Positioning:
The Polaris Magnum 325 was positioned as a mid-size, versatile ATV for recreational riding and utility tasks, known for its capable engine and 2x4 drivetrain.
Competitors:
Competed with similar offerings from brands like Honda (e.g., FourTrax 300/350), Yamaha (e.g., Big Bear 350), Suzuki (e.g., King Quad 300), and Kawasaki (e.g., Bayou 300).
Features:
Reliable engine, comfortable riding position, capable suspension for its class, user-friendly operation, solid build quality typical of Polaris at the time.
Value:
Essential for owners who perform their own maintenance or repairs, ensuring they source the correct OEM replacement parts, saving time and money by avoiding incorrect orders.
Primary Focus:
Parts Identification and Ordering
Included Sections:
Engine Assemblies, Chassis Components, Drivetrain, Electrical System, Bodywork, Accessories
Estimated Page Count:
Likely 100-300 pages (typical for a comprehensive parts manual of this era)
Type:
Parts Manual / Parts Catalog
Operating Systems:
All Versions of Windows & Mac
Software:
Adobe PDF Reader
Engine Components:
Crankshaft, piston, connecting rod (conrod), valves, camshaft (cam), carburetor (carb/carburettor), fuel pump, spark plug, ignition system (magneto, coil, stator), starter motor, engine oil, coolant
Drivetrain Components:
Transmission, primary reduction gear, drive train components, clutch, gearshift, driveshaft, differential (if applicable), rear axle
Chassis And Suspension:
Frame, front forks, triple trees, steering components, rear suspension (swinger, strut/shock absorber), swingarm, wheels, tires, brakes (rotors, pads, hydraulic system), handlebars
Electrical System:
Battery, charging system (rectifier, regulator), lights (headlights, taillights), switches, wiring harness
Bodywork And Plastics:
Fenders, seat, panels, plastic components, fuel tank, muffler
Identification:
Exploded views illustrating component location and relationship, part number identification for accurate ordering
Schematics:
Engine assembly schematics, wiring diagrams (potentially included for context), system diagrams
Part Ordering:
Facilitates correct part ordering by providing OEM part numbers
Diy Support:
Extremely helpful for DIY (Do It Yourself) repairs and maintenance by visualizing components
Depth:
Detailed component-level identification and part number referencing. Does not provide repair procedures but is essential for obtaining the correct parts for repair.
Engine Type:
4-Stroke, Single Cylinder
Cooling System:
Liquid-Cooled
Bore X Stroke:
Specific details would be in a full service manual, but typical for this displacement range.
Horsepower:
Estimated 20-25 HP (typical for this engine size and era).
Torque:
Estimated 20-25 lb-ft (typical).
Fuel Delivery:
Carburetor (specific model like Mikuni or Keihin would be detailed in a service manual).
Fuel Type:
Unleaded Gasoline
Oil Type:
Typically SAE 10W-40 or 20W-50 ATV-specific or motorcycle oil with JASO MA rating. Exact specification in manual.
Oil Capacity:
Approximately 2-3 quarts (exact in manual).
Length:
Approx. 76 inches (193 cm)
Width:
Approx. 42 inches (106.7 cm)
Height:
Approx. 45 inches (114.3 cm)
Dry Weight:
Approx. 535 lbs (243 kg)
Ground Clearance:
Approx. 5.5 inches (14 cm)
Front Tire Size:
AT 24x8-12 (Typical for this model)
Rear Tire Size:
AT 24x11-10 (Typical for this model)
Wheel Bolt Pattern:
Typically 4/110 or 4/156 for Polaris ATVs of this era (exact for Magnum 325 needs verification).
Atv Safety:
All ATVs carry inherent risks. Proper training, protective gear (helmet, gloves, boots, eye protection), and adherence to safe riding practices are essential. This manual does not cover safety guidelines but is crucial for correct parts to maintain safety features.
Braking System:
Hydraulic Disc Brakes (front and rear)
Lighting:
Dual Halogen Headlights, Taillight/Brake Light
Oil Change:
Typically every 100 hours or annually, whichever comes first (refer to full service manual for exact intervals).
Air Filter Cleaning:
Regular inspection and cleaning, especially in dusty conditions (refer to full service manual).
Spark Plug Replacement:
Typically every 1-2 years or as specified in the service manual.
Engine Oil Viscosity:
SAE 10W-40 or 20W-50 ATV/Motorcycle Oil (JASO MA approved recommended).
Coolant Type:
Ethylene Glycol based antifreeze/coolant, mixed 50/50 with distilled water. Exact Polaris recommended coolant or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Problems:
Early models might experience wear on the CVT belt, starter solenoid issues, or carburetor cleaning needs due to fuel varnish. Proper maintenance and part replacement are key to longevity.
Heritage:
Polaris Industries is a long-standing American manufacturer known for its pioneering work in snowmobiles and later expanding into ATVs, UTVs, and motorcycles.
Evolution:
The Magnum line was a significant part of Polaris's ATV lineup, evolving through various engine sizes and configurations. The 325cc engine represented a popular mid-range option for the early 2000s.
Production Years:
The Polaris Magnum 325 was produced around the early to mid-2000s. Specific production run details for 2002 are confirmed by this manual's title.
