Polaris Magnum 325/500 2002 Service Manual
Polaris Models Covered & Key Technical Specifications
Models: 2002 Magnum 325, 2002 Magnum 500
Sub-models / Variants: 2x4, 4x4, HDS, RMK
Model Years: 2002
Serial Numbers: A02CB32AA/FC, A02CD32AA/AB/FB, A02CD50AA/AB/FB/FC
Technical Data:
- Engine Displacement (325): 324 cc
- Engine Displacement (500): 499 cc
- Bore (325/500): 3.073" (78 mm) / 3.6248" (92 mm)
- Compression Pressure (325/500): 140-160 psi / 70-90 psi
- Operating RPM: 6000 RPM
- Ignition Timing: 30° ± 2° BTDC @ 5000 RPM
- Valve Clearance: 0.006" (0.15 mm) at TDC
- Transmission Capacity: 27 oz. (800 ml) / 13.5 oz. (400 ml)
- Engine Oil Capacity: 1.9 qts. (1.8 L) / 2 qts. (1.9 L)
Polaris Manual Features & Content Preview
- Official Polaris publication P/N 9916632
- Covers 2002 Polaris Magnum 325 and 500 ATV models, including 2x4, 4x4, HDS, and RMK variants equipped with SOHC 4-stroke engines
- Comprehensive 456-page volume detailing the exact factory specifications and maintenance intervals for the A02CB32AA, A02CD50AA, and general A02-series builds
- Includes 56 pages dedicated to engine specifications, 34 exploded-view diagrams, and 12 detailed maintenance tables covering chassis, electrical, and fuel systems
Service and Maintenance Overview
This official manual provides the essential technical data needed for comprehensive maintenance and routine service. The document breaks down into ten primary chapters. Mechanics will find complete coverage for general information, engine service, fuel systems, and body components. It also details the suspension, the Polaris Variable Transmission (PVT) system, final drive, and braking systems. The maintenance section is particularly thorough. It outlines periodic maintenance charts, pre-ride inspections, and specialized lubrication procedures for the front and rear gearcases, transmission, and cooling networks. Proper adherence to these factory maintenance schedules and mechanical guidelines is essential to maintain structural integrity and ensure safe off-road operation.
Specification and Data Highlights
Digging into the technical data reveals extensive service tables for the ES32PF and EH50PLE powerplants. Technicians get exact clearances, bore and stroke dimensions, and specific torque patterns for cylinder head and crankcase fasteners. Reference charts document jetting, clutch configurations, and oil flow diagrams for both engines. Fluid capacities for the transmission, cooling, and hub systems are clearly listed. You will also find spark plug gaps and ignition timing settings. All torque values for engine and chassis fasteners are documented in both ft. lbs. and Nm. Relying on these precise metrics allows technicians to accurately maintain the tight tolerances established by the original factory builds.
Customer Reviews
Read what our customers say about this Polaris ATV manual and share your own experience.