2001 Polaris Magnum 325 500 ATV Service Manual

Description

This Official 2001 Polaris Magnum 325/500 ATV Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 2001 Polaris Magnum 325 and 500 ATVs.

This Polaris ATV manual includes the following repair topics:

A Arm Replacement
Air Filter Service
Alternator Output Test
AWD Armature Plate Inspection
AWD Front Hub Exploded View
AWD Magnetic Coil Installation
AWD Magnetic Coil Removal
AWD Operation
AWD Testing
Battery Charging
Battery Inspection/Removal
Battery Installation
Battery Maintenance
Battery Service
Battery Terminal Bolts
Battery Testing
Battery OffSeason Storage
Body Assembly Exploded View
Brake Bleeding/Fluid Change
Brake Caliper Assembly Front
Brake Caliper Assembly Rear
Brake Caliper Disassembly Front
Brake Caliper Exploded View Front
Brake Caliper Exploded View Rear
Brake Caliper Inspection Front
Brake Caliper Installation Front
Brake Caliper Removal Front
Brake Caliper Removal/Inspection Rear
Brake Disc Inspection Front
Brake Disc Inspection Rear
Brake Disc Removal/Replacement Front
Brake Fluid Level
Brake Hose/Fitting Inspection
Brake Light Switch Testing
Brake Noise Troubleshooting
Brake Pad Application
Brake Pad Assembly Front
Brake Pad Inspection
Brake Pad Installation Rear
Brake Pad Kits
Brake Pad Removal Front
Brake Pad Removal Rear
Brake System Inspection
Brake System Operation
Brake System Service Notes
Brake Auxiliary Hydraulic
Brake Auxiliary Testing
Brakelight Lamp Replacement
Break in Period Cycle
Breather Filter Maintenance
Breather Hose
Cam Chain Drive Sprocket Installation
Cam Chain Tensioner Inspection
Cam Chain Tensioner Installation
Cam Chain Tensioner Removal
Cam Chain/Camshaft Installation
Cam Chain/Tensioner Blade
Camber & Caster
Camshaft Inspection
Camshaft Removal
Camshaft Timing
Carburetor Assembly
Carburetor Cleaning
Carburetor Disassembly
Carburetor Exploded View
Carburetor Float Bowl Draining
Carburetor Float Height Adjustment
Carburetor Float System
Carburetor Fuel Level Testing
Carburetor Inspection
Carburetor Main System
Carburetor Needle and Seat Testing
Carburetor Operation
Carburetor Pilot System
Carburetor Starter System
Carburetor System Function
Carburetor Venting Systems
CDI Output Test
Charging System Break Even Test
Charging System Testing
Choke Adjustment
Clutch Alignment
Clutch Offset
Cold Weather Kits
Combustion Chamber
Compression Release Installation
Compression Release Removal/Insp
Compression Test
Connecting Rod Bearing Clearance Insp
Connecting Rod Bearing Inspection
Connecting Rod Installation
Controls Inspection
Coolant Level Inspection
Coolant Strength
Coolant Temperature Sensor
Coolant Recommended
Cooling System Hoses
Cooling System Overview
Cooling System Pressure Test
Counter Balancer Installation
Counter Balancer Shaft End Play
Counter Balancer Shaft Removal/Inspection
Cover/Panel Removal
Crankcase Assembly
Crankcase Bearing Inspection
Crankcase Bearing Installation
Crankcase Disassembly
Crankcase Inspection
Crankcase Oil Strainer Inspection
Crankcase Separation
Cranking Output Test
Crankshaft Bearing Inspection
Crankshaft End Play Adjustment
Crankshaft End Play Inspection
Crankshaft Inspection
Crankshaft Installation
Crankshaft Removal/Inspection
Current Draw
CV Joint Handling Tips
Cylinder Cleaning
Cylinder Head Assembly
Cylinder Head Disassembly
Cylinder Head Inspection
Cylinder Head Installation
Cylinder Head Reconditioning
Cylinder Head Removal
Cylinder Head Warpage
Cylinder Honing
Cylinder Inspection
Cylinder Installation
Cylinder Removal
Cylinder Removal/Inspection
Decal Replacement
Decimal Equivalent Chart
Draining Recoil Housing
Drive Belt Installation
Drive Belt Removal/Inspection
Drive Belt Tension
Drive Clutch Assembly
Drive Clutch Bushing Service
Drive Clutch Disassembly
Drive Clutch Exploded View
Drive Clutch Inspection
Drive Clutch Operation
Drive Shaft Boot Replacement
Drive Sprocket Removal/Inspection
Driven Clutch Assembly
Driven Clutch Bushing Service
Driven Clutch Disassembly
Driven Clutch Operation
Dual Hydraulic Caliper Bleeding
EBS Drive Clutch Bushing Service
EBS Drive Clutch Inspection
EBS Driven Clutch Bushing Service
EBS Driven Clutch Disassembly
EBS Driven Clutch Disassembly/Insp
EBS Exploded View
EBS Moveable Sheave Bushing Inspection
EBS One Way Drive Clutch Inspection
EBS One Way Driven Clutch Inspection
EBS Operation Guidelines
EBS System Theory Of Operation
Electrical Service Notes
Electrical Special Tools
Electronic Speedometer Testing
Engine Accessible Components
Engine Assembly EHPL
Engine Assembly ESPF
Engine Bottom End Disassembly EHPL
Engine Bottom End Disassembly ESPF
Engine Designation Numbers
Engine Disassembly
Engine Exploded View EHPL
Engine Exploded View ESPF
Engine Fastener Torque Patterns
Engine Installation Notes
Engine Lubrication
Engine Mounts
Engine Removal
Engine Serial Number Location
Engine Service Data EHPL
Engine Service Data ESPF
Engine to Frame Ground
Engine Top End Disassembly EHPL
Engine Top End Disassembly ESPF
ETC Operation Test
ETC Switch Adjustment
ETC Switch Testing
Exhaust System Maintenance
Exhaust Valve Adjustment
Fan Control Circuit Testing
Fan Control Switch Bypass Test
Fan Control Switch Testing
Fan Motor Current Draw Test
Fastener Torque Flywheel Identification
Flywheel Installation
Flywheel Removal/Inspection
Frame Nuts Bolts
Fasteners
Front Axle Installation AWD
Front Axle Installation HDS
Front Axle Removal AWD
Front Axle Removal HDS
Front Axle Seal Sleeve Replacement
Front Hub Assembly
Front Hub Assembly HDS
Front Hub Bearing Adjustment AWD
Front Hub Disassembly
Front Hub Disassembly AWD
Front Hub Disassembly HDS
Front Hub Engagement Limiter
Front Hub Exploded View x
Front Hub Exploded View AWD
Front Hub Fluid Change
Front Hub Fluid Level Inspection
Front Hub Inspection HDS
Front Hub Installation
Front Hub Seal Replacement AWD
Front Hub/Wheel Bearing Installation
Front Prop Shaft Removal
Front Strut Ball Joint Replacement
Front Strut Weldment Replacement
Fuel Filter Maintenance
Fuel Flow Diagram
Fuel Line Maintenance
Fuel Pump Exploded View
Fuel Pump Service
Fuel Tank Assembly
Gear Position Switch Test
Gear Shift Boot Replacement
Gear Shift Selector Assembly
Gear Shift Selector Disassembly
Gear Shift Selector Installation
Gear Shift Selector Removal
Gearcase Assembly Front
Gearcase Assembly Front HDS
Gearcase Assembly Rear
Gearcase Disassembly Front
Gearcase Disassembly Front HDS
Gearcase Disassembly Rear
Gearcase Exploded View Front
Gearcase Exploded View Front HDS
Gearcase Exploded View Rear
Gearcase Installation Front
Gearcase Installation Front HDS
Gearcase Installation Rear
Gearcase Lubrication Front
Gearcase Lubrication Rear
Gearcase Removal Front
Gearcase Removal Front HDS
Gearcase Removal Rear
Glossary of Terms
Headlamp Service
Headlamp Switch Testing
Headlight Adjustment
Headlight Housing Replacement
Headlight Pod Assembly Exploded View
Hilliard Clutch Disassembly/Inspection
Honing to Oversize
Hot Light Testing
Identification Numbers
Idle Speed Adjustment
Ignition System Components Magnum
Ignition System Components Magnum
Ignition System Testing
Ignition Timing
Ignition Timing Curves
Indicator Lamp Replacement
Intake Valve Adjustment
Jet Part Numbers
Jetting Guidelines
Keys Replacement
Load Test Lubricants
Lubricants Recommended
Lubrication Chart
Lubrication Transmission
Machine Dimensions
Main Jet Selection
Maintenance Chart Periodic
Master Cylinder Assembly
Master Cylinder Disassembly
Master Cylinder Inspection
Master Cylinder Installation
Model & Serial Number Location
Model Identification
Neutral Light Testing
Oil & Filter Change Magnum
Oil & Filter Change Magnum
Oil Cooler Fan Control Magnum
Oil Filter Installation
Oil Flow EHPL
Oil Flow ESPF
Oil Level Inspection Magnum
Oil Pipe/Breather Pipes
Oil Pipes
Oil Pressure Test
Oil Pump Assembly
Oil Pump Installation
Oil Pump Priming Magnum
Oil Pump Removal/Inspection
Oil Pump Shaft End Play
One Way Valve Inspection
One Way Valve Installation
Paint Codes
Pilot Mixture Screw Adjustment (Altitude)
Pilot Screw Adjustment—Magnum
Pilot Screw Adjustment Magnum
Piston Identification
Piston Inspection
Piston Installation
Piston Removal
Piston Ring Installation
Piston Ring Installed Gap
Piston to Cylinder Clearance
Piston/Rod Inspection
Pre Ride Inspection
Pressure Relief Valve Installation
Pressure Relief Valve Magnum
Publication Numbers
Pump Shaft Oil Seal Installation
PVT Assembly
PVT Disassembly
PVT Drying
PVT Maintenance
PVT Overheating
PVT Overview
PVT System Operation
PVT System Sealing/Ducting Components
Radiator Cap Pressure Test
Radiator Coolant Level Inspection
Radiator Maintenance
Rear Axle Bearing Service
Rear Axle Installation
Rear Hub Inspection
Recoil Assembly
Recoil Disassembly/Inspection
Recoil Draining
Reverse Limit System
Reverse Limit System
Rocker Arm/Shaft Inspection
Rocker Shaft/Arm Assembly Installation
Rocker Shaft/Rocker Arm Assy/Installation
Sediment Tube Maintenance
Shift Linkage Adjustment
Shift Weights
Side Panel Removal
Spark Plug Maintenance
Special Tools PVT
Specific Gravity Test
Specifications Brake
Specifications Cooling System
Specifications Drive Clutch Spring
Specifications Model
Specifications Speed Limiter
Specifications Torque Brakes
Specifications Torque Engine
Specifications Torque Final Drive
Specifications Torque PVT
Specifications Torque Standard
Specifications Torque Steering
Specifications Torque Suspension
Specifications Torque Transmission
Speed Limiter Identification
Spider Removal
Starter Assembly
Starter Disassembly
Starter Drive
Starter Drive Installation
Starter Drive Removal/Inspection
Starter Motor Armature Testing
Starter Motor Brush Insp/Rplmnt
Starter Solenoid Bench Test
Starter System Test
Stator Installation
Stator Removal/Inspection
Steering Assembly Exploded View
Steering Maintenance
Steering Post Assembly
Strut Assembly
Strut Assembly AWD
Strut Casting Seal Replacement
Suspension Preload Adjustment
Suspension Front Inspection
Suspension Rear Inspection
Swingarm Exploded View
Swingarm Installation
Taillight Lamp Replacement
Tap Drill Chart
Tensioner Blade Installation
Thermistor Testing Magnum
Thermostat Installation
Throttle Cable Adjustment
Throttle Operation
Tie Rod Inspection
Timing Check Procedures
Tire Inspection
Tire Pressure
Tire Tread Depth
Toe Alignment
Torque Conversion Table
Torque Patterns Engine Transmission Assembly
Transmission Disassembly
Transmission Exploded View
Transmission I D Location
Transmission Installation
Transmission Linkage Adjustment
Transmission Removal
Troubleshooting Brakes
Troubleshooting Cooling System
Troubleshooting Engine
Troubleshooting Fuel System/Carb
Troubleshooting Ignition System
Troubleshooting PVT
Troubleshooting Spark Plug
Troubleshooting Starter System
Troubleshooting Transmission
U Joint Assembly
U Joint Disassembly
Unit of Measure Conversion Table
Valve Clearance
Valve Guide Removal/Installation
Valve Inspection
Valve Seal Testing
Valve Seat Inspection
Valve Seat Reconditioning
Vent Line Maintenance
Voltage Drop Test
Voltage Test Open Circuit
Water Pump Mechanical Seal Installation
Water Pump Mechanical Seal Removal
Water Pump Mechanical Seal Removal Engine Installed
Water Pump Shaft Oil Seal
Wheel Inspection
Wheel Installation
Wheel Removal Front or Rear
Wiring Diagram Magnum
Wiring Diagram Magnum HDS

Covers may vary.