2003 Magnum.pdf
(
14429 KB
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GENERAL
MAINTENANCE
ENGINE
CARBURETION
BODY AND STEERING
CLUTCHING
FINAL DRIVE
TRANSMISSION
BRAKES
ELECTRICAL
GENERAL INFORMATION
Specs
Model Identification
. . . . . . . . . . . . . . . . . . . . . . .
Serial Number Location
1.2
. . . . . . . . . . . . . . . . . . .
1.2
Machine Dimensions
. . . . . . . . . . . . . . . . . . . . .
Specifications - Magnum 330
1.3
. . . . . . . . . . . . . .
1.3--1.7
Publication Numbers
. . . . . . . . . . . . . . . . . . . . .
1.8
Replacement Keys
. . . . . . . . . . . . . . . . . . . . . . .
1.8
Special Tools
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque Specifications
1.9--1.12
. . . . . . . . . . . .
1.13
Tap Drill Charts
. . . . . . . . . . . . . . . . . . . . . . . . . .
Decimal Equivalent Chart
1.14
. . . . . . . . . . . . . . . . .
Unit of Measure Conversion Table
1.14
. . . . . . . . . .
1.15
Glossary of Terms
. . . . . . . . . . . . . . . . . . . . . . . .
1.16
1.1
GENERAL INFORMATION
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
A
0 5
C D
3 2 A A
Emissions &
Model Option
Year Designation
Basic Chassis
Designation
Engine Designation
ENGINE DESIGNATION NUMBERS
. . . . . . . . . . . . . . .
VIN IDENTIFICATION
ES32PFE102
Single, Oil/Air Cooled, SOHC 4 Stroke, Electric Start
World Mfg. ID
Vehicle Descriptor
Vehicle Identifier
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
3
2
A
*
5
P
0
0
0
0
0
0
4
X
A
C
D
Model
Year
Emissions
* This could be either
a number or a letter
Body Style
Individual Serial No.
Engine
Plant No.
Check Digit
Powertrain
ENGINE SERIAL NUMBER LOCATION
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This
information can be found on the sticker applied to the recoil housing on the right side of engine.(A) An additional
number is stamped on the center top of crankcase beneath the cylinder coolant elbow.
UNIT MODEL NUMBER AND SERIAL NUMBER LOCATION
The machine model number and serial number are
important for vehicle identification. The machine
serial number is stamped on the lower left side of
the frame tube.(B)
A
Front
B
TRANSMISSION I.D. NUMBER
LOCATION
The transmission I.D. number is located on
the right side of machine.
1.2
GENERAL INFORMATION
2003 -2005 Magnum 330 2x4
MODEL:
. . . . .
2004 MODEL NUMBER:
. . . . .
A04CB32AA, FC
2005 MODEL NUMBER:
. . . .
A05CB32AA
ENGINE MODEL:
. .
ES32PFE
Category
Dimension / Capacity
Length
81 in./206 cm
Width
46 in./116.8 cm
Height
46 in./116.8 cm
Wheel Base
49.75 in./126.37 cm
Dry Weight
590 lbs./267.6 kg
Gross Vehicle Weight
1060 Lbs. / 590 kg
Front Rack Capacity
90 lbs./40.8 kg
Rear Rack Capacity
180 lbs./81.7 kg
Towing Capacity
1000 lbs./454 kg
Hitch Tongue Capacity
100 lbs./45 kg
2005 Magnum 2x4
Body Style
Gen IV
2003 -2006 Magnum 330 4x4
MODEL:
. . . . .
2004 MODEL NUMBER: A04CD32AA, AB, AC, FB
2005 MODEL NUMBER: A05CD32AA, AB, AC
ENGINE MODEL:
. .
ES32PFE
Category
Dimension / Capacity
Length
81 in./206 cm
Width
46 in./116.8 cm
Height
46 in./116.8 cm
Wheel Base
49.75 in./126.37 cm
Dry Weight
637 lbs./288 kg
Gross Vehicle Weight
1100 Lbs. / 499 kg
Front Rack Capacity
90 lbs./40.8 kg
Rear Rack Capacity
180 lbs./81.7 kg
Towing Capacity
1000 lbs./454 kg
2005 Magnum 330 4x4
Hitch Tongue Capacity
100 lbs./45 kg
Front Cargo Box
Std.
Body Style
Gen IV
1.3
GENERAL INFORMATION
2003-2004 Magnum 330 2x4 and HDS
MODEL:
. . . . . . . . . .
MODEL NUMBER:
.
A04CB32AA, AC, FC
ENGINE MODEL:
. .
ES32PFE102
Engine
Platform
Drivetrain
Transmission Type
Fuji 4 stroke, Single Cylinder
Drumshift -- H/L/N/Rev/Park
Engine Model Number
ES32PFE102
Transmission Capacity
13.5 oz. / 400 ml
Engine Displacement
329cc
Rear Gearcase Capacity
10 oz. / 295 ml
Number of Cylinders
1
Gear Ratio :
Low
Rev
High
Front Drive
Rear Drive
10.49:1
6.20:1
4.0:1
3.7:1
3.1:1
Bore & Stroke (mm)
78.5 x 68 mm
Compression Ratio
9.2:1
Compression Pressure
70--90 psi w/ decompressor
Engine Idle Speed
1300
!
100 RPM
Clutch Type
PVT Non--EBS
Engine Max Operating Rpm
6900 RPM
Belt
3211077
Cooling System
Oil / Air w/ fan assist
Steering / Suspension
Front Suspension / Shock
Overheat Warning
Instrument Cluster
A--arm / MacPherson Strut
Lubrication
Wet Sump
Front Travel
6.7 in. / 17.02 cm
Oil Requirements / Capacity
Polaris 0W--40 1.9 qt. / 1.8 ltr
Rear Suspension / Shock
Swing Arm w/ Sachs Shocks
Exhaust System
USFS Approved
Rear Travel
7.1 in. / 18.03 cm
Carburetion
Carburetor model
Ground Clearance
6.75 in. / 17.14 cm
Mikuni BST 34mm
Shock Preload Adjustment
Front / Rear
Front --Non Adjustable.
Rear -- Cam Style-- Std.
Main Jet
122.5
Pilot Jet
42.5
Turning Radius
72 in. / 183 cm
Pilot Air Jet
160
Toe Out
1/8--1/4-- in / .0 -- .159 mm
Jet Needle -- Clip Position
4HB48--2
Wheels / Brakes
Wheel Size / Pattern -- Front
Needle Jet
P--0 (829) / After 1/1/2004 -- P--4
(829) --3rd Clip Position
Steel 24x8--12 / 4--156
Wheel Size / Pattern -- Rear
Steel 24x11--12 / 4--156
Pilot Screw
2 Turns Out
(Initial starting point, settings
may vary for each ATV)
Front Tire Model / Size
24 x 8--12
Rear Tire Model / Size
24 x 11--12
Float Height
13
!
1 mm / 0.51
!
0.40“
Recommended Air Pressure
Front -- 4 psi / Rear -- 3 psi
Fuel Delivery
Fuel Pump
Brake -- Front
Dual Hydraulic Disc
Fuel Capacity / Requirement
3.25 gal US / 12.3 ltr
87 Octane (minimum)
89 Oxygenated
Brake -- Rear
Dual Hydraulic Disc
JETTING CHART
Electrical
Alternator Output
AMBIENT TEMPERATURE
200 w @ 5000 RPM
Altitude
Below 40
"
F
Below 5
"
C
+40
"
F to +80
"
F
+5
"
C to +28
"
C
Voltage Regulator
3--Phase -- LR--390
0--1800
(0--6000)
above 1800
(above 6000)
Meters
(Feet)
127.5
122.5
Lights :
High Beam
30 watts
Low Beam
30 watts
120
115
Brake
Two 12V/26.9 watts
CLUTCH CHART
Standard helix spring position is 2 + 2
Tail
Two 12V/8.26 watts
Shift
Driven
Spring
Driven
Helix
Drive
Spring
Ignition System
DC/CDI Ignition
Altitude
Weight
Ignition Timing
30
" !
2
"
BTDC @ 5000 RPM
0--1800
(0--6000)
Blu/Grn
Black
41--35
16
Meters
(Feet)
(5630279)
(7041157)
(5133701)
Spark plug / Gap
NGK BKR6E/ .036 in
. /
0.9 mm
(7041782)
Black
1800--3700
(6000--12000)
20--38
Blu/Grn
41--35
Battery / Model / Amp Hr
Low Maintenance -- 14 Amp Hr
(7041157)
(7041782)
(5133701)
(5631357)
Circuit Breakers
Fan 10 amp / Harness 20 amp
Starting
Electric / Recoil Backup
Instrument Cluster
Analog Speedo w/ LCD
1.4
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