Utility Atv Segment:
The Polaris Magnum 325 4x4 was positioned as a capable and versatile utility ATV, suitable for work, trail riding, and recreational activities.
Competitors:
Competed with similar models from manufacturers like Honda (e.g., FourTrax Foreman), Yamaha (e.g., Kodiak), and Kawasaki (e.g., Prairie).
4X4 Capability:
True 4x4 drive system for enhanced traction in challenging terrain.
Engine Size:
325cc displacement offering a balance of power and usability.
Utility Focus:
Designed for practical applications with features like rack capacity and towing potential.
Comprehensive Coverage:
Covers all major component assemblies and their parts for the 2002 Polaris Magnum-325-4x4.
Key Assemblies Covered:
Engine, drivetrain, chassis, suspension, brakes, electrical system, body components, fuel system, cooling system, exhaust system.
Estimated Page Count:
Variable based on PDF generation, but typically 100-300 pages for a comprehensive parts manual.
Manual Type:
Parts Catalog / Parts Manual
Compatibility:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Engine Components:
Camshaft, carburetor, fuel injection (EFI), crankshaft, conrod (connecting rod), valves, intake, cylinder, piston, spark plug, cylinder head, primary reduction gear, magneto, starter, flywheel.
Drivetrain Components:
Drive train, transmission, drive shaft, rear axle, swingarm, swinger, drive clutch, driven clutch, belts, gears.
Chassis And Suspension:
Frame, suspension, front forks, rear shock/strut, wheel hubs, axles, tires, wheels, steering components (handlebar, trees, triple trees).
Brake System:
Brake calipers, brake pads, brake rotors, brake lines, brake levers, master cylinder.
Electrical System:
Battery, charging system, rectifier, stator, ignition system, lights (headlights, taillights), switches, starter motor, wiring harness.
Fuel And Cooling:
Fuel tank, fuel pump, carburetor components (jets, mixture screw, slow jet, pilot jet, main jet), radiator, coolant system, oil lubrication.
Body And Plastics:
Fenders, seat, body panels, plastics, handlebars, footpegs.
Part Identification:
Provides exploded views showing the location and relationship of components, along with corresponding part numbers for accurate ordering.
Schematics:
Includes schematics of engine assemblies and other systems to illustrate part relationships.
Depth Of Information:
Highly detailed for parts identification and ordering. Focuses on the 'what' and 'which' of parts, not the 'how-to' of repair procedures.
Engine Type:
Single-cylinder, four-stroke (likely SOHC).
Cooling System:
Liquid-cooled (common for this engine size and power output).
Horsepower:
Estimated 20-25 HP (typical for this class).
Torque:
Not specified, but expected to provide strong low-end torque for utility.
Fuel Delivery:
Carburetor (specifics like Mikuni or Keihin, jet sizes would be in the manual). EFI was also becoming more common, but the manual lists 'carburetor' prominently.
Fuel Type:
Unleaded gasoline.
Ignition System:
Electronic ignition, likely with a magneto and CDI unit.
Atv Safety Standards:
Compliant with ANSI/SVIA standards for ATVs.
Braking System:
Hydraulic disc brakes front and rear, providing effective stopping power.
4X4 Engagement:
On-demand or selectable 4WD system for improved traction in adverse conditions.
Frame Construction:
Robust steel frame designed for durability and rider support.
Lighting:
Dual headlights and a taillight for visibility.
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first. Exact interval specified in the owner's manual or implied by the parts manual's focus on oil filters and oil.
Air Filter Cleaning:
Frequent checks recommended, especially in dusty conditions. Service intervals typically 50 hours or as needed.
Spark Plug Replacement:
Recommended every 100-200 hours or as needed for optimal performance. Specific plug type detailed in the manual.
Engine Oil Type:
Polaris recommends specific synthetic or semi-synthetic ATV engine oils (e.g., SAE 10W-40 or 20W-50, depending on temperature). The manual would list the correct part number for the oil filter and potentially the recommended oil viscosity. Example: Polaris 2W/50 Synthetic 4-Stroke Oil.
Transmission Fluid:
CVT belt drive system, typically using a specific transmission fluid or gear oil. Check owner's manual for exact specification.
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture. Refer to owner's manual for correct ratio and type.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, brake pads, and steering components are common wear items on ATVs of this age and type.
Carburetor Issues:
Carburetors can sometimes become clogged or require adjustment due to fuel quality or infrequent use, affecting starting and running.
Polaris History:
Polaris Industries Inc. is an American manufacturer of snowmobiles, all-terrain vehicles (ATVs), motorcycles, and electric/hybrid vehicles. Founded in 1954, Polaris has a long history of innovation in powersports.
Magnum Series:
The Magnum series represented Polaris's commitment to utility and trail-ready ATVs, evolving through various engine sizes and feature sets.
Production Years Magnum 325:
The Magnum 325 was produced around the early 2000s, with the 2002 model being a key iteration. It was succeeded by other models in Polaris's lineup.
