3233826 3233827 3233829 3233869 3233831 3233832 3233788 3233324 3233711 3233867 3233524 3233910 3233018 3233036 3234028 3233019 3233529 3233865 3233846 3233874 3233859 3233858 3233860 3233915 3233916 3233849 3233875 3233850 3233851 3234027 3233718 3233853

1 1 1 8 1 1 1 1 1 2 1 1 1 1 1 4 1 1 4 4 1 17 1 2 2 1 1 1 2 3 2 2 1 3 1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Description

Ref. Part No.

Asm., Gearcase, Shaft Nut, Lock Bellcrank Screw Cover Pawl, Detent O-Ring Shaft, Shift Gear, 31T Seal, Triple Lip Washer Plug, Oil Fill Gearcase, Main Tube, Vent Drum, Shift Bearing Chain, Silent Shaft, Input Bearing, Ball Pipe, Knock Cover, Main, LH Screw Seal, Dual Lip Pin, Dowel Fork, Shift Rail, Shift Shaft Plate Dog, Engagement Spring, Wave Dog, Engagement Ring, Retaining Washer Gear, 33T Bearing, Needle Shaft, Reverse

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69

3233854 3233855 3233856 3234014 3233709 3233608 3233609 3233106 3233357 3233607 3233606 3233777 3233254 3233781 3233583 3233582 3233611 3233625 3233622 3233621 3233784 3233782 3233783 3233619 3233552 3234013 3233917 3233548 3233839 3233838 3233909 3233076 3233830 3233835 3233834

Qty.

1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Description

Sprocket, 24T Washer Gear, 30T Gear, 36T Gear, 48T Screw Cover, Bearing Ring, Snap Spacer Bearing, Ball Shaft, 10T Plug, Hex Flange Washer, Plug Cover, Output, Front Shim Button, Thrust Shim Shaft, Output, Front Shaft, Output, Rear Gear, 31T Chain, Silent Sprocket, 22/18T Sprocket, 22/22T Washer, Thrust Bushing Clamp, Tie Lockout, Park O-Ring Gear, 16T Disc, Lockout Star, Detent O-Ring Spring, Compression Switch Ring, Retaining 7/04

C8

REAR HOUSING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

16 3 4 5 6

25

7

24

8

9 10 11 14

13

7 23 12

15 16 15 14

17

18

19

20

21

22

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1341423 1 2 3 4 5 6 7 8 9 10 11 12

3233585 3233252 3233753 3233529 3233587 3233581 3233268 3233965 7670102 8450003-1525 7080307 3233524

Qty. Description

1 Asm., Gearcase, Rear (Incl. 1-8,12-25) 2 Screw 6 Screw 1 Cover, Output, Rear Housing 1 Pipe, Knock 1 O-Ring 1 Shim 2 Bearing, Ball 1 Gear, 31T 3 Clip AR Line, Fuel 1 Clamp,Hose 1 Tube, Vent

Ref. Part No.

13 14 15 16 17 18 19 20 21 22 23 24 25

3233970 3233711 3233324 3233878 3233577 3233969 3233714 3233699 3233968 3234003 3233963 3233582 3233583

Qty. Description

1 2 2 2 1 1 1 1 1 1 1 1 1

Gearcase, Rear Housing Plug, Oil Fill Washer Seal, Triple Lip Bushing Shaft, Pinion, 10T Bearing, Ball Ring, Retaining Ring, Retaining Seal, Triple Lip Spring, Wave Button, Thrust Shim 7/02

C9

GEAR SELECTOR MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 2

3

10

4 9

5

6 6

8

7

5

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5

5412003 7512024 5411007 5435042 7515175

Qty. Description

1 1 1 2 2

Cover Screw Knob, Gear Selector Shift Mount, Gear Selector Screw

Ref. Part No.

6 7 8 9 10

7542122 1821135 7542324 1013315-067 7518342

Qty. Description

2 1 2 1 2

Nut, Nylok Asm., Linkage Rod Nut, Nylok Selector, Gear Bolt 7/04

C10

SWING ARM/REAR/GEARCASE MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

17 2 3

1

9

4

10

5 6 15 34

33

32

30 29

7

7

6

11 12

16 13

15

14

8

13 12

11

31 6 19

19

18

20

27 26 28 25

21

22

24 23

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

Qty. Description

1 2 3 4 5

5411531 5134211 7515513 5244882 -------

1 1 4 1 1

6 7 8 9 10 11 12 13 14 15 16 17

7515481 7552603 7517604 7555721 7547065 5133387 5133388 3514399 3514398 5812447 1541820 5412202 1380202 7661913

2 2 3 3 3 1 1 2 2 2 1 1 1 1

O-Ring Hub, Wheel, AWD Stud Disc, Brake, Rear Asm., Brake Caliper (See Rear Brake Pg. A12 for Details) Screw Washer, Spring Lock Bolt Washer Nut, Nylon Nut, Jam Pivot, Threaded, LH Bearing, Tapered Roller Cone Bearing, Tapered Roller Cup Foam Asm., Swing Arm (Incl. 12) O-Ring Asm., Prop Shaft, Rear Pin, Spring

Ref. Part No.

18 19 20 21 22 23 24

Qty. Description

5133389 7553201 7517585 5134212 7517612 5411531 -------

1 8 8 1 3 1 1

25 1012881 5242851-067 5811716 26 5132698 27 5411707 28 7170910 29 5245050 30 7512017 31 1013264-067 32 3514342 33 7710507 34 7512325

1 1 1 1 1 1 2 2 1 1 1 4

Pivot, Swing Arm, RH Washer, Split Lock Bolt Axle, Rear Screw O-Ring Asm., Gearcase, Rear (See Rear Housing Pg. C9 for Details) Asm., Skid Plate, Rear Plate, Skid, Rear Housing Pad, Rubber Collar, Axle Lock O-Ring Decal, Hitch Clamp, Brake Line, Rear Screw Tube, Axle, LH Bearing Hubstrut Ring, Retaining Bolt 7/04

C11

SHOCK MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

4

5

9

6 1

8

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4

7542439 7515415 5241147 7041849-385 7041849-067

Qty. Description

2 1 1 1 1

Nut, Nylok Screw Retainer, Shock Spring, Compression (AA) Spring, Compression (AB)(AC)

Ref. Part No.

5 6 7 8 9

7041964 5630551 5132021 5433212 7515438

Qty. Description

1 1 1 2 1

Shock, Rear Axle Cam, Adjusting, Spring Tube Bushing Screw 7/04

C12

TRANSMISSION MOUNTING MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4 5

3

2 1

6

7

2 9

8

10

14

13 10

1

11

12

12

13

16

14 2 15

2

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

------1 2 3 4 5 6 7 8

7515417 7547108 7052075 7080693 7512024 7080307 8450003-1525 7512377

Qty. Description

Ref. Part No.

1 Asm., Gearcase (See Gearcase Pg. C8 for Details) 2 Screw 6 Nut, Flange Lock 1 Fitting, T 1 Clamp, Hose 1 Screw 1 Clamp, Hose AR Line, Vent 2 Bolt, Carriage

9 10 11 12 13 14 15 16

7542321 7555976 5247343 7517289 7552603 7515522 5242820-067 -------

Qty. Description

2 3 1 4 4 4 1 1

Nut, Flange Washer, Flat Mount, Rear Transmission Screw Washer, Spring Lock Bolt Mount, Transmission Mount, Engine,Rear (See Engine Mounting Pg. B2, Ref. 15) 7/03

C13

CRANKCASE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

7

8

9 4

5

3

1

6

10

2 11

12 13

19

12 18

17 16 15

14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 3083669 2 3080103 3 3087125 4 5 6 7 8 9

3087157 3087116 3086395 3087266 3084205 3084839

Qty. Description

1 Bushing, Starter 2 Pin, Dowel 1 Asm., Crankcase (Incl. 1-6,9,13,15,18,19) 1 Asm., Plug, Blind 2 Pin, Dowel 1 Bearing, Ball 2 Knock, Pipe 3 Asm., Screw and Washer 1 Seal, Oil

Ref. Part No.

10 11 12 13 14 15 16 17 18 19

3087128 3087065 3087066 3087155 3084849 3087156 3086749 3082956 3087117 3086399

Qty. Description

1 1 2 1 1 2 1 1 8 1

Gauge, Oil O-Ring Union Plug Union Bolt, Flange Plug Gasket Bolt, Flange Bolt, Flange 7/04

C14

CARBURETOR MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2 45

3 4

44 5 43 7

6

8

37 40 41

42

9

39

38 36 35 34

10 11

33

14

13

12

31 12

15 29

26

16

28

25

27

24

17

23

22

18 21 20 19

D1

30

32

CARBURETOR MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.

Ref. Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

3130507 3130508 3131554 3130752 3130732 3131588 3130541 3130540 3130504 3130014 3131458 3130515 ------3130518 3130519 3130361 3130594 3130532 3130520 3130590 3130521 3130529 3130591

Qty. Description

1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 1 1 1 4 1 1 1 2

Ring E-Ring Needle, Jet Ring Asm., Diaphragm Jet, Needle Screw Washer, Spring Asm., Jet Block Washer Jet, Main, #122.5 Seal Packing E-Ring Cap Pin, Float Plate O-Ring Screw Asm., Float Body Screw Asm., Float Screw

Ref. Part No.

Qty. Description

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

3131360 3130533 3130526 3131423 3130836 3130502 3130589 3130514 3130501 3130513 3130543 3130535 3130511 3130199 3130538 3131228 3130625 3131590

1 1 1 1 1 1 1 1 2 1 1 4 1 1 1 1 1 1

42 43 44 45

3084205 3131129 3130503 3130924

2 1 1 4

Valve, Needle O-Ring Jet, Pilot, #42.5 Screw, Adjust Spring Valve, Throttle, 100 Spring Ring Screw Asm., Throttle Shaft Guide, Cable Screw Cover Holder, Guide Spring Asm., Plunger Jet, Air, Pilot, #160 Asm., Carburetor (Incl. 1-33,36-41,43-45) Asm., Screw and Washer Spring Asm., Cover Screw 7/04

D2

CYLINDER MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

6

4

7

5

4

29 1

2

8

28 27

26

9 10

11

13

12 10

11

14 25 24

23 15

16

17

11 16 22

18

17

19

21 4 20 Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

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

3087259 3086414 3087159 3084874 3089272 3089271 3085850 3087034 3084858 3084994 3084798 3084859 3086418 3089270

Qty. Description

2 2 4 13 1 1 1 1 1 2 3 1 4 1

Cover, Valve O-Ring Bolt, Flange Bolt, Flange Asm., Plug Asm., Cover, Breather (Incl. 7) Asm., Pipe Gasket, Breather Cover Seal, Intake Valve Guide, Valve Fin, Damper A Seal, Exhaust Valve Asm., Bolt and Washer Asm., Cylinder Head (Incl. 9,10,12,14,16,28)

Ref. Part No.

15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

3086421 3085326 3080530 3086787 3087266 3086407 3087236 3087238 3087050 3083166 3081497 3081330 3086416 3087275 3087160

Qty. Description

1 2 2 2 2 1 1 1 1 1 1 2 1 2 2

Gasket, Exhaust Stud Washer, Spring Lock Nut Knock, Pipe Gasket, Cylinder Unit, Cylinder Gasket, Head Asm., Adapter Asm., Adapter Band (Incl. 25) Asm., Screw and Washer Bolt, Socket, Head Gasket, Cam Knock, Pipe Bolt, Flange 7/04

D3

CRANKSHAFT and PISTON MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 4

2 3 4 5

5

6 15

8

7 16

8 9 10 15

11 13

12 6 14

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 3087244 3087245 3087246 2 3087241 3087242 3087243 3 3086846 4 3084167 5 3087240 6 3087239 7 3087051 8 3240168

Qty. Description

1 1 1 1 1 1 1 2 2 1 1 2

Set, Piston, Ring, Standard Set, Piston, Ring, .010 Inch/.25MM O/S Set, Piston, Ring, .020 Inch/.50MM O/S Set, Piston, Standard (Incl. 4) Set, Piston, .010 Inch/.25MM O/S (Incl. 4) Set, Piston, .020 Inch/.50MM O/S (Incl. 4) Pin, Piston Clip, Piston Pin Bolt, Connecting Rod Asm., Connecting Rod (Incl. 5,14) Asm., Crankshaft (Incl. 16) Key, Woodruff

Ref. Part No.

9 3086434 3086435 3086436 3086437 10 3086492 11 3085528 12 3086767 13 3083905 14 3086426 15 3086427 3086798 3086799 16 3085815

Qty. Description

1 1 1 1 1 1 1 1 2 2 2 2 2

Spacer, .4 Spacer, .6 Spacer, .8 Spacer, 1.0 Sprocket 1 Nut, Slit Washer Nut, Lock Nut Bearing, Standard Bearing, 0.05 Bearing, 0.25 Bearing, Ball 7/04

D4

INTAKE and EXHAUST MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4 1

3

2

1 2 11

5 6 7

6

9

10

8

8

21

20 19

22

7

23

12 18

17

24

26

25 16

27 13 14

28 15

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

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

3084911 3084912 3084910 3087053 3085836 3084908 3087203 3087248 3086439 3086804 3087247 3084899 3085778 3086441

Qty. Description

2 2 2 1 1 4 2 2 1 1 1 1 1 1

Screw, Adjusting Nut Asm., Rocker Arm (Incl. 1-3) Shaft, Rocker Washer, Wave Collet, Valve Retainer, Spring, Valve Spring, Valve Asm., Lever, Release Spring, Return Asm., Camshaft (Incl. 9-12) Pin, Dowel Valve, Intake Valve, Exhaust

Ref. Part No.

15 16 17 18 19 20 21 22 23 24 25 26 27 28

3086445 3086444 3086448 3086493 3087132 3087131 3087129 3087130 3083361 3086443 3087249 3086449 3086446 3084924

Qty. Description

1 1 1 1 1 1 1 1 2 1 1 1 1 1

Guide, Chain Chain, Timing Gasket, Tensioner Asm., Tensioner (Incl. 18-22) Pin Spring, Tensioner Plug Gasket, Plug Bolt, Flange Sprocket 2 Washer Bolt, Flange Asm., Lever Asm., Bolt, Pivot, Lever 7/04

D5

RECOIL STARTER MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2

3

5

4

6

7 8 9 14

11

13

8

10

12

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7 8

3084822 3083463 3083378 3083379 3084744 3085266 3086749 3082956

Qty. Description

1 1 1 1 1 1 2 2

Asm., Reel Spring, Return Ratchet Spring, Friction Plate, Friction Asm., Bolt and Washer Plug Gasket

Ref. Part No.

9 10 11 12 13

3083669 3083185 3084750 3087150 3087163 3087164 14 3085083

Qty. Description

1 1 1 9 1 1 1

Bushing, Starter Spring, Spiral Bushing Bolt, Flange Asm., Recoil (Incl. 1-6,9-11,13,14) Asm., Starter Case (Incl. 11) Asm., Rope 1/03

D6

OIL PUMP and OIL FILTER MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1

2 3 4

5 6

11 10 9 8

7

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6

3086749 3082956 3086455 3086222 3087256 3086454

Qty. Description

1 1 1 1 1 1

Plug Gasket Spring, Relief Valve Valve, Oil Relief Bolt, Flange Unit, Strainer, Oil

Ref. Part No.

7 8 9 10 11

3084963 3087255 3086450 3086452 3086453

Qty. Description

1 5 1 1 1

Asm., Filter, Oil Screw, Counter Sunk Cover, Oil Pump Rotor, Inner Rotor, Outer 1/03

D7

MAGNETO MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

2 1

3

8

4

7

5 6

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4

3087036 3087037 3070172 3084978

Qty. Description

1 1 1 1

Ref. Part No.

Asm., Ignition Coil (Incl. 2) Cap, Spark Plug Plug, Spark O-Ring

5 6 7 8

3089275 3081657 3087251 3088209

Qty. Description

1 5 1 1

Asm., Stator Plate Asm., Bolt and Washer Flywheel w/Wiring Gear Asm., CDI System 7/04

D8

STARTING MOTOR MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

4

3

2

5

1 6

7 1

8

11 12 5 13

10 9

14

15 16

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5 6 7

3084981 3087030 3084982 3085353 3088169 3083649 3084408 3082038 3085034

Qty. Description

1 1 1 1 1 2 3 2 1

Asm., Motor, Starting (Incl. 1-5,7-11) Asm., Gear Shaft (Incl. 13-16) Set, Washer Asm., Armature Set, Brush, Carbon Nut, Flange O-Ring Asm., Bolt and Washer Asm., Cover, Rear

Ref. Part No.

8 9 10 11 12 13 14 15 16

3085033 3240114 3084983 3084405 7555908 3084412 3084411 3084410 3084409

Qty. Description

1 1 2 2 1 1 1 1 1

Asm., Front Bracket (Incl. 9) O-Ring Asm., Set Bolt (Incl. 5) Ring, Rubber Washer Clip Spring, Weight Spring, Return Clip 7/04

D9

FUEL PUMP MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

3

2

2

4

1

4

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

3085275 1 3084999 2 3085356

Qty. Description

1 Asm., Fuel Pump (Incl. All) 1 Asm., Screw and Washer 2 Asm., Screw and Washer

Ref. Part No.

3 3084591 4 3084998

Qty. Description

4 Asm., Screw and Washer 1 Diaphragm, Gasket Set 1/03

D10

TOOL KIT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC

1 8

2

3 9 4

5

10

6

7 11

Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current Ref. Part No.

1 2 3 4 5

3086485 2870725 3085001 3085002 ------3085569

Qty. Description

1 1 1 1 1 1

Kit, Tool (Incl. 2-7) Gauge, Tire Pressure Wrench, Open 8-10mm Wrench, Open 12-14mm Wrench, Plug Puller, Spark Plug (Wrench Handle)

Ref. Part No.

6 7 8 9 10 11

3082657 2682572 2871515 9919487 2873647 2874743

Qty. Description

1 1 1 1 1 1

Screwdriver Pouch, Tool Kit Lube, U-Joint, 3 oz., Case Owner’s Manual, ‘05 Magnum 2x4/4x4 Wrench, Torx Wrench, Open End, 1/2 x 9/16 7/04

D11

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PRINTED IN THE USA

PARTS MANUAL PN 9919490 and MICROFICHE PN 9919491 7/04