2002 Polaris Magnum 325 & 500 ATV Service Manual

Covers Magnum 325 & 500 with procedures for carburetor, fuel system, ignition timing, engine oil, cooling system, and more. A02CB32AA/FC & A02CD32AA/AB/FB

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Polaris Models Covered & Key Technical Specifications

Models: 2002 Magnum 325, 2002 Magnum 500
Sub-models / Variants: 2x4, 4x4, HDS, RMK
Build 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)
Technical Specifications
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Document Number / Seller:
32238 / Dennis Perez
File Size:
41.83 MB
File Type:
PDF
Language:
English
Pages:
456
Printable:
Yes
Category:
ATV
Last updated / verified
Apr 2, 2026

Polaris Manual Features & Content Preview

2002 Polaris Magnum 325 and 500 Technical Service Documentation

  • Covers 2002 Polaris Magnum 325 and 500 ATV models, including 2x4, 4x4, HDS, and RMK variants with SOHC 4-stroke engines
  • Official Polaris publication P/N 9916632
  • Contains 56 pages of engine specifications, 34 exploded-view diagrams, and 12 detailed maintenance tables
  • Downloads to your account within seconds of checkout
  • Indexed PDF search covers every chapter and appendix
  • Re-download the file any time, no expiration
  • This 456-page volume provides the exact specifications and maintenance intervals established by the factory for the A02CB32AA and A02CD50AA model-year builds

Service and Maintenance Overview

This 2002 Polaris Magnum 325 and 500 service manual provides technical data for the full range of maintenance and engine repair tasks. The document is structured into ten primary chapters covering general information, maintenance, engine service, fuel system details, body and suspension components, the PVT (Polaris Variable Transmission) system, final drive, transmission, braking systems, and electrical specifications. The maintenance section details the periodic maintenance charts, pre-ride inspections, and specialized lubrication procedures for front and rear gearcases, transmission, and cooling systems.

Specification and Data Highlights

Technical depth includes comprehensive service data tables for the ES32PF and EH50PLE engines, listing clearances, bore and stroke dimensions, and torque patterns for cylinder head and crankcase fasteners. Reference charts document jetting, clutch configurations, and oil flow diagrams for both powerplants. The manual lists fluid capacities for transmission, cooling, and hub systems, along with spark plug gaps and ignition timing settings. Torque values for engine fasteners are documented in ft. lbs. and Nm to assist in maintaining the factory-specified integrity of the 2002 Polaris Magnum 325 and 500 builds.

Note: This page is a contents overview for the manual. It does not provide repair or diagnostic instructions. An official 456-page Polaris OEM workshop manual covering the 2002 Magnum 325 and 500, documenting engine, chassis, electrical, and fuel-injection specifications for the A02-series build.

Document Reference: Polaris Service Manual, Form 9916632

Manual FAQ, Purchase & Download Details

Which major vehicle systems are covered in the manual chapter index? keyboard_arrow_down

Chapter index lists coverage for general information, maintenance, the engine, fuel system, body and suspension, PVT system, final drive, transmission, brakes, and electrical systems.

Are there reference tables included for unit conversions or torque specifications? keyboard_arrow_down

General information section includes torque conversion charts for pound-foot and pound-inch values. It also contains unit of measure conversion tables and standard torque specification guidelines.

Is the manual structured to cover the engine and transmission specifications for the Magnum 325 and 500 models? keyboard_arrow_down

Document contains detailed specification pages for both the 2002 Magnum 325 and 500 models. These pages provide technical reference data such as bore and stroke dimensions, compression pressure norms, and fluid capacities for the engine and transmission. The information is organized by model number and engine variant for quick reference.

What is the format of the document provided upon purchase? keyboard_arrow_down

Product is provided as a digital PDF document.

Does the manual include electrical reference values or connector information for the ignition system? keyboard_arrow_down

Electrical sections list specific reference data such as alternator output in watts and ignition timing specifications. These sections also provide identification cues for components like the flywheel and CDI marking to assist in identifying the correct electrical system data.

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