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2002 Polaris Magnum 325, 500 ATV manual Preview image 1
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2002 Polaris Magnum 325, 500 ATV manual

Models covered in this manual:

  • 2002 Polaris Magnum 500
  • 2002 Polaris Magnum 325
  • Polaris Magnum 325 4x4
  • Polaris Magnum 325 2x4
  • Polaris Magnum 325 2x4 HDS
  • Polaris Magnum 325 4x4 HDS
  • Polaris Magnum 500 4x4
  • Polaris Magnum 500 2x4

Production/model years: 2002

File specifications

File size: 41.83 MB
File type: PDF
Language: English

Printable: Yes
Estimated download time: 0.86 Minutes
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Product Information

Table of Contents

CHAPTER 1 - GENERAL INFORMATION

  • Model Identification
  • Serial Number Location
  • Machine Dimensions
  • Specifications - Magnum 325/HDS
  • Specifications - Magnum 500/HDS/RMK
  • Publication Numbers
  • Paint Codes
  • Replacement Keys
  • Standard Torque Specifications
  • Torque Conversion Chart
  • Decimal Equivalent Chart
  • Unit of Measure Conversion Table
  • Tap Drill Charts
  • Glossary of Terms

CHAPTER 2 - MAINTENANCE

  • Maintenance Schedule
  • Engine Oil Change
  • Spark Plug Maintenance
  • Air Filter Maintenance
  • Fuel Filter Maintenance
  • Coolant System Maintenance
  • Drive Belt Inspection
  • Battery Maintenance
  • Brake System Inspection
  • Suspension Inspection
  • Tire and Wheel Maintenance

CHAPTER 3 - ENGINE

  • Engine Removal and Installation
  • Cylinder Head and Valve Service
  • Piston and Cylinder Service
  • Crankshaft and Crankcase Service
  • Cooling System Service
  • Lubrication System Service
  • Carburetor Adjustment

CHAPTER 4 - FUEL SYSTEM

  • Fuel Tank Removal and Installation
  • Fuel Pump Service
  • Fuel Line Inspection and Replacement
  • Carburetor Service and Adjustment

CHAPTER 5 - BODY/SUSPENSION

  • Body Panel Removal and Installation
  • Seat Removal and Installation
  • Front Suspension Service
  • Rear Suspension Service
  • Steering System Service

CHAPTER 6 - PVT SYSTEM

  • PVT (Polaris Variable Transmission) Overview
  • Drive Belt Inspection and Replacement
  • Clutch Service and Adjustment

CHAPTER 7 - FINAL DRIVE

  • Final Drive Removal and Installation
  • Final Drive Gear Service
  • Axle Inspection and Replacement

CHAPTER 8 - TRANSMISSION

  • Transmission Removal and Installation
  • Transmission Gear Service
  • Shift Mechanism Service

CHAPTER 9 - BRAKES

  • Brake System Overview
  • Front Brake Service
  • Rear Brake Service
  • Brake Line Inspection and Replacement

CHAPTER 10 - ELECTRICAL

  • Electrical System Overview
  • Battery Service
  • Charging System Service
  • Ignition System Service
  • Lighting System Service
  • Wiring Diagram

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