2004 Polaris Magnum 330 4x4 Parts Manual

MAGNUM 330 4X4 Model #A04CD32AA Model #A04CD32AB Model #A04CD32AC Model #A04CD32FB PARTS MANUAL PN 9918626 and MICROFICHE PN 9918627 7/03

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TABLE OF CONTENTS MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB Parts Manual A A- ARM/STRUT MOUNTING C2 ................. AIR BOX B6 ............................... C CARBURETOR D7-8 ........................... CARBURETOR MOUNTING B3-4 .................. CLUTCH COVER C6 ......................... CONTROLS - MASTER CYLINDER/BRAKE LINE A8 .. CONTROLS - THROTTLE ASM./CABLE B13 ........ CRANKCASE D4 ............................ CRANKSHAFT and PISTON D6 ................. CYLINDER D5 .............................. D DECALS A13 ............................... DRIVE CLUTCH C3 .......................... DRIVE SHAFT B7-8 ........................... DRIVEN CLUTCH C4-5 ......................... E ELECTRICAL/TAILLIGHT C7 ................... ENGINE MOUNTING B1-2 ....................... EXHAUST SYSTEM B5 ....................... F FRONT BRAKE A10 .......................... FRONT CAB A5 ............................. FRONT HOUSING C9-10 ......................... FRONT PROP SHAFT B9-10 ...................... FRONT RACK and BUMPER MOUNTING A7 ........ FRONT STORAGE BOX A9 .................... FRONT STRUT B11 ........................... FRONT WHEEL B12 .......................... FUEL PUMP D14 ............................. FUEL TANK B3-4 ............................. G GEAR SELECTOR C14 ........................ GEARCASE C11 ............................. GEARCASE C12 ............................. H HANDLEBAR C1 ............................ I INTAKE and EXHAUST D9 ..................... M MAGNETO D12 .............................. O OIL COOLING A14 ........................... OIL PUMP and OIL FILTER D11 .................. R RACK MOUNTING, REAR A6 .................. REAR BRAKE A11-12 ........................... REAR CAB and SEAT A3-4 ..................... REAR HOUSING C13 .......................... REAR WHEEL DRIVE C8 ...................... RECOIL STARTER D10 ........................ S SHOCK MOUNTING D2 ....................... STARTING MOTOR D13 ........................ STEERING POST B14 ......................... SWING ARM/REAR/GEARCASE MOUNTING D1 ..... T TOOL KIT E1 ............................... TRANSMISSION MOUNTING D3 ................. 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 SEAT MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB 25 24 2 7 3 6 9 10 15 14 16 17 18 38 13 19 20 32 5 35 40 41 1 39 36 11 4 37 3 31 33 30 8 27 23 34 26 6 28 29 10 28 21 22 12

A4 REAR CAB and SEAT MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7661645 10 Rivet (AA)(AB)(AC) 2 7511930 2 Bolt 3 7555792 4 Washer 4 5811107 1 Foil, Rear Cab, Rear 5 5432117-382 5435164-455 5432117-400 1 1 1 Cab, Rear, Silver Vapor Metallic (AA)(FB) Cab, Rear, New Break Up (AB) Cab, Rear, Camo Green Metallic (AC) 6 7541925 4 Nut, Nylok 7 5224592 1 Retainer, Seat Latch 8 5811308 1 Foil, Tape, Rear Cab 9 7512242 4 Screw 10 7555859 14 Washer, Flat 11 7512085 2 Screw 12 7556034 2 Washer 13 5431786 1 Box, Tool 14 7621403 2 Rivet 15 5211033 2 Bracket, Lever Retainer 16 1040387 1 Latch, Seat 17 7041370 1 Spring, Latch 18 2683437-070 2682958-070 1 1 Asm., Seat, Black Covering, Seat, Black 19 7517375 2 Screw 20 5431787 1 Cover, Tool Box 21 7515199 3 Screw 22 1040447-067 1 Box, Battery 23 ------- 1 Asm., Front Gearcase (See Front Hous- ing Pg. C9 and C10 for Details) 24 7552603 4 Washer, Spring Lock 25 7512492 4 Screw 26 5435005 1 Guard, Rock 27 7556065 7 Washer 28 7517386 9 Screw 29 7558301 2 Washer, Flat 30 7542122 8 Nut, Nylok 31 5412156 8 Grommet 32 7517987 8 Screw 33 1014293-067 1 Frame, Main 34 5432221-070 5433219-070 5434404-070 5434405-070 1 1 1 1 Footwell, LH, Black (AA)(AB)(AC) Footwell, RH, Black (AA)(AB)(AC) Guard, Mudflap, Footrest, LH (FB) Guard, Mudflap, Footrest, RH (FB 35 7512232 21 Screw 36 5811111 1 Foil, Rear Fender 37 5811322 1 Foil, Tape 38 7170007 1 Decal, 4 Stroke Carburetor/Filter 39 5811087 1 Foil 40 7670057 12 Nut, U-Type Speed 41 5431796-070 5431797-070 5434408-070 5434409-070 1 1 1 1 Guard, Mud, Rear, LH (AA)(AB)(AC) Guard, Mud, Rear, RH (AA)(AB)(AC) Guard, Mudflap, Rear, LH (FB) Guard, Mudflap, Rear, RH (FB) 7/03

A5 FRONT CAB MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB 7 8 9 13 22 15 3 2 23 21 17 16 20 9 1 5 5 6 14 11 10 10 4 11 18 21 12 19 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 5811491 1 Foil, Side Panel, RH 2 5812484 1 Foil, Side Panel, RH 3 2632284-382 2632848-455 2632284-400 2632633-382 2632849-455 2632633-400 1 1 1 1 1 1 Asm., Panel w/Foam, LH, Silver Vapor Metallic (AA)(FB) Asm., Panel w/Foam, LH, New Break Up (AB) Asm., Panel w/Foam, LH, Camo Green Metallic (AC) Asm., Panel w/Foil, RH, Silver Vapor Me- tallic (AA)(FB) Asm., Panel w/Foil, RH, New Break Up (AB) Asm., Panel w/Foil, RH, Camo Green Me- tallic (AC) 4 5811797 1 Foam, Panel, Side, LH 5 7512232 10 Screw 6 5811801 1 Foam, Cab, Front 7 5435110-382 5435166-455 5435110-400 1 1 1 Cover, Front, Silver Vapor Metallic (AA)(FB) Cover, Front, New Break Up (AB) Cover, Front, Camo Green Metallic (AC) 8 2632747-382 2632847-455 2632747-400 1 1 1 Asm., Cab, Foam, Front, Silver Vapor Me- tallic (Incl. Warning Decals)(AA)(FB) Asm., Cab, Front, New Break Up (Incl. Warning Decals)(AB) Asm., Cab, Foam, Front, Camo Green Metallic (Incl. Warning Decals)(AC) 9 7670057 12 Nut, Speed, U-Type 10 5245394-067 5246021-067 1 1 Shield, Splash, LH Guard, Splash, RH 11 7621509 2 Rivet 12 7515158 2 Screw 13 7670135 7547240 4 4 Nut, Speed (AA)(AB) Nut, Tinnerman, Push-On (FB) 14 7517312 2 Screw 15 5431798-070 5431799-070 5434406-070 5434407-070 1 1 1 1 Guard, Mud, Front, LH (AA)(AB) Guard, Mud, Front, RH (AA)(AB) Guard, Mudflap, Front, LH (FB) Guard, Mudflap, Front, RH (FB) 16 7541925 2 Nut, Nylok 17 7555792 2 Washer 18 5812138 1 Foam, Panel, LH 19 7556034 2 Washer 20 7512085 2 Screw 21 7542122 3 Nut, Nylok 22 7512126 1 Bolt 23 7558221 2 Washer, Flat 7/03

A6 REAR RACK MOUNTING MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB 4 3 1 2 8 12 11 10 13 7 9 9 8 12 12 5 6 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7518280 2 Screw 2 7517983 2 Screw 3 2670174-070 1 Asm., Rack, Rear (Incl. Ref. 4 and Warning Decal) 4 7079927 2 Decal, Reflector, Red 5 7517312 2 Screw 6 7555859 2 Washer, Flat 7 1013724-067 1 Support, Rear Rack 8 7512329 6 Bolt 9 7558402 16 Washer, Flat 10 5334092 2 Spacer 11 5246394-067 2 Mount, Front, Rear Rack 12 7542324 8 Nut, Nylok 13 7512371 2 Bolt 7/03

A7 FRONT RACK and BUMPER MOUNTING MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB 1 6 17 18 3 16 2 7 5 11 9 10 12 13 14 15 8 4 7 4 7 6 7 4 8 4 17 18 7 1 2 4 5 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 7512232 6 Screw 2 1013744-067 1013746-067 1 1 Support, Front Rack, LH Support, Front Rack, RH 3 5810467 1 Plug, Frame 4 7515399 6 Screw 5 1014099-067 1014101-067 1 1 Mount, Rack, LH Mount, Rack, RH 6 2431011 2431012 4030061 1 1 2 Asm., Headlight, Side ,LH Asm., Headlight, Side, RH Bulb, Headlamp, 30W 7 7542324 4 Nut, Nylok 8 7555954 4 Washer 9 7515391 2 Screw 10 7515390 2 Screw 11 5432155-070 1 Bumper 12 1013772-067 1 Guard, Brush 13 7670094 6 Nut, U-Type 14 7512097 6 Screw 15 5433923 5433924 1 1 Shield, Radiator Side, LH Shield, Radiator Side, RH 16 5244729-067 5244730-067 1 1 Extension, Frame, LH Extension, Frame, RH 17 7512329 2 Bolt 18 7558402 2 Washer, Flat 7/03

A8 CONTROLS - MASTER CYLINDER/BRAKE LINE MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB 13 18 9 12 14 16 17 3 10 11 19 2 1 8 7 6 4 15 5 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 2010196 1 Asm., Master Cylinder, LH 1 5411297 1 Boot, Brake Line, Rubber 2 5410988 2 Seal 3 4110164 1 Switch 4 2201834 1 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 5 7517899 2 Screw 6 2201836 1 Kit, Master Cylinder Park Brake Lever (Incl. Lever, Spring) 7 2201833 1 Kit, Master Cylinder Clamp (Incl. Clamp, Screws) 8 2201835 1 Kit, Master Cylinder Lever (Incl. Pin, Lever, Clip) 9 1910565 1 Line, Brake, JB to Rear 10 7621462 1 Rivet 11 7080539 1 Clamp, Nylon 12 1910474 1 Line, Brake, Left Front 13 7512024 2 Screw 14 7080138 4 Cable Tie 15 8360031-34 1 Conduit 16 1910475 1 Line, Brake, Right Front 17 7052292 1 Fitting, Cross 18 1910470 1 Line, Brake, Pod 19 1910499 1 Bolt, Banjo 7/03

A9 FRONT STORAGE BOX MAGNUM 330 4X4 A04CD32AA and MAGNUM 330 4X4 A04CD32AB and MAGNUM 330 4X4 A04CD32AC and MAGNUM 330 4X4 A04CD32FB 4 6 7 1 12 3 19 5 8 9 11 16 10 17 2 18 15 13 14 4 7 5 5 Part numbers may have changed since this microfiche was issued. To ensure that correct parts are received, refer to PartSmart, which is updated monthly. Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1 1253528 1 Asm., Front Cover (Incl. 2-5,8,17) 2 7518216 6 Screw 3 7081101 6 Ring, Tie Down 4 5334257 2 Latch, Wire 5 7512076 6 Screw 6 5521641 1 Seal, Front Compartment 7 7081125 7081145 1 1 Latch, 1/4 Turn, RH Latch, 1/4 Turn, LH 8 7542324 6 Nut, Nylok 9 7515399 6 Screw 10 7555958 4 Washer, Flat 11 5133825 2 Pin, Hinge, Front 12 5435073-070 1 Base, Front Box w/Decals 13 7541925 2 Nut, Nylok 14 7555792 2 Washer 15 7512007 2 Bolt 16 5412352 3 Plug, Compartment 17 5246928 2 Channel, Lid 18 7512024 2 Screw 19 7081124 2 Cable, Lid, Front 7/03

2004 Polaris Magnum 330 4x4 Parts Manual

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