2002 Magnum 325 4x2 Pistons noise - Page 2 - Polaris ATV Forum
ATV Repair and Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

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post #11 of 21 (permalink) Old 08-22-2019, 07:51 AM Thread Starter
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Originally Posted by latebird View Post
The 325 crankshaft is a plain bearing rod (not roller bearing) - I don't think Mr. Crankshaft can repair a one piece crankshaft.

Plain bearing cranks can be machined to an undersize by an automotive machine shop and Polaris list's .05 and .25 mm (.002 and .010" respectively) undersized bearing inserts. The good news is if the rod is damaged, it is still available. Many times the bearing shells are available while the rod is not or vice versa.

Regardless, you need to take the motor apart to find out what needs to be replaced or repaired - might end up being the camshaft and head or piston and cylinder.
I wonder if I should look for a rebuilt motor or try to fix this one?
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post #12 of 21 (permalink) Old 08-22-2019, 09:08 AM
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Quote:
Originally Posted by cimolifam View Post
Where is a good place to get parts?
You might gets the parts from Rocky Mountain ATV, MOTOSPORT.COM, EBAY, AMAZON, stave7119 or me.

If you find a rebuilt motor, it will probably be from powersportsnation.com or nflow

If you find that the engine needs rebuilt and you want your engine rebuilt, I could do it for you as could stave7119 or possibly polman500. Stave7119 and myself are semi-retired. I believe stave works out of his garage and I have my own shop. I charge $60 an hour, but every rebuild is different - I quote parts, but I estimate labor. Typical parts and labor to rebuild a 325 motor is about $1200 more or less.

Maybe when you find out what the problem is better advice could be offered.

Shop Owner and Mechanic with over 50 years experience
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post #13 of 21 (permalink) Old 08-22-2019, 06:14 PM
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Sorry, Oregon is too far from Illinois for me to be hands on. I will help as I can. You can get parts from Partzilla.com, a dealership or bikebandit.com. There are others that some of those here use also. I can't remember them all though. A lot of what you will need will have to be OEM which you can get through the parts places on line. Piston wouldn't be though. The best bet for the piston kit would be to take the cylinder and old piston to a machine shop and have them measure it. Then they can get the correct piston kit for the rebuild.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #14 of 21 (permalink) Old 08-28-2019, 10:51 AM Thread Starter
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Quote:
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Quote:
Originally Posted by cimolifam View Post
Where is a good place to get parts?
You might gets the parts from Rocky Mountain ATV, MOTOSPORT.COM, EBAY, AMAZON, stave7119 or me.

If you find a rebuilt motor, it will probably be from powersportsnation.com or nflow

If you find that the engine needs rebuilt and you want your engine rebuilt, I could do it for you as could stave7119 or possibly polman500. Stave7119 and myself are semi-retired. I believe stave works out of his garage and I have my own shop. I charge $60 an hour, but every rebuild is different - I quote parts, but I estimate labor. Typical parts and labor to rebuild a 325 motor is about $1200 more or less.

Maybe when you find out what the problem is better advice could be offered.
I found a top end kit, crank shaft, and a new card on Amazon and eBay. I should be ordering it this next week.

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2002 Polaris Magnum 325 2x4
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post #15 of 21 (permalink) Old 08-28-2019, 10:53 AM Thread Starter
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Originally Posted by stave7119 View Post
Sorry, Oregon is too far from Illinois for me to be hands on. I will help as I can. You can get parts from Partzilla.com, a dealership or bikebandit.com. There are others that some of those here use also. I can't remember them all though. A lot of what you will need will have to be OEM which you can get through the parts places on line. Piston wouldn't be though. The best bet for the piston kit would be to take the cylinder and old piston to a machine shop and have them measure it. Then they can get the correct piston kit for the rebuild.
Well let me check with Scottie to see if has the transporter fixed. any advise / help would be great. Is there a place to get a online service manual for it?
Thank you

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2002 Polaris Magnum 325 2x4
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post #16 of 21 (permalink) Old 08-28-2019, 12:06 PM
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I have the manual for the 2000-2001 Trailboss 325 - same engine as the 325 Magnum - in PDF for free if you want it - just PM me your email address and a reminder of what manual you need

Shop Owner and Mechanic with over 50 years experience
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post #17 of 21 (permalink) Old 08-28-2019, 03:35 PM Thread Starter
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I have the manual for the 2000-2001 Trailboss 325 - same engine as the 325 Magnum - in PDF for free if you want it - just PM me your email address and a reminder of what manual you need
PM sent

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post #18 of 21 (permalink) Old 08-28-2019, 06:39 PM
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Quote:
Originally Posted by latebird View Post
Quote:
Originally Posted by cimolifam View Post
Where is a good place to get parts?
You might gets the parts from Rocky Mountain ATV, MOTOSPORT.COM, EBAY, AMAZON, stave7119 or me.

If you find a rebuilt motor, it will probably be from powersportsnation.com or nflow

If you find that the engine needs rebuilt and you want your engine rebuilt, I could do it for you as could stave7119 or possibly polman500. Stave7119 and myself are semi-retired. I believe stave works out of his garage and I have my own shop. I charge $60 an hour, but every rebuild is different - I quote parts, but I estimate labor. Typical parts and labor to rebuild a 325 motor is about $1200 more or less.

Maybe when you find out what the problem is better advice could be offered.
I am semi-retired....That just means I suck at being retired! I have a dedicated workshop and do some work there. My labor rate is too cheap at a flat $100 but I am just doing work for other people as a hobby, not a business. I do work another part time job so if you are in a hurry, I probably won't be where you want to bring your machine.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #19 of 21 (permalink) Old 08-29-2019, 12:45 PM Thread Starter
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I have the manual for the 2000-2001 Trailboss 325 - same engine as the 325 Magnum - in PDF for free if you want it - just PM me your email address and a reminder of what manual you need
I got it!! Thank you!! I am going to read over it and see what I need in the way of tools and start taking the motor apart.

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2002 Polaris Magnum 325 2x4
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post #20 of 21 (permalink) Old 08-29-2019, 03:47 PM
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Good luck my friend! As far as I know the only special tools you will need will be the primary clutch removal tool and the castle nut tool behind the flywheel. That is if you need to take it all the way down to the crankshaft.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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