Hi, I just picked up my second Polaris ATV, a 2000 model (I'm told) 325 Magnum.

I had a question guys, as I'll be working on this one a bit. The thing runs fine, but it's seen a hard life. I got it for 700 dollars, and my 2004 330 Magnum has been a real work horse... so I figured I'd get a second ATV of similar design.

This new (to me) 2000 325 Magnum has had the front 4x4 shafts removed, and the guy I got it from said that the previous owner did that because the 4x4 was locking up. It runs fine as a 2wd, and has apparently been running this way on a farm for quite some time.

The front differential seems to be working... the two sides where the shafts were removed from both turn when the vehicle is in motion. This is the case whether the 4x4 button is switched on or not; the drive shaft sides from the front diff both turn.

It's possible that the universal in one or both shafts went bad, and the previous owner removed the shafts for that reason. Another thought I had was that the front wheels may have been binding up due to the 4x4 not activating correctly--I had this happen on my 330 Magnum and it actually ended up being a loose ground at the battery. Lots of folks said it was hilman clutch (or something like that) in the wheels... but I got lucky; it was just a ground wire on that 330.

I will have a service manual on the way soon. But here is my question:

Is there any way that I can check the front diff to be sure that it's okay before I buy shafts to put in this thing? It is turning, as mentioned, so it's not stuck and it doesn't grind... I just can't figure whether it's supposed to turn all the time (even when 4x4 is off) or not.

Dan

 

I've seen this several times over the years. Probably both the drive shafts and internal hub parts were worn and the previous owner took the easy way out. You have to tear the hubs apart to check things out. Several good videos on you tube that can help you become acquainted with this system while waiting for the manual which can help even more. The main areas to check are the coil sleeve,inner pole on the strut itself. If the sleeve is damaged,usually takes a new sleeve and coil as it gets damaged trying to remove the old sleeve. If the inner pole of the strut is ground down,the strut is junk! It's a given to always replace armature plates also and inner strut seal if the struts are still ok. Drive shaft assys you can find cheap on ebay or places like Sixity.If the struts looks like this,then be prepared to spend some more $.

 

old polaris tech, thanks for letting me know. I have read your posts over the last few years (lurking) while working on my 330 Magnum. It rarely needs any repairs, just routine maintenance. I've learned a lot seeing your words of wisdom, and may God bless you for helping out so many folks.

would something like this (one for each side) be what I would need, to replace the hubs and shafts at the same time? http://www.ebay.com/itm/2000-2001-2002-Polaris-Xpedition-325-4x4-Front-CV-Axle-Shaft-Right-/331482812902?hash=item4d2dea51e6&vxp=mtr
I'll see what I can find out with this thing. I'd like to put it back to AWD capable, but for a farm ATV I think it'll do fine as it is. I'll post back when I learn more.

Thanks again.

Dan

 

You'd need a couple of these.http://www.ebay.com/itm/POLARIS-MAGNUM-325-4X4-2000-2002-COMPLETE-FRONT-CV-AXLE-LEFT-OR-RIGHT-7006-/381221509796?hash=item58c2929aa4&vxp=mtr Plus what ever may be needed in the hubs. Whether armature plates,roll cages, coil sleeves,coils,bearings,seals,etc or possibly struts.That you'd have to take the hub apart to find out.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse Plus several videos on you tube on what's involved.

 

I've definitely got plenty to learn. Thanks for your patience, and all the help.