2005 Polaris Magnum 330 4x4 Parts Manual

PARTS MANUAL PN 9919490 and MICROFICHE PN 9919491 7/04 MAGNUM 330 4X4 Model #A05CD32AA Model #A05CD32AB Model #A05CD32AC

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TABLE OF CONTENTS MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC Parts Manual A A-ARM B14 ................................ AIR BOX B6 ............................... C CARBURETOR 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 .............................. D DECALS A13 ............................... DRIVE CLUTCH C1 .......................... DRIVE SHAFT, FRONT B7 ..................... DRIVEN CLUTCH C2 ......................... E ELECTRICAL/TAILLIGHT C4 ................... ENGINE MOUNTING B1-2 ....................... EXHAUST SYSTEM B5 ....................... F FRONT 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 ............................. G GEAR SELECTOR C10 ........................ G GEARCASE C7 ............................. GEARCASE C8 ............................. H HANDLEBAR B13 ............................ I INTAKE and EXHAUST D5 ..................... M MAGNETO D8 .............................. O OIL COOLING A14 ........................... OIL PUMP and OIL FILTER D7 .................. R RACK MOUNTING, REAR A6 .................. REAR BRAKE A11-12 ........................... REAR CAB and SEAT A3-4 ..................... REAR HOUSING C9 .......................... REAR WHEEL DRIVE C5 ...................... RECOIL STARTER D6 ........................ S SHOCK MOUNTING C12 ....................... STARTING MOTOR D9 ........................ STEERING POST B12 ......................... STRUT MOUNTING B14 ........................ STRUT, FRONT B9 .......................... SWING ARM/REAR/GEARCASE MOUNTING C11 ..... T TOOL KIT D11 ............................... TRANSMISSION MOUNTING C13 ................. W WHEEL, 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 SEAT MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC 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 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 7661645 10 Rivet 2 7511930 2 Bolt 3 7555792 4 Washer 4 5811107 1 Foil, Rear Cab, Rear 5 5432117-382 5432117-400 5435164-455 1 1 1 Cab, Rear, Silver Vapor Metallic (AA) Cab, Rear, Camo Green Metallic (AB) Cab, Rear, New Break Up (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 2683222-070 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 Housing Pg. C6 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 1 1 Footwell, LH, Black Footwell, RH, Black 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 1 1 Guard, Mud, Rear, LH Guard, Mud, Rear, RH 7/04

A5 FRONT CAB MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC 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 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 5811491 1 Foil, Side Panel, RH 2 5812484 1 Foil, Side Panel, RH 3 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, LH 5 7512232 10 Screw 6 5811801 1 Foam, Cab, Front 7 5435110-382 5435110-400 5435166-455 1 1 1 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 Green Metallic (Incl. Warning Decals)(AB) Asm., Cab, Front, New Break Up (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 4 Nut, Speed 14 7517312 2 Screw 15 5431798-070 5431799-070 1 1 Guard, Mud, Front, LH Guard, Mud, Front, RH 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 7/04

A6 REAR RACK MOUNTING MAGNUM 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 8 12 12 5 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 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 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC 1 6 15 16 3 14 2 7 5 9 8 10 11 12 13 4 7 4 7 6 7 4 4 15 16 7 1 2 4 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 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 7517977 4 Screw 9 5432155-070 1 Bumper 10 1013772-067 1 Guard, Brush 11 7670094 6 Nut, U-Type 12 7512097 6 Screw 13 5433923 5433924 1 1 Shield, Radiator Side, LH Shield, Radiator Side, RH 14 5244729-067 5244730-067 1 1 Extension, Frame, LH Extension, Frame, RH 15 7512329 2 Bolt 16 7558402 2 Washer, Flat 10/03

A8 CONTROLS - MASTER CYLINDER/BRAKE LINE MAGNUM 330 4X4 A05CD32AA and MAGNUM 330 4X4 A05CD32AB and MAGNUM 330 4X4 A05CD32AC 29 34 25 28 30 32 33 18 26 27 35 17 24 22 21 19 31 20 23 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 2010238 1 Asm., Master Cylinder, LH 17 5410988 2 Seal 18 4110164 1 Switch 19 2202725 1 Kit, Master Cylinder Cap (Incl. Cap, Screws, Sight, Gasket) 20 7517899 2 Screw 21 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 Rear 26 7621462 1 Rivet 27 7080539 1 Clamp, Nylon 28 1910838 1 Line, Brake, Left Front 29 7512024 2 Screw 30 7080138 4 Cable Tie 31 8360031-34 1 Conduit 32 1910839 1 Line, Brake, Right Front 33 7052292 1 Fitting, Cross 34 1910470 1 Line, Brake, Pod 35 1910499 1 Bolt, Banjo 7/04

A9 FRONT STORAGE BOX MAGNUM 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 10 17 2 18 15 13 14 4 7 5 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 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

2005 Polaris Magnum 330 4x4 Parts Manual

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