PARTS MANUAL PN 9919490 and MICROFICHE PN 9919491 7/04
E 2004 Polaris Sales Inc.
MAGNUM 330 4X4Model #A05CD32AAModel #A05CD32ABModel #A05CD32AC
TABLE OF CONTENTSMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
Parts Manual
AA-ARM B14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AIR BOX B6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCARBURETOR D1-2. . . . . . . . . . . . . . . . . . . . . . . . . . .CARBURETOR MOUNTING B3-4. . . . . . . . . . . . . . . . . .CLUTCH COVER C3. . . . . . . . . . . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/BRAKE LINE A8. .CONTROLS - THROTTLE ASM./CABLE B11. . . . . . . .CRANKCASE C14. . . . . . . . . . . . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D4. . . . . . . . . . . . . . . . .CYLINDER D3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DDECALS A13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C1. . . . . . . . . . . . . . . . . . . . . . . . . .DRIVE SHAFT, FRONT B7. . . . . . . . . . . . . . . . . . . . .DRIVEN CLUTCH C2. . . . . . . . . . . . . . . . . . . . . . . . .
EELECTRICAL/TAILLIGHT C4. . . . . . . . . . . . . . . . . . .ENGINE MOUNTING B1-2. . . . . . . . . . . . . . . . . . . . . . .EXHAUST SYSTEM B5. . . . . . . . . . . . . . . . . . . . . . .
FFRONT BRAKE A10. . . . . . . . . . . . . . . . . . . . . . . . . .FRONT CAB A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .FRONT HOUSING C6. . . . . . . . . . . . . . . . . . . . . . . . .FRONT PROP SHAFT B8. . . . . . . . . . . . . . . . . . . . . .FRONT RACK and BUMPER MOUNTING A7. . . . . . . .FRONT STORAGE BOX A9. . . . . . . . . . . . . . . . . . . .FUEL PUMP D10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .FUEL TANK B3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GGEAR SELECTOR C10. . . . . . . . . . . . . . . . . . . . . . . .
GGEARCASE C7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .GEARCASE C8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HHANDLEBAR B13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
IINTAKE and EXHAUST D5. . . . . . . . . . . . . . . . . . . . .
MMAGNETO D8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OOIL COOLING A14. . . . . . . . . . . . . . . . . . . . . . . . . . .OIL PUMP and OIL FILTER D7. . . . . . . . . . . . . . . . . .
RRACK MOUNTING, REAR A6. . . . . . . . . . . . . . . . . .REAR BRAKE A11-12. . . . . . . . . . . . . . . . . . . . . . . . . . .REAR CAB and SEAT A3-4. . . . . . . . . . . . . . . . . . . . .REAR HOUSING C9. . . . . . . . . . . . . . . . . . . . . . . . . .REAR WHEEL DRIVE C5. . . . . . . . . . . . . . . . . . . . . .RECOIL STARTER D6. . . . . . . . . . . . . . . . . . . . . . . .
SSHOCK MOUNTING C12. . . . . . . . . . . . . . . . . . . . . . .STARTING MOTOR D9. . . . . . . . . . . . . . . . . . . . . . . .STEERING POST B12. . . . . . . . . . . . . . . . . . . . . . . . .STRUT MOUNTING B14. . . . . . . . . . . . . . . . . . . . . . . .STRUT, FRONT B9. . . . . . . . . . . . . . . . . . . . . . . . . .SWING ARM/REAR/GEARCASE MOUNTING C11. . . . .
TTOOL KIT D11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TRANSMISSION MOUNTING C13. . . . . . . . . . . . . . . . .
WWHEEL, 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.
A3
REAR CAB and SEATMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2524
2
7
3
6
910
15
14
16
1718
38
13
19
20
32
5
35
40
41
1
39
36
114
37 3
31
33
30
8
27
23
34
26
6
28
29
E 2004 Polaris Sales Inc.
10 28
21
22
12
A4
REAR CAB and SEATMAGNUM 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 currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-382
5432117-4005435164-455
111
Cab, Rear, Silver Vapor Metallic (AA)Cab, Rear, Camo Green Metallic (AB)Cab, Rear, New Break Up (AC)
6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw10 7555859 14 Washer, Flat11 7512085 2 Screw12 7556034 2 Washer13 5431786 1 Box, Tool14 7621403 2 Rivet15 5211033 2 Bracket, Lever Retainer16 1040387 1 Latch, Seat17 7041370 1 Spring, Latch18 2683222-070
2682958-07011
Asm., Seat, BlackCovering, Seat, Black
19 7517375 2 Screw20 5431787 1 Cover, Tool Box21 7515199 3 Screw
22 1040447-067 1 Box, Battery23 ------ -- -- -- -- 1 Asm., Front Gearcase
(See Front Housing Pg. C6 for Details)24 7552603 4 Washer, Spring Lock25 7512492 4 Screw26 5435005 1 Guard, Rock27 7556065 7 Washer28 7517386 9 Screw29 7558301 2 Washer, Flat30 7542122 8 Nut, Nylok31 5412156 8 Grommet32 7517987 8 Screw33 1014293-067 1 Frame, Main34 5432221-070
5433219-07011
Footwell, LH, BlackFootwell, RH, Black
35 7512232 21 Screw36 5811111 1 Foil, Rear Fender37 5811322 1 Foil, Tape38 7170007 1 Decal, 4 Stroke Carburetor/Filter39 5811087 1 Foil40 7670057 12 Nut, U-Type Speed41 5431796-070
5431797-07011
Guard, Mud, Rear, LHGuard, Mud, Rear, RH
7/04
A5
FRONT CABMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
7
8
9
13
22
15
32
2321
171620
9
1
5
5
6
14
11
10
10
4
11
18
21
E 2004 Polaris Sales Inc.
12
19
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 5811491 1 Foil, Side Panel, RH2 5812484 1 Foil, Side Panel, RH3 2632284-177
2632848-455
2632633-382
2632849-455
1
1
1
1
Asm., Panel w/Foam, LH, Black Metallic(AA)(AB)Asm., Panel w/Foam, LH, New Break Up(AC)Asm., Panel w/Foil, RH, Silver Vapor Me-tallic (AA)(AB)Asm., Panel w/Foil, RH, New Break Up(AC)
4 5811797 1 Foam, Panel, Side, LH5 7512232 10 Screw6 5811801 1 Foam, Cab, Front7 5435110-382
5435110-4005435166-455
111
Cover, Front, Silver Vapor Metallic (AA)Cover, Front, Camo Green Metallic (AB)Cover, Front, New Break Up (AC)
8 2632981-382
2632981-400
2632982-455
1
1
1
Asm., Cab, Foam, Front, Silver Vapor Me-tallic (Incl. Warning Decals)(AA)Asm., Cab, Foam, Front, Camo GreenMetallic (Incl. Warning Decals)(AB)Asm., Cab, Front, New Break Up(Incl. Warning Decals)(AC)
9 7670057 12 Nut, Speed, U-Type10 5245394-067
5246021-06711
Shield, Splash, LHGuard, Splash, RH
11 7621509 2 Rivet12 7515158 2 Screw13 7670135 4 Nut, Speed14 7517312 2 Screw15 5431798-070
5431799-07011
Guard, Mud, Front, LHGuard, Mud, Front, RH
16 7541925 2 Nut, Nylok17 7555792 2 Washer18 5812138 1 Foam, Panel, LH19 7556034 2 Washer20 7512085 2 Screw21 7542122 3 Nut, Nylok22 7512126 1 Bolt23 7558221 2 Washer, Flat
7/04
A6
REAR RACK MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
4
3
1
2
8
12
11
10
13
7
9
9
812
12
E 2004 Polaris Sales Inc.
5
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 7518280 2 Screw2 7517983 2 Screw3 2670174-070 1 Asm., Rack, Rear
(Incl. Ref. 4 and Warning Decal)4 7079927 2 Decal, Reflector, Red5 7517312 2 Screw6 7555859 2 Washer, Flat
7 1013724-067 1 Support, Rear Rack8 7512329 6 Bolt9 7558402 16 Washer, Flat10 5334092 2 Spacer11 5246394-067 2 Mount, Front, Rear Rack12 7542324 8 Nut, Nylok13 7512371 2 Bolt
7/03
A7
FRONT RACK and BUMPER MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1
6
15
16
3
14
2
7
5
9
8
10
1112
13
4
7
4
7
6
7
4
4
15
167
E 2004 Polaris Sales Inc.
1
2
4
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512232 6 Screw2 1013744-067
1013746-06711
Support, Front Rack, LHSupport, Front Rack, RH
3 5810467 1 Plug, Frame4 7515399 6 Screw5 1014099-067
1014101-06711
Mount, Rack, LHMount, Rack, RH
6 243101124310124030061
112
Asm., Headlight, Side, LHAsm., Headlight, Side, RHBulb, Headlamp, 30W
7 7542324 4 Nut, Nylok
8 7517977 4 Screw9 5432155-070 1 Bumper10 1013772-067 1 Guard, Brush11 7670094 6 Nut, U-Type12 7512097 6 Screw13 5433923
543392411
Shield, Radiator Side, LHShield, Radiator Side, RH
14 5244729-0675244730-067
11
Extension, Frame, LHExtension, Frame, RH
15 7512329 2 Bolt16 7558402 2 Washer, Flat
10/03
A8
CONTROLS - MASTER CYLINDER/BRAKE LINEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
29
34
25
28
30
3233
18
2627
35
17
24
22
21
19
31
20
E 2004 Polaris Sales Inc.
23
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
2010238 1 Asm., Master Cylinder, LH17 5410988 2 Seal18 4110164 1 Switch19 2202725 1 Kit, Master Cylinder Cap
(Incl. Cap, Screws, Sight, Gasket)20 7517899 2 Screw21 2201836 1 Kit, Master Cylinder Park Brake Lever
(Incl. Lever, Spring)22 2201833 1 Kit, Master Cylinder Clamp
(Incl. Clamp, Screws)23 2202410 1 Kit, Piston
(Incl. Piston, Seals, Boot, Spring)24 2201835 1 Kit, Master Cylinder Lever
(Incl. Pin, Lever, Clip)
25 1910565 1 Line, Brake, JB to Rear26 7621462 1 Rivet27 7080539 1 Clamp, Nylon28 1910838 1 Line, Brake, Left Front29 7512024 2 Screw30 7080138 4 Cable Tie31 8360031-34 1 Conduit32 1910839 1 Line, Brake, Right Front33 7052292 1 Fitting, Cross34 1910470 1 Line, Brake, Pod35 1910499 1 Bolt, Banjo
7/04
A9
FRONT STORAGE BOXMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
4
6
7
1
12
3
19
5
8
9
11
16 1017
2
18
15
13
14
4
7
5
5
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 1253528 1 Asm., Front Cover (Incl. 2-5,8,17)2 7518216 6 Screw3 7081101 6 Ring, Tie Down4 5334257 2 Latch, Wire5 7512076 6 Screw6 5521641 1 Seal, Front Compartment7 7081125
708114511
Latch, 1/4 Turn, RHLatch, 1/4 Turn, LH
8 7542324 6 Nut, Nylok9 7515399 6 Screw
10 7555958 4 Washer, Flat11 5133825 2 Pin, Hinge, Front12 5435073-070 1 Base, Front Box w/Decals13 7541925 2 Nut, Nylok14 7555792 2 Washer15 7512007 2 Bolt16 5412352 3 Plug, Compartment17 5246928 2 Channel, Lid18 7512024 2 Screw19 7081124 2 Cable, Lid, Front
7/03
A10
FRONT BRAKEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
12 3
456
7 8
9
10
11
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
19108411910842
11
Asm., Brake Caliper, LH (Incl. 1-7,9,10)Asm., Brake Caliper, RH (Incl. 1-7,9,10)
1 7515489 1 Screw, Socket Set2 5134639
51346401930642
111
Caliper, Brake, LHCaliper, Brake, RHKit, Front Brake Boot
3 5410494 1 Boot, Pin Seal4 1930665 1 Kit, Piston and Seal (Incl. 5-7)
5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)7 5132294 1 Piston, Brake, Long8 2202412 1 Kit, Front Brake Pad9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 7080352 1 Screw, Bleeder
7/04
A11
REAR BRAKEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
25
24
14
23
13
5
12
16
20
17
21
11
18
1312
2223
29
14
17
910
2
3, 4
62
4
243,
2 2, 6
28
26
27
19 15
1 1 1, 1 1,
15
15
19
22
E 2004 Polaris Sales Inc.
19
7
8
30
A12
REAR BRAKEMAGNUM 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 currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1910680 1 Asm., Caliper1 2201873 1 Kit, Anvil Body2 2201870 1 Kit, Slide Bolt3 2201872 1 Kit -Seal4 2201869 1 Kit, Piston and Seal5 2201732 1 Kit, Bracket Pad, Rear Axle6 2202414 1 Kit, Brake Pad Assembly7 7512018 1 Screw8 7080573 1 Clamp, Rubber Coated9 7512084 6 Screw10 5434041 3 Clamp, Brake Line11 1930854 1 Asm., Reservoir, Brake, Rear12 7080003 2 Clamp, Hose13 1910675 1 Hose, Reservoir14 7515158 2 Screw15 7558301 3 Washer, Flat
16 1012753-067 1 Pivot, Mount, Brake, Rear17 7542122 2 Nut, Nylok18 7512240 2 Bolt19 7517386 3 Screw20 1014009-067 1 Rod, Brake21 7041750 1 Spring, Torsion, Brake22 7555919 2 Washer23 5433189 2 Bushing, Pedal Pivot24 7661401 1 Pin, Cotter25 1910791 1 Asm., Brake, Master Cylinder, Foot26 5410988 6 Seal27 1910499 3 Bolt, Banjo28 1910516 1 Line, Brake, Foot, Master Cylinder to
Rear29 7042075 1 Spring30 7670126 1 Clip, Retaining
7/04
A13
DECALSMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2 385 7
12
24
1417
6
2021
25 LH
RH
109
23
16
E 2004 Polaris Sales Inc.11
14
18
151319
22
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 54354247173013
11
Badge, 50 Years (If built before 7/05/04)Urocal, 50th Anniversary(If built after 7/05/04)
2 7172572 2 Decal, Warning, Front and Rear Rack3 7172579
71725807172533
7172534
111
1
Decal, “AWD”, Side Panel, Lower, LH (AC)Decal, “AWD”, Side Panel, Lower, RH (AC)Decal, “AWD”, Side Panel, Lower, LH(AA)(AB)Decal, “AWD”, Side Panel, Lower, RH(AA)(AB)
4 7171495 1 Decal, Arrow, ATP Container, RH5 7172531
717253211
Decal, Side Panel, Upper, LH (AA)(AB)Decal, Side Panel, Upper, RH (AA)(AB)
6 7172559 1 Decal, Age Warning, 16, ATV7 7079780 1 Decal, Warning, AWD Switch8 7172576
7172529
71725777172530
11
11
Decal, “Magnum 330”,Tank Side, LH (AC)Decal, “Magnum 330”,Tank Side, LH(AA)(AB)Decal, “Magnum 330”, Tank Side, RH (AC)Decal, “Magnum 330”, Tank Side, RH(AA)(AB)
9 7078465 1 Logo, Polaris Star
10 707991670797737171879
111
Decal, “POLARIS”, Front Cover (AA)Decal, “POLARIS”, Front Cover (AB)Decal, “POLARIS”, Front Cover, Gold (AC)
11 7172569 1 Decal, Warning, Front Rack, 90 lbs12 7074220 1 Decal, “MacPherson Strut”13 7171473 1 Decal, Reflector, Amber, RH14 7172562 1 Decal, Drain Recoil15 7171472 1 Decal, Reflector, Amber, LH16 7079672 1 Decal, Foot Brake17 7172564 1 Decal, Warning, Override, AWD18 7171494 1 Decal, Arrow, ATP Container, LH19 7172578 2 Decal, Side Panel, Upper (AC)20 7172566 1 Decal, Passenger Warning21 7172571 1 Decal, Tire Pressure22 7079927 2 Decal, Reflector, Red23 7079960
70799597172066
111
Decal, “POLARIS”, Rear (AA)Decal, “POLARIS”, Rear (AB)Decal, “POLARIS”, Rear, Gold (AC)
24 7172561 1 Decal, Discretionary Warning, Drum Shift25 7172560 1 Decal, Warning, General, CPSC
8/04
A14
OIL COOLINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
14
1
13
11
3
10
12
6
9
17
2
8
7
15
18
16
4
4
5 E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 5412355 2 Hose, Cooler, Threaded 90 Degree2 7512084 1 Screw3 7080851 1 Clamp, Hose4 7515133 4 Bolt5 7547069 2 Nutsert6 5245416-067 1 Bracket, Oil Cooler, Top7 7542122 4 Nut, Nylok8 5248139
754213012
Bracket, Lower Oil CoolerNut, Rivet
9 7555932 4 Washer, Nylon
10 7517659 4 Screw11 2410534 1 Asm., Motor, Fan12 7670111 4 U-Clip13 5433353 1 Shroud, Fan14 4010934 1 Thermister15 7558301 4 Washer, Flat16 7512240
751216344
Bolt (If built before 2/21/04)Bolt (If built after 2/21/04)
17 1240191 1 Cooler, Oil18 7080999 1 Cable Tie
7/04
B1
ENGINE MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
28
17
26
8
20
5
12
2
13
14
1
27
2223
2425 15
79
19
31
6
18
11
2729
21
4
16
4
10
3
4
4
4
4
4
E 2004 Polaris Sales Inc.
29
29
30
B2
ENGINE MOUNTINGMAGNUM 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. Description Ref. Part No. Qty. Description
1 8450003-1525 AR Line, Fuel2 7052075 1 Fitting, Tee3 1202789 1 Engine, ES320PFE1034 7547108 8 Nut, Flange Lock5 5247341 1 Bracket, Motor Mount6 7552901 2 Washer, Spring Lock7 7512232 1 Screw8 4010132 1 Cable, Ground Engine9 7512315 2 Bolt10 5412248 1 Mount, Rubber11 7555823 1 Washer, Flat12 5411721 1 Boot, Clutch Intake13 7080511 1 Clamp, Narrow Band14 8360009-600 AR Line, Fuel15 1013133-067 1 Mount, Engine, Rear16 7517289 2 Screw
17 3021119 1 Mount, Rubber, Rear18 7555815 2 Washer19 7515417 2 Screw20 5247342 1 Mount, Lower Front21 3021181 1 Mount, Rubber, Engine22 5430261 1 Bushing23 5210748 1 Washer, Flat24 7575202 1 Washer, Interlock25 7512566 1 Bolt26 4010095 1 Cable, Battery/Engine27 8450103 AR Hose, Fuel28 2530009 1 Filter29 7080003 8 Clamp, Hose30 8450040-150 AR Line, Fuel31 7546601 2 Nut, Nylok
7/04
B3
FUEL TANK and CARBURETOR MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
5
8
19 18
7
1615
3
2 9
14
4
13
12
1024
23
22
13
21
20
6
1
11
E 2004 Polaris Sales Inc.
1918
18
19
17
26
25
B4
FUEL TANK and CARBURETOR MOUNTINGMAGNUM 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. Description Ref. Part No. Qty. Description
1 2520409 1 Asm., Tank, Fuel2 5812123 1 Gasket3 2873626 1 Kit, Fuel Gauge4 8360009-600 AR Hose, Vent5 5431053 1 Vent, Tank6 7512277 2 Bolt7 7558301 2 Washer, Flat8 5222154
522215511
Bracket, Fuel, Cover Mount, LHBracket, Fuel, Cover Mount, RH
9 5811899 1 Seal, Foam10 7542105 1 Nut, Hex11 7552801 1 Washer, Spring Lock12 5245671-067 1 Bracket, Carburetor Support13 7547069 5 Nutsert
14 7517505 1 Screw15 5432559 1 Knob, Fuel Valve16 5432733 1 Nut, Fuel Valve17 7052161 1 Valve, 3-Way18 7080003 8 Clamp, Hose19 8450103 AR Line, Fuel20 3084205 2 Asm., Screw and Washer21 5245674-067 1 Mount, Carburetor22 3110050 1 Mount, Carburetor23 7512276 2 Bolt24 7555859 3 Washer, Flat25 7515136 2 Screw26 7052364 1 Fitting, Fuel, Duel Outlet
7/04
B5
EXHAUST SYSTEMMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
7
11
3
1
8
2
4
10
6
9
13 14
15
10
16
12
9
5
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542324 2 Nut, Nylok2 7555716 2 Washer, Flat3 5410436 2 Washer, Rubber4 5412233 2 Dampener, Vibration5 5010192 2 Bushing6 7515316 2 Bolt, Carriage7 1261215-029 1 Silencer, Black8 7512666 1 Bolt
9 7041804 4 Spring, Exhaust10 5243517 2 Seal, Exhaust11 1261222-029 1 Headpipe, Black12 7041687 1 Spring, Exhaust13 7542301 2 Nut14 3110064 1 Mount, Torque Stop15 1260960-029 1 Manifold, Black16 3086237 1 Gasket, Exhaust
7/04
B6
AIR BOXMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
26
1
2
3
4
6
7
8
91011
1213
15161718
1920
22
23
25
17
5
2114
24
E 2004 Polaris Sales Inc.6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7518306 1 Screw2 7558301 1 Washer, Flat3 5812023 1 Seal, Airbox, Intake4 5433920 1 Duct, Inlet, Airbox Cover5 7517317 2 Screw6 5810317 2 Pad7 5433769 1 Cover, Air Box8 5811482 1 Seal, Air Box Cover9 5242044 6 Clip, Air Box10 5432601 1 Collar, Carburetor Inlet11 7080699 1 Clamp, Hose12 5433396 1 Cap, Rubber13 5411866 1 Hose, Breather
14 7080694 2 Clamp, Hose, Spring15 7080511 1 Clamp, Narrow Band16 5411588 1 Boot, Carburetor17 7080413 2 Clamp, Narrow Band18 5433180 1 Duct, Carburetor Inlet19 5830128 1 Gasket, Carburetor Inlet20 5435758 1 Box, Air Intake, 4 Stroke21 7556091 2 Spacer22 5435299 1 Plug, Trap23 5812111 1 Foil, Air Box, RH24 8450059-100 AR Line, Fuel25 7080650 1 Clamp, Hose26 1253372 1 Asm., Filter
7/04
B7
FRONT DRIVE SHAFTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2 43
1
E 2004 Polaris Sales Inc.
35
6
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1332288 2 Asm., Drive Shaft, Front1 7670092 2 Circlip2 1590395 2 Joint (CV, Inner)3 7710557 2 Circlip
4 2202826 2 Kit, Boot(Inner)(Incl. Clamps and Grease)
5 2201015 1 Kit, Boot(Outer)(Incl. Clamps and Grease)
6 1590396 1 Joint, CV (Outer)3/04
B8
FRONT PROP SHAFTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1 23
46
7
5E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1380229 1 Asm., Front Prop Shaft (Incl. 1-4)1 3260133 1 Yoke, Gear Case, Front2 2202015 2 Kit, Cross and Bearing3 1380188 1 Shaft, Prop
4 3260131 1 Yoke, Propshaft, Transmission5 7080424 1 Fitting, Lubrication6 5411092 1 O-Ring7 7661913 1 Pin, Spring
7/03
B9
FRONT STRUTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1234
5
6
7
8
10
1112
13
15
14
171618
1920
21
22
9
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 7547104 2 Nut2 7555749 2 Washer3 5810291 2 Spacer, Rubber4 5432872 2 Ball, Pivot, Top5 5132062 2 Spacer6 5432871 2 Ball, Pivot, Bottom7 5243364 2 Retainer, Spring8 7042312-385
7042312-06722
Spring, Compression, Silver (AA)Spring, Compression, Black (AB)(AC)
9 5411608 2 Bumper10 7518340 4 Bolt, Flange11 5134154
513415511
Support, Hubstrut, LHSupport, Hubstrut, RH
12 3514342 2 Bearing, Hubstrut13 7710507 2 Ring, Retaining14 7080306 2 Fitting, Lubrication w/Ball15 ------ -- -- -- -- 1 Asm., Brake Caliper
(See Front Brake Pg. A10 for Details)16 7558402 4 Washer, Flat17 7552901 4 Washer, Spring Lock18 7512365 4 Screw, Cap19 7542343 4 Nut, Flange20 7080367 2 Clamp, Cable21 5211115 2 Washer22 7041761 2 Strut, Front
7/04
B10
FRONT WHEELMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
12
3
4
9
11
10
56
8
7
12
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 7512325 8 Bolt2 5244314 2 Disc, Brake, Front3 7515513 8 Stud4 5134310 2 Hub, Wheel, AWD5 7556004 2 Washer6 7542810 2 Nut, Slotted7 7661401 2 Pin, Cotter
8 5411164 2 Hub, Dust Cover9 1520269-486
1520269-06722
Rim, Front, Silver (AA)Rim, Front, Black (AB)(AC)
10 7547237 8 Nut, Flange11 5411709 2 Tire, Front, 24x8-1212 1525017 2 Valve, Rim
7/04
B11
CONTROLS - THROTTLE ASM./CABLEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
3
1
6
5
4
2
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434113 1 Cover, Throttle Control2 5410193 1 O-Ring3 5411439 1 O-Ring
4 7081181 1 Cable, Throttle5 2010230 1 Asm., Throttle Control (Incl.6)6 2010191 1 Asm., Throttle Clamp
7/04
B12
STEERING POSTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
31
4
2
5
8
10
6
9
7
2
5
6
1
E 2004 Polaris Sales Inc.
11
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542324 4 Nut, Nylok2 5433866 2 Bushing, Steering, Upper3 1822630-067 1 Post Steering4 5246732 1 Bracket, Upper Steering Bushing5 7517428 4 Bolt, Carriage6 7556162 2 Bushing
7 5222393 1 Flangette8 3514352 1 Bearing9 7547158 1 Nut, Slotted Hex10 7661633 1 Pin, Cotter11 7558402 2 Washer, Flat
7/04
B13
HANDLEBARMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
5
1
7 8
10
11
13
14
19
20
3
21
4
6
18
21
912
24
1615
17
2
22
23
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7078465 1 Logo, Polaris Star2 7518176 2 Screw3 7080922 1 Nut, Choke4 7081176 1 Cable, Choke5 5435256-070 1 Panel, Instrument6 7515189 4 Screw7 5248182 1 Bracket, Instrument Panel8 ------ -- -- -- -- 1 Asm., Master Cylinder
(See Control - Master Cyl./Brake LinePg. A8 for Details)
9 5433903 1 Spacer, Switch, LH10 4010592 1 Switch, Handlebar, Hi/Lo/Off11 5433834-070 2 Grip, Handlebar12 5432952 1 Plug, Hole13 7517625 1 Screw, Set14 5334127-067 1 Tube, Handlebar15 5132382 1 Cap, Hall Sensor
16 4010298 1 Sensor, Hall Effect17 7517658 1 Screw18 5631517
563151611
Block, Handlebar, PeggedBlock, Handlebar
19 7542122 4 Nut, Nylok20 ------ -- -- -- -- 1 Asm., Throttle Control (See Controls -
Throttle Asm./Cable Pg. B11, Ref. 5)21 4011002
543196440102784010321
1111
Switch, IgnitionCover, KeyBlank, Key, Series 2000, 6700, 6800Blank, Key, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.
22 5433733 1 Nut, Ignition23 5412138 1 Mount, Rubber24 3280450 1 Cluster, Instrument
7/04
B14
A-ARM/STRUT MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
28
18
1716
15
1413
20
10
11
6
24
1
2
3
4
5
8
23
21
22 2526
2625
22
7
19
6
9
12
27
27
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most currentRef. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080927 2 Joint, Ball2 5211121 2 Bracket, Ball Joint3 5410548 2 Boot, Rubber4 7512284 4 Bolt, Socket5 7542438 2 Nut, Castle6 7661203 4 Pin, Cotter7 5435028-070
5435029-07011
Shield, CV Joint, Black, LHShield, CV Joint, Black, RH
8 7512084 6 Screw9 7517909 2 Bolt10 7556099 4 Washer11 7547177 2 Nut, Lock12 5411920 1 Boot, Seal, Rod End13 7061054 2 Rod, End, LH14 7547028 2 Nut, Jam, LH15 5020926 2 Rod, Tie
16 7542711 2 Nut, Jam17 7061034 2 Rod End, RH18 5411291 2 Boot, Seal, Rod End19 7515415 2 Screw20 1820805 2 Asm., Tie Rod (Incl. 13-18)21 5133806 2 Shaft, A-Arm22 5434551 4 Bushing, A-Arm, Long23 2202280
220228111
Kit, A-Frame, LH (Incl. 6,21,22,25,26)Kit, A-Frame, RH (Incl. 6,21,22,25,26)
24 ------ -- -- -- -- 1 Support, Hubstrut(See Front Strut Pg. B9, Ref. 11)
25 7512492 4 Screw26 7552603 4 Washer, Spring Lock27 7555832 2 Washer28 7542439 2 Nut, Nylok
7/04
C1
DRIVE CLUTCHMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
12 11
4
10
2 3 4
5
98
67
1
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1321976 1 Asm., Drive Clutch, Wide(Incl. All Less 6,11)
1 7518062 6 Screw2 5430945 6 Washer, Multilube3 1321457 3 Asm., Roller and Bushing4 5431936 6 Button, Clutch5 5210752
524298152107535210754
ARARARAR
Spacer, .020Spacer, .025Spacer, .032Spacer, .050
6 5630279 3 Weight, Shift, 167 7512266 3 Bolt, Shoulder8 7541906 3 Nut, FLEXLOC9 3576504 1 Bearing, Moveable10 5020422 3 Pin, Roller11 7041157 1 Spring, Clutch12 3576510 1 Cover, Bearing
7/04
C2
DRIVEN CLUTCHMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
6
5
23
4
16
13
12
11
98
7
1
10
14
15
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7556120 AR Bushing2 5220646 1 Washer, Domed3 7552901 1 Washer, Spring Lock4 7515382 1 Bolt5 1322337 1 Asm., Driven Clutch (Incl. 7-16)6 3211077 1 Belt, Drive7 5430766 3 Button, Ramp8 7511854 3 Bolt9 7710448 1 Ring, Retaining
10 5244116 1 Spacer11 5133701 1 Ramp, Stationary12 7041782 1 Spring, Clutch13 3576511 1 Bearing, Moveable, 1 Inch14 3576504 1 Bearing, Moveable, 1/2 Inch15 7556804 AR Washer, .03016 7555898
7556076ARAR
Washer, .020Washer, .025
7/03
C3
CLUTCH COVERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
3
7
89
13 12
14
181920
4
65
151
17
2
21
16
1
9
116
1110
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7517386 3 Screw2 2632513 1 Asm., Foam, Clutch Air Inlet3 2201956 1 Kit, Inner Clutch Cover4 5433363 1 Duct, Inlet5 7517599 5 Asm., Bolt and Washer6 7080909 1 Clamp, Narrow Band7 5521578 1 Seal, Outer, Clutch Cover8 5434255-070 1 Cover, Clutch, Outer9 7512094 9 Screw10 5410542 1 O-Ring11 5434264 1 Plug, Drain
12 7172746 1 Decal, “Automatic Transmission”13 7172563 1 Decal, Warning, Clutch Cover14 5411489 1 Boot, Duct15 7080707 2 Clamp, Narrow Band16 7558301 2 Washer, Flat17 5434213 1 Duct, Air Outlet18 ------ -- -- -- -- 3 Asm., Screw and Washer
(See Crankcase Pg. C14, Ref. 8)19 5242046 1 Bracket, Clutch Seal20 5410575 1 Seal, Cover Case21 5411795 1 Stopper, Inner Clutch Cover
7/04
C4
ELECTRICAL/TAILLIGHTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1
2
3 4
5
67
89 12
11
21
20
13
19
14 1516
17
1822
11
25
28
27
26
23
E 2004 Polaris Sales Inc.
24
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2410500 1 Harness, Main2 2200593 1 Kit, Circuit Breaker, 20 AMP3 2410320 1 Asm., Taillight (Incl. 4-9)4 4032046 1 Lens, Taillight5 4032029 2 Screw, Taillight6 4030043 1 Bulb, Taillight7 4032045 1 Gasket, Taillight8 ------ -- -- -- -- 1 Backing, Taillight/Brake Light9 7670054 2 Nut, Speed10 7518287 2 Nut, Flange11 7571602 4 Washer12 7512027 2 Screw13 5810290 3 Pad, Battery14 2202213 1 Kit, Battery Bolt
15 4010095 1 Cable, Battery/Engine16 7010032 2 Hook, Battery Strap17 5412499 1 Strap, Battery Holddown18 4010774 1 Battery19 5431769 1 Cover, Battery20 4010094 1 Cable, Battery/Solenoid21 4010093 1 Cable, Solenoid/Starter22 7512007 2 Bolt23 4011088 1 Module, Electronic Control24 7512024 2 Screw (AA)25 7541925 2 Nut, Nylok26 4020139 2 Clip, Rosebud27 7080138 9 Cable Tie28 7670109 2 Clip, Routing
7/04
C5
REAR WHEEL DRIVEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
56
89
1
10
7
3
4
2
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7661404 2 Pin, Cotter2 7547237 8 Nut, Flange3 5131649 1 Hub, Wheel, Rear (RH Side)4 7515513 8 Stud5 5411936 2 Tire, 24x11-126 1525017 2 Valve, Rim
7 1520564-3851520457-067
22
Rim, Rear (AA)Rim, Rear (AB)(AC)
8 7555796 2 Washer, Cone9 7543005 2 Nut, Castle10 5411164 2 Cover, Dust, Hub
7/04
C6
FRONT HOUSINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2
13
56
78
910
11
1214
1516
1718
19
2021
22
25
14
6
23
13
13
7
E 2004 Polaris Sales Inc.
2
1
3 4
24
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341497 1 Asm., Front Gearcase3233955 1 Kit, Bolt
1 3234163 1 Screw, Set2 3234159 1 Asm., Cover Plate
(Incl. Output Cover, Insert and Coil)3 3234164 1 Button, Thrust4 3234165 1 Plate, Thrust5 3234161 1 Shim, Armature Plate6 3233926 2 Bearing, Roller Ball7 3233953 1 Asm., Race/Output Hub (Incl. 22)8 3233928 1 Pin, Dowel9 3234166 1 Clutch Housing/Ring Gear10 3234167
------ -- -- -- --
1
1
Asm., Roll Cage(Incl. Spring and Roll Cage)Spring
11 3233957 14 Kit, Roll
12 3234169 1 Bushing13 3233956 1 Kit, Minor Repair
(Incl. O-Rings and Seals)14 3233918 11 Bolt15 3233947 1 Cover, Input16 3234112 1 Bearing, Roller Ball17 3233944 1 Shaft, Pinion, 11T18 ------ -- -- -- -- 1 Bushing19 ------ -- -- -- -- 1 Gearcase, LH20 3233942 1 Plug, Oil Fill21 3233951 1 Asm., Drain Plug
(Incl. Plug and Washer)22 3233929 1 Bearing, Needle, Roller Thrust23 3234168 1 Asm., Clutch (Incl. 9-11)24 3234162 1 Ring, Retaining, Internal25 3234160 1 Plate Armature
7/03
C7
GEARCASEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2
6869
19
64
12
54
8
3
36
67
37
2423
25
1
16
17
33
45
35
6
53
1110
6362
566665
9
18
5559
57
7
5250
26
15
39
47
45
51 4849
58
14
21
32
3130 29
34
28
43
4041
44
38
4227
46
3
13
20
22
6160
2423
33
33
29
313029
28
15
15
15
21
18
18
19
9
E 2004 Polaris Sales Inc.
C8
GEARCASEMAGNUM 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. Description Ref. Part No. Qty. Description
1341372 1 Asm., Gearcase, Shaft1 3233961 1 Nut, Lock2 3233906 1 Bellcrank3 3233826 8 Screw4 3233827 1 Cover5 3233829 1 Pawl, Detent6 3233869 1 O-Ring7 3233831 1 Shaft, Shift8 3233832 1 Gear, 31T9 3233788 2 Seal, Triple Lip10 3233324 1 Washer11 3233711 1 Plug, Oil Fill12 3233867 1 Gearcase, Main13 3233524 1 Tube, Vent14 3233910 1 Drum, Shift15 3233018 4 Bearing16 3233036 1 Chain, Silent17 3234028 1 Shaft, Input18 3233019 4 Bearing, Ball19 3233529 4 Pipe, Knock20 3233865 1 Cover, Main, LH21 3233846 17 Screw22 3233874 1 Seal, Dual Lip23 3233859 2 Pin, Dowel24 3233858 2 Fork, Shift25 3233860 1 Rail, Shift Shaft26 3233915 1 Plate27 3233916 1 Dog, Engagement28 3233849 2 Spring, Wave29 3233875 3 Dog, Engagement30 3233850 2 Ring, Retaining31 3233851 2 Washer32 3234027 1 Gear, 33T33 3233718 3 Bearing, Needle34 3233853 1 Shaft, Reverse
35 3233854 1 Sprocket, 24T36 3233855 1 Washer37 3233856 1 Gear, 30T38 3234014 1 Gear, 36T39 3233709 1 Gear, 48T40 3233608 4 Screw41 3233609 1 Cover, Bearing42 3233106 1 Ring, Snap43 3233357 1 Spacer44 3233607 1 Bearing, Ball45 3233606 1 Shaft, 10T46 3233777 1 Plug, Hex Flange47 3233254 1 Washer, Plug48 3233781 1 Cover, Output, Front49 3233583 1 Shim50 3233582 1 Button, Thrust51 3233611 1 Shim52 3233625 1 Shaft, Output, Front53 3233622 1 Shaft, Output, Rear54 3233621 1 Gear, 31T55 3233784 1 Chain, Silent56 3233782 1 Sprocket, 22/18T57 3233783 1 Sprocket, 22/22T58 3233619 1 Washer, Thrust59 3233552 1 Bushing60 3234013 1 Clamp, Tie61 3233917 1 Lockout, Park62 3233548 1 O-Ring63 3233839 1 Gear, 16T64 3233838 1 Disc, Lockout65 3233909 1 Star, Detent66 3233076 1 O-Ring67 3233830 1 Spring, Compression68 3233835 1 Switch69 3233834 1 Ring, Retaining
7/04
C9
REAR HOUSINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
14
6
3
1
13
21
5
4
2
1918
12
16
10
17 2220
15
724
8
7
1615
25
9
14
11 23
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1341423 1 Asm., Gearcase, Rear(Incl. 1-8,12-25)
1 3233585 2 Screw2 3233252 6 Screw3 3233753 1 Cover, Output, Rear Housing4 3233529 1 Pipe, Knock5 3233587 1 O-Ring6 3233581 1 Shim7 3233268 2 Bearing, Ball8 3233965 1 Gear, 31T9 7670102 3 Clip10 8450003-1525 AR Line, Fuel11 7080307 1 Clamp,Hose12 3233524 1 Tube, Vent
13 3233970 1 Gearcase, Rear Housing14 3233711 2 Plug, Oil Fill15 3233324 2 Washer16 3233878 2 Seal, Triple Lip17 3233577 1 Bushing18 3233969 1 Shaft, Pinion, 10T19 3233714 1 Bearing, Ball20 3233699 1 Ring, Retaining21 3233968 1 Ring, Retaining22 3234003 1 Seal, Triple Lip23 3233963 1 Spring, Wave24 3233582 1 Button, Thrust25 3233583 1 Shim
7/02
C10
GEAR SELECTORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1
2
3
9
4
6
10
5
6
7
8
5
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5412003 1 Cover2 7512024 1 Screw3 5411007 1 Knob, Gear Selector Shift4 5435042 2 Mount, Gear Selector5 7515175 2 Screw
6 7542122 2 Nut, Nylok7 1821135 1 Asm., Linkage Rod8 7542324 2 Nut, Nylok9 1013315-067 1 Selector, Gear10 7518342 2 Bolt
7/04
C11
SWING ARM/REAR/GEARCASE MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1 2 34
5
67 8
9 1011 12
1415
16
18
1920
21
33
22
2324
25
262728
17
313234
7611
12
196
15
29
30
13
13
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5411531 1 O-Ring2 5134211 1 Hub, Wheel, AWD3 7515513 4 Stud4 5244882 1 Disc, Brake, Rear5 ------ -- -- -- --
75154817552603
1
22
Asm., Brake Caliper(See Rear Brake Pg. A12 for Details)ScrewWasher, Spring Lock
6 7517604 3 Bolt7 7555721 3 Washer8 7547065 3 Nut, Nylon9 5133387 1 Nut, Jam10 5133388 1 Pivot, Threaded, LH11 3514399 2 Bearing, Tapered Roller Cone12 3514398 2 Bearing, Tapered Roller Cup13 5812447 2 Foam14 1541820 1 Asm., Swing Arm (Incl. 12)15 5412202 1 O-Ring16 1380202 1 Asm., Prop Shaft, Rear17 7661913 1 Pin, Spring
18 5133389 1 Pivot, Swing Arm, RH19 7553201 8 Washer, Split Lock20 7517585 8 Bolt21 5134212 1 Axle, Rear22 7517612 3 Screw23 5411531 1 O-Ring24 ------ -- -- -- -- 1 Asm., Gearcase, Rear (See Rear
Housing Pg. C9 for Details)25 1012881
5242851-0675811716
111
Asm., Skid Plate, RearPlate, Skid, Rear HousingPad, Rubber
26 5132698 1 Collar, Axle Lock27 5411707 1 O-Ring28 7170910 1 Decal, Hitch29 5245050 2 Clamp, Brake Line, Rear30 7512017 2 Screw31 1013264-067 1 Tube, Axle, LH32 3514342 1 Bearing Hubstrut33 7710507 1 Ring, Retaining34 7512325 4 Bolt
7/04
C12
SHOCK MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2
6
59
3
4
1
78
1
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7542439 2 Nut, Nylok2 7515415 1 Screw3 5241147 1 Retainer, Shock4 7041849-385
7041849-06711
Spring, Compression (AA)Spring, Compression (AB)(AC)
5 7041964 1 Shock, Rear Axle6 5630551 1 Cam, Adjusting, Spring7 5132021 1 Tube8 5433212 2 Bushing9 7515438 1 Screw
7/04
C13
TRANSMISSION MOUNTINGMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
1
2
8 9
14 13
1212
1314
10
2
110
11
15
16
2
2
7
E 2004 Polaris Sales Inc.
3
6
5
4
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
-- -- -- -- -- -- -- 1 Asm., Gearcase(See Gearcase Pg. C8 for Details)
1 7515417 2 Screw2 7547108 6 Nut, Flange Lock3 7052075 1 Fitting, T4 7080693 1 Clamp, Hose5 7512024 1 Screw6 7080307 1 Clamp, Hose7 8450003-1525 AR Line, Vent8 7512377 2 Bolt, Carriage
9 7542321 2 Nut, Flange10 7555976 3 Washer, Flat11 5247343 1 Mount, Rear Transmission12 7517289 4 Screw13 7552603 4 Washer, Spring Lock14 7515522 4 Bolt15 5242820-067 1 Mount, Transmission16 ------ -- -- -- -- 1 Mount, Engine,Rear
(See Engine Mounting Pg. B2, Ref. 15)
7/03
C14
CRANKCASEMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
36
12
13
9
5
15
18
19
16
7
17
14
12
10
11
8
12
4
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3083669 1 Bushing, Starter2 3080103 2 Pin, Dowel3 3087125 1 Asm., Crankcase
(Incl. 1-6,9,13,15,18,19)4 3087157 1 Asm., Plug, Blind5 3087116 2 Pin, Dowel6 3086395 1 Bearing, Ball7 3087266 2 Knock, Pipe8 3084205 3 Asm., Screw and Washer9 3084839 1 Seal, Oil
10 3087128 1 Gauge, Oil11 3087065 1 O-Ring12 3087066 2 Union13 3087155 1 Plug14 3084849 1 Union15 3087156 2 Bolt, Flange16 3086749 1 Plug17 3082956 1 Gasket18 3087117 8 Bolt, Flange19 3086399 1 Bolt, Flange
7/04
D1
CARBURETORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
41
32
29
9
44
5
43
12
4
6
36
33
31
1230
1312
1415
21
19
26
1110
3
22
20
16
24
18
25
35
23
45
3839
8
7
40
34
28
27
17
42
37
E 2004 Polaris Sales Inc.
D2
CARBURETORMAGNUM 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. Description Ref. Part No. Qty. Description
1 3130507 1 Ring2 3130508 1 E-Ring3 3131554 1 Needle, Jet4 3130752 1 Ring5 3130732 1 Asm., Diaphragm6 3131588 1 Jet, Needle7 3130541 2 Screw8 3130540 2 Washer, Spring9 3130504 1 Asm., Jet Block10 3130014 1 Washer11 3131458 1 Jet, Main, #122.512 3130515 2 Seal13 ------ -- -- -- -- 1 Packing14 3130518 1 E-Ring15 3130519 1 Cap16 3130361 1 Pin, Float17 3130594 1 Plate18 3130532 1 O-Ring19 3130520 4 Screw20 3130590 1 Asm., Float Body21 3130521 1 Screw22 3130529 1 Asm., Float23 3130591 2 Screw
24 3131360 1 Valve, Needle25 3130533 1 O-Ring26 3130526 1 Jet, Pilot, #42.527 3131423 1 Screw, Adjust28 3130836 1 Spring29 3130502 1 Valve, Throttle, 10030 3130589 1 Spring31 3130514 1 Ring32 3130501 2 Screw33 3130513 1 Asm., Throttle Shaft34 3130543 1 Guide, Cable35 3130535 4 Screw36 3130511 1 Cover37 3130199 1 Holder, Guide38 3130538 1 Spring39 3131228 1 Asm., Plunger40 3130625 1 Jet, Air, Pilot, #16041 3131590 1 Asm., Carburetor
(Incl. 1-33,36-41,43-45)42 3084205 2 Asm., Screw and Washer43 3131129 1 Spring44 3130503 1 Asm., Cover45 3130924 4 Screw
7/04
D3
CYLINDERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
3
21
20
14
10
4
9 12
16
12
22
27
5
11 13
29
19
2324
25
26
15
18
17
10
12
1617
4
11
11
4
6 7
828
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3087259 2 Cover, Valve2 3086414 2 O-Ring3 3087159 4 Bolt, Flange4 3084874 13 Bolt, Flange5 3089272 1 Asm., Plug6 3089271 1 Asm., Cover, Breather (Incl. 7)7 3085850 1 Asm., Pipe8 3087034 1 Gasket, Breather Cover9 3084858 1 Seal, Intake Valve10 3084994 2 Guide, Valve11 3084798 3 Fin, Damper A12 3084859 1 Seal, Exhaust Valve13 3086418 4 Asm., Bolt and Washer14 3089270 1 Asm., Cylinder Head
(Incl. 9,10,12,14,16,28)
15 3086421 1 Gasket, Exhaust16 3085326 2 Stud17 3080530 2 Washer, Spring Lock18 3086787 2 Nut19 3087266 2 Knock, Pipe20 3086407 1 Gasket, Cylinder21 3087236 1 Unit, Cylinder22 3087238 1 Gasket, Head23 3087050 1 Asm., Adapter24 3083166 1 Asm., Adapter Band (Incl. 25)25 3081497 1 Asm., Screw and Washer26 3081330 2 Bolt, Socket, Head27 3086416 1 Gasket, Cam28 3087275 2 Knock, Pipe29 3087160 2 Bolt, Flange
7/04
D4
CRANKSHAFT and PISTONMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
7
16
6
5
14
15
10
8
11
2
1
4
9
1312
5
15
6
4
8
3
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 308724430872453087246
111
Set, Piston, Ring, StandardSet, Piston, Ring, .010 Inch/.25MM O/SSet, Piston, Ring, .020 Inch/.50MM O/S
2 308724130872423087243
111
Set, Piston, Standard (Incl. 4)Set, Piston, .010 Inch/.25MM O/S (Incl. 4)Set, Piston, .020 Inch/.50MM O/S (Incl. 4)
3 3086846 1 Pin, Piston4 3084167 2 Clip, Piston Pin5 3087240 2 Bolt, Connecting Rod6 3087239 1 Asm., Connecting Rod (Incl. 5,14)7 3087051 1 Asm., Crankshaft (Incl. 16)8 3240168 2 Key, Woodruff
9 3086434308643530864363086437
1111
Spacer, .4Spacer, .6Spacer, .8Spacer, 1.0
10 3086492 1 Sprocket 111 3085528 1 Nut, Slit12 3086767 1 Washer13 3083905 1 Nut, Lock14 3086426 2 Nut15 3086427
30867983086799
222
Bearing, StandardBearing, 0.05Bearing, 0.25
16 3085815 2 Bearing, Ball7/04
D5
INTAKE and EXHAUSTMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
11
12
23
9 10
13
14
8
76
4
2
16
24
2
15
27
1817
2526
28
1
31
76
8
5
21
22
2019
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084911 2 Screw, Adjusting2 3084912 2 Nut3 3084910 2 Asm., Rocker Arm (Incl. 1-3)4 3087053 1 Shaft, Rocker5 3085836 1 Washer, Wave6 3084908 4 Collet, Valve7 3087203 2 Retainer, Spring, Valve8 3087248 2 Spring, Valve9 3086439 1 Asm., Lever, Release10 3086804 1 Spring, Return11 3087247 1 Asm., Camshaft (Incl. 9-12)12 3084899 1 Pin, Dowel13 3085778 1 Valve, Intake14 3086441 1 Valve, Exhaust
15 3086445 1 Guide, Chain16 3086444 1 Chain, Timing17 3086448 1 Gasket, Tensioner18 3086493 1 Asm., Tensioner (Incl. 18-22)19 3087132 1 Pin20 3087131 1 Spring, Tensioner21 3087129 1 Plug22 3087130 1 Gasket, Plug23 3083361 2 Bolt, Flange24 3086443 1 Sprocket 225 3087249 1 Washer26 3086449 1 Bolt, Flange27 3086446 1 Asm., Lever28 3084924 1 Asm., Bolt, Pivot, Lever
7/04
D6
RECOIL STARTERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
13
6
4
7
10
5
312
11
8
12
14
9
8
7
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3084822 1 Asm., Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Asm., Bolt and Washer7 3086749 2 Plug8 3082956 2 Gasket
9 3083669 1 Bushing, Starter10 3083185 1 Spring, Spiral11 3084750 1 Bushing12 3087150 9 Bolt, Flange13 3087163
308716411
Asm., Recoil (Incl. 1-6,9-11,13,14)Asm., Starter Case (Incl. 11)
14 3085083 1 Asm., Rope
1/03
D7
OIL PUMP and OIL FILTERMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
11
9
1
10
8
2
4
7
5
6
3
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3086749 1 Plug2 3082956 1 Gasket3 3086455 1 Spring, Relief Valve4 3086222 1 Valve, Oil Relief5 3087256 1 Bolt, Flange6 3086454 1 Unit, Strainer, Oil
7 3084963 1 Asm., Filter, Oil8 3087255 5 Screw, Counter Sunk9 3086450 1 Cover, Oil Pump10 3086452 1 Rotor, Inner11 3086453 1 Rotor, Outer
1/03
D8
MAGNETOMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
7
4
6
1
2
8 3
5
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 3087036 1 Asm., Ignition Coil (Incl. 2)2 3087037 1 Cap, Spark Plug3 3070172 1 Plug, Spark4 3084978 1 O-Ring
5 3089275 1 Asm., Stator Plate6 3081657 5 Asm., Bolt and Washer7 3087251 1 Flywheel w/Wiring Gear8 3088209 1 Asm., CDI System
7/04
D9
STARTING MOTORMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
9
11
1
5
10
4
3
12
16
15
14
13
67
8
21
E 2004 Polaris Sales Inc.
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3084981 1 Asm., Motor, Starting (Incl. 1-5,7-11)3087030 1 Asm., Gear Shaft (Incl. 13-16)
1 3084982 1 Set, Washer2 3085353 1 Asm., Armature3 3088169 1 Set, Brush, Carbon4 3083649 2 Nut, Flange5 3084408 3 O-Ring6 3082038 2 Asm., Bolt and Washer7 3085034 1 Asm., Cover, Rear
8 3085033 1 Asm., Front Bracket (Incl. 9)9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 5)11 3084405 2 Ring, Rubber12 7555908 1 Washer13 3084412 1 Clip14 3084411 1 Spring, Weight15 3084410 1 Spring, Return16 3084409 1 Clip
7/04
D10
FUEL PUMPMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
4
1
3 2
2
4
E 2004 Polaris Sales Inc.
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3085275 1 Asm., Fuel Pump (Incl. All)1 3084999 1 Asm., Screw and Washer2 3085356 2 Asm., Screw and Washer
3 3084591 4 Asm., Screw and Washer4 3084998 1 Diaphragm, Gasket Set
1/03
D11
TOOL KITMAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC
2
7
1
9
3
4
8
10
5
6
E 2004 Polaris Sales Inc.
11
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
3086485 1 Kit, Tool (Incl. 2-7)1 2870725 1 Gauge, Tire Pressure2 3085001 1 Wrench, Open 8-10mm3 3085002 1 Wrench, Open 12-14mm4 ------ -- -- -- -- 1 Wrench, Plug5 3085569 1 Puller, Spark Plug (Wrench Handle)
6 3082657 1 Screwdriver7 2682572 1 Pouch, Tool Kit8 2871515 1 Lube, U-Joint, 3 oz., Case9 9919487 1 Owner’s Manual, ‘05 Magnum 2x4/4x410 2873647 1 Wrench, Torx11 2874743 1 Wrench, Open End, 1/2 x 9/16
7/04