SPORTSMAN 335 Model #A00CH33AC Model #A00CH33AD …pi54.com/corp/manuals/Parts/9915990r03.pdf · A6 REARCABand SEAT SPORTSMAN335A00CH33ACandSPORTSMAN335A00CH33ADandSPORTSMAN335A00CH33AEandSPORTSMAN

PARTS MANUAL PN 9915990 and MICROFICHE PN 9916574 6/00

SPORTSMAN 335Model #A00CH33ACModel #A00CH33ADModel #A00CH33AEModel #A00CH33AFModel #A00CH33AG

Rev. 03

E 2000 Polaris Sales Inc.

TABLE OF CONTENTSSPORTSMAN 335 A00CH33AC and A00CH33AD and A00CH33AE and A00CH33AF and SPORTSMAN 335

A00CH33AGParts Manual

AA-ARM/STRUT MOUNTING C3. . . . . . . .AIR BOX B3. . . . . . . . . . . . . . . . . . . . . .

CCARBURETOR D7-8. . . . . . . . . . . . . . . . .CLUTCH COVER C6. . . . . . . . . . . . . . . .CONTROLS - MASTER CYLINDER/BRAKE

LINE B11. . . . . . . . . . . . . . . . . . . . . .CONTROLS - THROTTLE ASM./

CABLE B10. . . . . . . . . . . . . . . . . . . .CRANKCASE D3. . . . . . . . . . . . . . . . . .CRANKSHAFT and PISTON D5. . . . . . . .CV JOINT - BTB B4. . . . . . . . . . . . . . . .CYLINDER D4. . . . . . . . . . . . . . . . . . . . .

DDECALS A10-11. . . . . . . . . . . . . . . . . . . . . .DRIVE CLUTCH C4. . . . . . . . . . . . . . . . .DRIVE SHAFT REAR B5. . . . . . . . . . . . .DRIVEN CLUTCH C5. . . . . . . . . . . . . . . .

EELECTRICAL/TAILLIGHT C7. . . . . . . . . .ENGINE MOUNTING A13-14. . . . . . . . . . . . .EXHAUST SYSTEM B1. . . . . . . . . . . . . .

FFRAME MOUNTING C2. . . . . . . . . . . . . .FRONT BRAKE B9. . . . . . . . . . . . . . . . .FRONT CAB A7. . . . . . . . . . . . . . . . . . .FRONT HOUSING C12. . . . . . . . . . . . . . .FRONT RACK and BUMPER

MOUNTING A9. . . . . . . . . . . . . . . . .FRONT STRUT B7. . . . . . . . . . . . . . . . .FRONT WHEEL B8. . . . . . . . . . . . . . . . .FUEL PUMP D14. . . . . . . . . . . . . . . . . . . .

FFUEL TANK B2. . . . . . . . . . . . . . . . . . . .

GGEAR SELECTOR D2. . . . . . . . . . . . . . .GEARCASE (CASES & SNORKEL) D1. .GEARCASE

(INTERNAL COMPONENTS) C13-14. . . .

HHANDLEBAR and HEADLIGHT POD B13-14.

IINTAKE and EXHAUST D6. . . . . . . . . . .

MMAGNETO D12. . . . . . . . . . . . . . . . . . . . .

OOIL COOLING SYSTEM A12. . . . . . . . . . .OIL FILTER D11. . . . . . . . . . . . . . . . . . . .OIL PUMP D10. . . . . . . . . . . . . . . . . . . . .OIL TANK C1. . . . . . . . . . . . . . . . . . . . .

PPROP SHAFT B6. . . . . . . . . . . . . . . . . .

RREAR BRAKE/FOOT PEDAL C9. . . . . . .REAR CAB and SEAT A5-6. . . . . . . . . . . .REAR RACK MOUNTING A8. . . . . . . . . .REAR SUSPENSION C10-11. . . . . . . . . . . . .REAR WHEEL DRIVE C8. . . . . . . . . . . . .RECOIL STARTER D9. . . . . . . . . . . . . . .

SSTARTING MOTOR D13. . . . . . . . . . . . . .STEERING POST B12. . . . . . . . . . . . . . . .

TTOOL KIT E1. . . . . . . . . . . . . . . . . . . . .

The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for as-sembly.

2000 SPORTSMAN 335 SPECIFICATIONSBRAKES

Type/BrakesType/Brakes - AuxiliaryPark Brake

Hydraulic DiscHydraulic Disc

Hydraulic Lock, All Wheel

CAPACITIES

Coolant Capacity (quarts)Fuel Tank (gallons)Gearcase Oil (ounces)Engine Counter Balance 10W30Oil (quarts) InjectorOil (quarts) Engine OW40Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

N/A3.7532N/AN/A2.259018030

Standard850

DRIVE TRAIN

Type PVT

DRIVE CLUTCH

Center Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color

101/2#16

Blue/Green

DRIVEN CLUTCH

Helix AngleSpring Position

Compound2-2

DIMENSIONAL FEATURES

Approx. Turning RadiusBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (lbs. dry)Wheel Base (inches)Width (inches)

65�6x7x14

N/A10.545.58133670

50.5046

ENGINE

Engine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc’s)Compression RatioCooling

Alternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)

Main JetPilot JetNeedle JetCut AwayAir Screw/Pilot ScrewJet Needle

IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

ES33PFE024 Cycle, Single Cyl.

Dry Sump78 x 70mm

3349.2:1 Effective

Air Cooledw/Fan Assist Oil Cooler

200WStandard

1/BST34(CV type)15040P9N/A2.5

5F14-3CDI

30 @ 3500.028

NGK BKR7EUSFS Appr.

GEARCASETransmissionShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

PRDSide Lever

9.5/15.87/13.83/12:1

3.16:1N/AN/AShaft

GRAPHICS

Body StyleBumper Caps/Polyprop.Cargo Box or BedFender, Front

Fender, Rear

FootwellFrame/SteelFront Cover

Handlebar Cover w/DecalHeadlight/Dash Pod

Rack, FrontRack, RearRims

Seat VinylSide Panel

Spring, FrontSpring, RearTank CoverTool Box Cover

w/lettering Color

Gen IVN/AN/A

Olive Green (A00CH33AC)(A00CH33AE)Porsche Red (A00CH33AD)(A00CH33AF)

Medium Yellow (A00CH33AG)Olive Green (A00CH33AC)(A00CH33AE)Porsche Red (A00CH33AD)(A00CH33AF)

Medium Yellow (A00CH33AG)Black

Semi Flat BlackOlive Green (A00CH33AC)(A00CH33AE)Porsche Red (A00CH33AD)(A00CH33AF)

Medium Yellow (A00CH33AG)Black

Olive Green/Black (A00CH33AC)(A00CH33AE)Porsche Red/Black (A00CH33AD)(A00CH33AF)

Medium Yellow (A00CH33AG)BlackBlack

Black (AC)(AE)(AG)Aluminum (AD)(AF)

BlackOlive Green (A00CH33AC)(A00CH33AE)Porsche Red (A00CH33AD)(A00CH33AF)

Medium Yellow (A00CH33AG)BlackBlackN/AN/AN/A

ELECTRICAL

Headlight - Handlebar (watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillights (watts)Brake Light (watts)Indicator Bulb

1 Single Beam, 60WN/A

2 Single Beam, 27W8.26W26.9W1.0W

SUSPENSION

Front Type -Front Travel (inches)

Rear Type -Rear Travel (inches)ShockAdjustment

MacPherson Strut6.25

Independent9.5

2 - 1� Bore Gas BagCAM

TIRES & WHEELS

Tire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

Titan24x8-1224x11-10

N/A55

N/A

Polaris Industries Inc. reserves the right tomake changes in designand specifications and/or tomake additions or improvements to its productswithout notice.

2000 ATV PUBLICATION NUMBERS

MODEL MODEL NO. OWNER’SMANUAL

OWNER’SMANUAL

SUPPLEMENT

PARTSMANUAL

PARTSMICROFICHE

ASSEMBLYINSTRUCTIONS

Sportsman 335 A00CH33AC 9915299 9915770 9915990 9916574 9915774

Sportsman 335 A00CH33AD 9915299 9915770 9915990 9916574 9915774

Sportsman 335 A00CH33AE 9915299 9915770 9915990 9916574 9915774

Sportsman 335 A00CH33AF 9915299 9915770 9915990 9916574 9915774

Sportsman 335 A00CH33AG 9915299 9915770 9915990 9916574 9915774

A5

REAR CAB and SEATSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN

335 A00CH33AF and SPORTSMAN 335 A00CH33AG

2

7

3

6

910

14

13

15

16

17

4140

12

19

21

23

36

5

43

44

45

1

42

38

11

24

25

4

39

18

3

34

31

33

32

34

8

3029

28

3537

20

3029

6

32

22

26

27

E 2000 Polaris Sales Inc.

A6

REAR CAB and SEATSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


Ref. Part No. Qty. Description Ref. Part No. Qty. Description

1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-191

5432117-136

5432117-053

1

1

1

Cab, Rear, Olive Green(A00CH33AC)(A00CH33AE)Cab, Rear, Porsche Red(A00CH33AD)(A00CH33AF)Cab, Rear, Med Yellow (A00CH33AG)

6 7541925 4 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Cab, Rear9 7512242 4 Screw10 7555859 4 Washer, Flat11 7512085 2 Screw12 5433640 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat16 7041370 1 Spring, Latch17 2682441-070

2681747-07058111045811105

1111

SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small

18 5410414 8 Bumper, Rubber19 7512130 2 Screw20 7555748 2 Washer21 5431787 1 Cover, Tool Box

22 7052095 1 Fitting, 90 Degree23 5410896 1 Cap, Drain24 7661638 4 Rivet25 5242953-067 1 Guard, Clutch26 5243829 1 Strap, Fuel Pump Mounting27 7621509 7 Rivet, Plastic28 ------ -- -- -- -- 1 Asm., Front Gearcase

(See Front Housing Pg. C12 for Details)29 7552603 11 Washer, Spring Lock30 7512492 11 Screw31 1012979-067

1013359-06711

Frame, Main (If built before 3/13/00)Frame, Main (If built after 3/13/00)

32 7517377 4 Screw33 5432280 2 Spacer, Footwell34 7542122 28 Nut, Nylok35 7072533 1 Decal - Hitch36 7517376 4 Screw37 5432221-070

5433219-07011

Footwell, Black, LHFootwell, Black, RH

38 5811111 1 Foil, Foam, Fender, Rear39 5811106 2 Foil, Rear Cab, Front40 7073761 1 Decal - Carb Information41 7077446 1 Decal - Filter Element42 5811087 1 Foil, Foam43 7512232 12 Screw44 7670057 12 Nut45 5431796-070

5431797-07011

Guard, Mud, Rear, LHGuard, Mud, Rear, RH

6/00

A7

FRONT CABSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


6

7

5

8

910

12

32

23

20

4

1617

14 13

15

21

8

1

4

4

11

22

1918


1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5810996 1 Foil, Foam, Side Panel3 5431809-191

2620085-191

5431809-136

2620085-136

2632289-053

2620085-053

1

1

1

1

1

1

Panel, Side, LH, Olive Green(A00CH33AC)(A00CH33AE)Panel/Foil, RH, Olive Green(A00CH33AC)(A00CH33AE)Panel, Side, LH, Porsche Red(A00CH33AD)(A00CH33AF)Panel/Foil, RH, Porsche Red(A00CH33AD)(A00CH33AF)Panel/Foam, LH Med Yellow(A00CH33AG)Panel/Foil, RH Med Yellow(A00CH33AG)

4 7512232 10 Screw5 2631987-191

2631987-136

2631987-053

1

1

1

Cab, Front, Olive Green(A00CH33AC)(A00CH33AE)Cab, Front, Porsche Red(A00CH33AD)(A00CH33AF)Cab, Front, Med Yellow (A00CH33AG)

6 5432088-191

5432088-136

5432088-053

1

1

1

Cover, Front, Olive Green(A00CH33AC)(A00CH33AE)Cover, Front, Porsche Red(A00CH33AD)(A00CH33AF)Cover, Front, Med Yellow (A00CH33AG)

7 7670085 2 Clip, Spring8 7670057 10 Nut9 7670068 2 Nut10 7661645 4 Rivet11 7517312 2 Screw12 5431798

543179911

Guard, Mud, Front, LHGuard, Mud, Front, RH

13 7541925 2 Nut, Nylok14 7555792 2 Washer15 7512085 2 Screw16 7555931 2 Washer, Flat17 7542122 2 Nut, Nylok18 52449131-067

5244914-06711

Guard, Splash, LHGuard, Splash, RH

19 7517685 1 Screw20 5811917 2 Shield, Deflector21 5411668 AR Line, Breather22 7670109 1 Clip, Routing23 7621509 3 Rivet, Plastic

6/00

A8

REAR RACK MOUNTINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


5

4

3

7

11 12

138

8

9

14

1

15

6

10

2

2

8

7

9

8


1 2871501 1 Kit - Rack Extender, Rear (Incl. 15)2 7517685 4 Screw3 7517686 2 Screw4 2670174 1 Asm., Rear Rack

(Incl. 5 & Warning Decal)5 2670070 2 Reflector, Red6 5241663-067 1 Bracket, Silencer, Frame7 7512329 4 Bolt8 7558402 6 Washer, Flat

9 7542324 8 Nut, Nylok10 7670096 2 Nut, Chimney11 1040524-067

1040525-06711

Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH

12 5333332-067 4 Spacer13 7515385 4 Screw14 1040490-067 1 Support, Rear Rack15 7517208 6 Screw

3/00

A9

FRONT RACK and BUMPER MOUNTINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


14

15

16

1718

19

13

7

5

9

1011

20

21

22

2

3

4

12

4

8

1

7

6

4


1 7517685 4 Screw2 2670180 1 Asm., Front Rack

(Incl. 3 & Warning Decal)3 2670071 2 Reflector, Amber4 7515399 6 Screw5 2200775 1 Kit - Front Rack Mount6 7547069 4 Nutsert7 7542324 4 Nut, Nylok8 7558403 2 Washer9 5432155-070 1 Bumper10 7515391 2 Screw11 7515390 2 Screw12 7555954 2 Washer

13 1013210-0671013211-067

11

Support, Front Rack, LHSupport, Front Rack, RH

14 7512232 4 Screw15 2431014

24310154030059

112

Headlight, LHHeadlight, RHBulb, Replacement, 27W

16 7515382 2 Bolt17 7558402 4 Washer, Flat18 5810467 1 Plug, Frame19 5244623-067

5244624-06711

Extension, Frame, LHExtension, Frame, RH

20 5241583-067 1 Guard, Brush21 5240591-067 1 Grill, Brush Guard22 7621330 9 Rivet

1/00

A10

DECALSSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AE and SPORTSMAN 335 A00CH33AG

12 3

54 6

9

1011

124

13 14

3 15 16

179 LH

RH

1

7

8

5


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution, 4W3 7078455

7078456

7078774

7078775

1

1

1

1

Decal - “4x4 INDY SHAFT DRIVE”, LH(A00CH33AC)(A00CH33AE)Decal - “4x4 INDY SHAFT DRIVE”, RH(A00CH33AC)(A00CH33AE)Decal - “4x4 INDY SHAFT DRIVE”, LH(A00CH33AG)Decal - “4x4 INDY SHAFT DRIVE”, RH(A00CH33AG)

4 7078452 2 Decal - ‘‘POLARIS”, Side Panel5 7078809

7078810

7079208

7079209

1

1

1

1

Decal - “335”, Tank Side, LH(A00CH33AC)(A00CH33AE)Decal - “335”, Tank Side, RH(A00CH33AC)(A00CH33AE)Decal - “335”, Tank Side, LH(A00CH33AG)Decal - “335”, Tank Side, RH(A00CH33AG)

6 7074935 1 Decal - Warning, AWD Switch7 7078003 1 Decal - Headlight Adjustment8 7078808

7079207

1

1

Decal - “335 FOUR STROKE”, FrontCover (A00CH33AC)(A00CH33AE)Decal - “335 FOUR STROKE”, FrontCover (A00CH33AG)

9 7074220 1 Decal - “MacPherson Strut”10 7078354 1 Decal - Discretionary Warning11 7078577 1 Decal - Drain Recoil12 7078315

7078465

1

1

Logo, 45th Anniversary(If built before 12/31/99)Logo, Polaris Star (If built after 12/31/99)

13 7079604 1 Decal - Warning, Override, AWD14 7078253 1 Decal - Age Warning, ATV15 7077920 1 Decal - Passenger Warning16 7075834 1 Decal - Tire Pressure17 7077919 1 Decal - Warning, General, CPSC

10/00

A11

DECALSSPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AF

15

2

17

14

10

12

9

6

16

13

4 53

1

4

3

11

9

LH

RH

1

7

8

5


1 7074954 2 Decal - Rack/Warning2 7074110 1 Decal - Load Distribution, 4W3 7078455

707845611

Decal - “4X4 INDY SHAFT DRIVE”, LHDecal - “4X4 INDY SHAFT DRIVE”, RH

4 7078452 2 Decal - “POLARIS”, Side Panel5 7078809

707881011

Decal - “335”, Tank Side, LHDecal - “335”, Tank Side, RH

6 7074935 1 Decal -Warning AWD Switch7 7078003 1 Decal - Headlight Adjustment8 7078808 1 Decal - “335 FOUR STROKE” Front

Cover

9 7074220 1 Decal - “MacPherson Strut”10 7078354 1 Decal - Discretionary Warning11 7078577 1 Decal - Drain Recoil12 7078315

7078465

1

1

Logo, 45th Anniversary(If built before 12/31/99)Logo, Polaris Star (If built after 12/31/99)

13 7076273 1 Decal - Override Switch, AWD14 7078253 1 Decal - Age Warning, ATV15 7077920 1 Decal - Passenger Warning16 7075834 1 Decal - Tire Pressure17 7077919 1 Decal - Warning, General, CPSC

1/00

A12

OIL COOLINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


15

10

13

2

12

20

1

19

9

11

14

16

5

17

8

18

4

6

7

83


1 7080474 2 Clamp, Hose2 5411769 1 Hose, Inlet3 7080862 1 Clamp, Hose4 7542105 4 Nut5 5243783-067 1 Bracket, Top6 7542122 2 Nut, Nylok7 7080573 1 Clamp, Rubber Coated8 7512240 8 Screw9 7517659 4 Screw10 2410157 1 Motor, Fan

11 7670111 4 U-Clip12 5433353 1 Shroud13 4010274 1 Thermister14 7052244 1 Plug, Drain15 1240064 1 Cooler, Oil to Air16 3021186 4 Mount, Rubber17 5244069-067 1 Bracket, Bottom18 7515184 2 Screw19 7080866 1 Clamp, Hose20 5411806 1 Hose, Outlet

1/00

A13

ENGINE MOUNTINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


28

42

45

40

21

8

33

4

3029

34

23

5

2

31

3938

41

27

32

43

16

36

3

37

1

46

9

26

22

2

77

16

9

1110

13

65

2425

35

17

18

12

20

17

15

44

19

14

3

3

2

19

19

1919

19

A14

ENGINE MOUNTINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN



1 7546601 2 Nut2 7080003 8 Clamp, Hose3 8450040-600 AR Line, Fuel4 ------ -- -- -- -- 1 Asm., Carburetor

(See Carburetor Pg. D8, Ref. 9)5 7080511 2 Clamp, Narrow Band6 5410995 1 Boot, Carburetor7 8450003-1525 AR Line, Fuel8 7052075 1 Fitting, Tee9 3110032 2 Mount, Carburetor, Rubber10 7552605 2 Washer, Split Lock11 7542105 2 Nut12 3084205 2 Screw and Washer13 5211626-067 1 Strap, Carb Mount14 7547069 2 Nutsert15 8360009-600 AR Line, Fuel16 3110044 2 Mount, Rubber, Top17 7512315 2 Bolt18 7552901 2 Washer, Spring Lock19 7542411 8 Nut, Flange Lock20 7080694 1 Clamp, Spring Hose21 5411857 1 Line, Breather22 7555815 2 Washer23 3110046 2 Mount, Rubber, Front24 7080539 1 Clamp, Nylon25 7621462 1 Rivet26 5224658-067 1 Strap, Frame Support27 7512566 1 Bolt

28 7575202 1 Washer29 5210748 1 Washer, Flat30 5430261 1 Bushing31 5410421 1 Boot, Clutch Intake32 ------ -- -- -- -- 1 Asm., Drive Clutch, ATV-08

(See Drive Clutch Pg. C4, Ref. 14)33 ------ -- -- -- -- 2 Screw and Washer

(See Crankcase Pg. D3, Ref. 6)34 ------ -- -- -- -- 1 Bracket, Retainer, Seal

(See Clutch Cover Pg. C6, Ref. 23)35 7080474 2 Clamp, Hose36 7515417 2 Screw37 5241150-067 1 Mount, Engine, Front38 3080285 2 Nut39 3080530 2 Washer, Lock40 1260771-029 1 Manifold, Black41 ------ -- -- -- -- 1 Gasket, Exhaust

(See Cylinder Pg. D4, Ref. 27)42 3085826 1 Engine, ES33PFE02-SB NOTE: The

Short Block assembly contains acrankcase assembly, cylinder & cylin-der head assembly and a piston &crankshaft assembly. Prior authoriza-tion is required for warranty consider-ation.

43 5241453-067 1 Mount, Engine, Top44 7512232 1 Screw45 4010132 1 Cable, Ground, Engine46 2530009 1 Filter

1/00

B1

EXHAUST SYSTEMSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


14

9

15

5

14

7

3

1

8

13

10

2

12

6

12

7

4

5

16

5

8

1312

7

8

32

1

1111


1 7542324 3 Nut, Nylok2 7555716 3 Washer, Flat3 5410436 3 Washer, Rubber4 7555863 2 Washer5 5010192 3 Bushing6 ------ -- -- -- 1 Bracket, Silencer Frame (See Rear

Rack Mounting Pg. A8, Ref. 6)7 5410241 3 Dampener, Vibration8 7515316 3 Bolt, Carriage

9 1260715-029 1 Silencer, Exhaust10 7512666 1 Bolt11 7042031 2 Spring, Exhaust12 7515197 4 Screw13 7555935 4 Washer14 5241678 2 Shield, Heat, Exhaust15 1260716-029 1 Pipe, Exhaust16 5240898 1 Seal, Exhaust

1/00

B2

FUEL TANKSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


20

5

15 12

9

1817

1

2

11

3

19

14

16

7

4

13

8

6

14

10


1 5430725 1 Cap, Gas Tank2 5810144 1 Gasket, Cap3 5811310 1 Seal, Foam4 8360009-600 AR Line, Fuel5 5431053 1 Vent, Tank6 7512247 2 Screw7 7552801 2 Washer, Spring Lock8 7558301 2 Washer, Flat9 5222154-067

5222155-06711

Bracket, Mounting, Rear, LHBracket, Mounting, Rear, RH

10 7542143 4 Insert

11 5810317 2 Pad, Fuel Tank Bracket12 7052146 1 Fitting, Fuel Outlet, Main13 8450040-600 AR Line, Fuel14 7080003 4 Clamp, Hose15 7052149 1 Fitting, Fuel Outlet, Reserve16 7517505 1 Screw17 5432559 1 Knob, Fuel Valve18 5432733 1 Nut, Fuel Valve19 7052161 1 Valve, 3-Way20 2511289 1 Asm., Fuel Tank (Incl. 5,12,15)

1/00

B3

AIR BOXSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


4

17

18

9

5

20

22

10

16

23

7

8

2

21

113

25

26

6

14

13

15

19

15

2412

1

3

15

15


1 5811633 1 Sleeve, Pre-cleaner2 7080595 1 Filter, Air3 7080413 2 Clamp, Narrow Band4 5432601 1 Collar, Carb Inlet5 5432868 1 Cover, Air Box6 7517541 4 Screw7 5433293 1 Duct, Air Inlet8 5411422 1 Gasket, Intake9 5811482 1 Seal, Air Box Cover10 5811626 1 Seal, Foam11 5432086 1 Duct, Clutch Air Inlet12 ------ -- -- -- -- AR Line, Breather (See Engine Mounting

Pg. A14, Ref. 21)13 2530029 1 Filter, Breather

14 8450073-600 AR Line, Breather15 7080699 4 Clamp, Hose16 5432774 1 Box, Air Intake17 5830128 1 Gasket, Carb Inlet Duct18 5432858 1 Duct, Carb Inlet19 5411668 1 Line, Breather20 5432377 1 Plug, Trap21 8450059-150 AR Line, Fuel22 7080650 1 Clamp, Hose23 5811650 1 Foil, Air Box24 7558301 2 Washer, Flat25 7515179 2 Screw26 5242044 6 Clip, Air Box

3/00

B4

CV JOINT - BTBSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


BTB

1012 3 4 5

6

7

8 9

12

13

11


1 1380119 2 CV Housing w/Sleeve2 5222299 1 Sleeve, Drive Shaft Seal3 3260115 1 Clamp, CV Joint, Large4 7670091 1 Circlip, Drive Shaft5 5411106 1 Boot, CV Joint6 1380094 1 Shaft (Incl. 4)7 1380092 1 Cardon (Incl. 4,6,8,9)

8 2200771 1 Kit - Cross and Bearing9 3260130 1 Yoke, Splined10 7661913 3 Pin, Spring11 7080627 1 Clamp, Band, Small12 2200773 1 Kit - Boot, CV Joint (Incl. 3,5,11)13 2200961 2 Kit - Drive Shaft w/Sleeve

1/99

B5

REAR DRIVE SHAFTSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


986 72 5

11

31

10

254


1380142 2 Asm., Drive Shaft, Rear (Incl. 1-9)1 1590280 1 CV Joint2 1350044 2 Clamp, Large3 1350046 1 Grease, 30g4 7710505 1 Ring, Retaining5 1350045 2 Boot

6 1350043 2 Clamp, Small7 1350047 1 Grease, 50g8 1590281 1 Joint, Plunging9 1350042 1 Ring, Spring10 2201374 1 Kit - Boot (Gear Side)11 2201373 1 Kit - Boot (Wheel Side)

3/00

B6

PROP SHAFTSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


2 34

57

6

3

1


1380146 1 Shaft, Prop1 7661913 1 Pin2 1350050 1 Yoke, End3 1350051 2 Unit, Pack

4 1350049 1 Bar, Shaft5 1350053 1 Yoke, Slip6 7080873 1 Fitting7 5411092 1 O-Ring

2/00

B7

FRONT STRUTSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


1

2

35

67

9

10

4

1112

13

15

16

8

14

17

18

19

21

4

20

2223

24

2526

27

1112

4


1 5411608 2 Bumper2 7041761 2 Strut, Front3 5211115 2 Washer4 7558402 10 Washer, Flat5 7080573 2 Clamp, Rubber Coated6 7542303 4 Nut, FLEXLOC7 7512365 4 Screw8 7552901 4 Washer, Spring Lock9 5810439 2 Retainer, Strut Casting Wire10 ------ -- -- -- -- 1 Asm., Front Brake Caliper, RH

(See Front Brake Pg. B9 for Details)11 3554509 4 Bearing, Tapered Roller12 3554507 4 Bearing, Tapered Roller Cup13 5222193 2 Sleeve, Hubstrut Seal14 7080306 2 Fitting, Lubrication15 2410133 2 Coil, Magnetic

16 2201311

2201312

1

1

Asm., Hubstrut, Heavy, LH (42mm)(Incl. 9,12-15,23)Asm., Hubstrut, Heavy, RH (42mm)(Incl. 9,12-15,23)

17 7041375-067 2 Spring, Compression18 5243364 2 Retainer, Spring19 5432871 2 Ball, Pivot, Bottom20 7515339 4 Bolt21 5132062 2 Spacer22 ------ -- -- -- -- 1 Kit - Drive Shaft w/Sleeve

(See CV Joint - BTB Pg. B4, Ref. 13)23 3610028 2 Seal, Hubstrut24 5432872 2 Ball, Pivot, Top25 5810291 2 Spacer, Rubber26 7555749 2 Washer27 7547104 2 Nut, Nylok

1/00

B8

FRONT WHEELSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


9

10

1113

1

26

23

4

68

7

14

1524

23 6

16 17 1920

22

125

5

21

18

25


1 7512325 8 Bolt2 3610019 2 Seal, Front Hub3 5211148 2 Plate, Armature4 1520281 2 Clutch, Front Hub, Elec./Mech.5 3554506 4 Bearing, Tapered Roller Cone6 3554507 4 Bearing, Tapered Roller Cup7 7515523 8 Stud8 1520243 2 Asm., Hub w/Bearing Race (Incl. 2,6,7)9 3250028 2 Cage, Roll10 3250010 12 Roll11 3250032 2 Spring, Garter12 1321814 2 Spacer13 3250030 2 Cam14 7052045 2 Plug, Magnetic Drain

15 5411709 2 Tire (24x8-12)16 7556004 2 Washer17 7542810 2 Nut18 7661401 2 Pin, Cotter19 5410470 2 O-Ring20 5432611 2 Cap, Hub21 7512027 6 Screw22 7542459 8 Nut23 1520269-117 2 Rim, Front, Black24 1525017 2 Valve, Rim25 5243676 2 Disc, Brake (AE)(AF)(AG)26 5242935 2 Disc, Brake (AC)(AD)

8/00

B9

FRONT BRAKESPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


1

2 3

89

11

10

121314

4

5 6 7


1910309 1 Asm., Front Brake Caliper, LH (Incl. 1-7,9,10)(A00CH33AC)(A00CH33AD)

1910310 1 Asm., Front Brake Caliper, RH (Incl. 1-7,9,10)(A00CH33AC)(A00CH33AD)

1910427 1 Asm., Front Brake Caliper, LH (Incl. 1-7,9,10)(A00CH33AE)(A00CH33AF)(A00CH33AG)

1910428 1 Asm., Front Brake Caliper, RH (Incl. 1-7,9,10)(A00CH33AE)(A00CH33AF)(A00CH33AG)

1 7080352 1 Screw, Bleeder2 7515489 1 Screw, Socket Set3 5131115

51311161930642

111

Caliper, Brake, LHCaliper, Brake, RHKit - Front Brake Boot

4 1930665 1 Kit - Piston and Seals (Incl. 5-7)5 5410779 1 Ring, Molded Square (.094)6 5410780 1 Ring, Molded Square (.103 x .134)

7 5132294 1 Piston, Brake, Long8 2200465

2200901

2201149

2201398

1

1

1

1

Kit - Front Brake Pad, General Duty(A00CH33AC)(A00CH33AD)(A00CH33AG)Kit - Front Brake Pad, Severe Duty(A00CH33AC)(A00CH33AD)(A00CH33AG)Kit - Front Brake Pad, Soft(A00CH33AC)(A00CH33AD)(A00CH33AG)Kit - Front Brake Pad(A00CH33AE)(A00CH33AF)

9 1910411 1 Mount, Caliper10 5410495 1 Boot, Bushing11 5410494 1 Boot, Pin Seal12 ------ -- -- -- -- 4 Washer (See Front Strut Pg. B7, Ref. 4)13 ------ -- -- -- -- 4 Washer (See Front Strut Pg. B7, Ref. 8)14 ------ -- -- -- -- 4 Screw (See Front Strut Pg. B7, Ref. 7)

6/00

B10

CONTROLS - THROTTLE ASM./CABLESPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


5

2

4

3

6

1


1 5410193 1 O-Ring2 5433806 1 Cover3 5411439 1 O-Ring

4 7080709 1 Cable, Throttle5 2010188 1 Asm., Throttle Control (Incl. 2,3,6)6 2010191 1 Asm., Throttle Clamp

1//00

B11

CONTROLS - MASTER CYLINDER/BRAKE LINESPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


2

3

5

10

6

4

12

1

11

13

23

27

17

20

21

22

22

25

24

2616

18

19

28

15

14

98

7


20500782200809

11

Asm., Master Cylinder (Incl. 1-6,10-13)Kit - Master Cylinder Reservoir (Incl. 1-3,13)

1 1930797 2 Bolt, Cap2 1930796 1 Cap, Reservoir3 1930795 1 Diaphragm4 2200808 1 Kit - Master Cylinder Clamp5 1930799 1 Asm., Piston, Master Cylinder6 1930804 1 Rivet7 2201034 1 Kit - Brake Lever w/Park Latch (Incl. 6-9)8 ------ -- -- -- -- 1 Spring, Flat9 2201090 1 Kit - Park Brake Lever (Incl. 6,8)10 1930806 1 Nut11 1930792 2 Bolt, Reservoir12 1930805 1 Bolt, Handle13 ------ -- -- -- -- 1 Ring, Square, Reservoir14 5411297 1 Boot, Brake Line, Rubber

15 5410988 2 Seal16 4110164 1 Switch17 ------ -- -- -- -- 1 Line, Rear Brake (See Rear Brake/Foot

Pedal Pg. C9, Ref. 5)18 7621462 2 Rivet19 7080539 2 Clamp, Nylon20 8360031-30 1 Conduit21 1930752 1 Line, Brake, Left Front w/Fittings22 7080138 6 Cable Tie23 7512024 2 Screw24 1930753 1 Line, Brake, Right Front w/Fittings25 8360011-38 1 Tubing, Convoluted26 7052129 1 Fitting, Inverted Flare Cross27 1930817 1 Line, Brake, Pod28 1930674 1 Bolt, Banjo

10/99

B12

STEERING POSTSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN

335 A00CH33AF and SPORTSMAN 335 A00CH33AG1

17

1615

3

4

5

14

10

136

7

11

6

6

9

12

7

8

2


1 1843051 1 Asm., Steering Post (Incl. 13,14)2 7080631 1 Clip3 5433415 1 Bushing, Steering, Console4 7080424 1 Fitting, Lubrication5 7515321 2 Bolt6 7555878 3 Washer7 5410772 2 O-Ring8 5431571 1 Spacer, Steering Post9 7543203 1 Nut

10 7661633 1 Pin, Cotter11 5431570 1 Bushing, Steering, Lower12 7661632 2 Rivet13 5431574 1 Plug, Grease, Steering14 7080433 1 Fitting, Lubrication15 5433416 1 Bushing, Steering, Upper16 5222999-067 1 Bracket, Upper Steering Bushing17 7542324 2 Nut, Nylok

10/99

B13

HANDLEBAR and HEADLIGHT PODSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


33

9

40

1011

16

41

1

2

3 14

6

7

8

12

15

17

18

21

2526

3029

39

35

34

3631

23

28

4

4

5

24

38

32

22

27

1920

13

37

B14

HANDLEBAR and HEADLIGHT PODSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN



1 3280290 1 Speedometer2 5430967

40400534040054

111

Plug, IndicatorIndicator, Hot TemperatureIndicator, Neutral/Reverse

3 7511881 3 Screw4 7670086 3 Nut, U-Type5 2460668 1 Harness, Headlight Pod6 ------ -- -- -- 1 Asm., Throttle Control (See Controls -

Throttle Asm./Cable Pg. B10, Ref. 5)7 5242987-067 1 Tube, Handlebar8 2200774

5630616-067

1

2

Kit - Handlebar Block(Incl. Blocks and 8,12,30)Block, Handlebar Retainer

9 7541933 2 Nut, Brass10 7555868 2 Washer, Lock11 7558212 2 Washer, Flat12 7515189 4 Screw13 3280291 1 Clamp, Speedometer14 5433042-191

5433042-136

5433042-053

1

1

1

Pod, Headlight, Upper(A00CH33AC)(A00CH33AE)Pod, Headlight, Upper(A00CH33AD)(A00CH33AF)Pod, Headlight, Upper (A00CH33AG)

15 ------ -- -- -- -- 1 Asm., Master Cylinder(See Controls - Master Cylinder/BrakeLine Pg. B11 for details)

16 5432926 1 Spacer, Switch, LH17 4010262 1 Switch, Handlebar18 5431030 2 Grip, Handlebar19 5432952 1 Plug20 7517625 1 Screw

21 5240586-067 1 Bracket, Pod Mounting22 7517317 2 Screw

23 4032079 1 Knob, Adjusting24 5411120 1 Boot, Headlight25 4032077 1 Collar, Locking26 4032075

287044811

Lens and ReflectorBulb, Headlight, Halogen

27 4032078 1 Rod, Adjusting28 5410163 2 O-Ring29 7080726

220018811

Cable, Choke w/AdjusterKit - Choke Control

30 7542122 4 Nut, Nylok31 7670089 2 Nut, U-Type32 4010283 1 Receptacle, Pod Mount, 12V33 7080631 1 Clip, Cable Retaining34 7522021 2 Screw35 5433366-070 1 Pod, Headlight, Lower36 4110264

4010278

4010321

11

1

Switch, Ignition (Incl. Key)Key, Blank, Series 2000, 6700, 6800.NOTE: Your key can be duplicatedonly by obtaining a key blank from Po-laris and having it cut by mating it withyour existing key.Key, Blank, Series 2200, 2300, 2700,2800. NOTE: Your key can be dupli-cated only by obtaining a key blankfrom Polaris and having it cut by mat-ing it with your existing key.

37 5433733 1 Nut, Ignition38 5433534 1 Cover, Key39 7080229 1 Nut, Choke Slide40 4040081

40102985132382

111

Sensor (If built before 8/09/99)Sensor (If built after 8/09/99)Cap, Sensor (Only w/4010298

41 7517658 1 Screw

10/00

C1

OIL TANKSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


13

1

2

4

9

8

6

7

11

12

23

1617

19

2021

22

18

5

3

10

10

15

To Airbox

14


1 7511848 2 Screw2 5211523 1 Plate, Vent, Oil Tank3 5830053 1 Gasket, Oil Reservoir4 7052163 1 Fitting5 5411668 AR Line, Breather6 5432289 1 Dipstick7 5410889 1 O-Ring8 7052280 1 Fitting, 90 Degree Elbow9 7517102 1 Bolt, Banjo10 7555896 2 Washer, Copper11 7052133 1 Tube, Banjo Intake12 2530020 1 Screen, Oil Filter

13 5132491 1 Tank, Oil, LH14 7542122 2 Nut, Nylok15 5411042 1 Grommet16 5410828 2 Grommet, Mounting, Reservoir17 5333204 2 Bushing18 7558301 2 Washer, Flat19 7512130 2 Screw20 7051524 1 Plug, Magnetic21 5850135 1 Washer, Nylon22 7515158 9 Screw23 5131255 1 Tank, Oil, RH

11/02

C2

FRAME MOUNTINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


1

2

3

5

7

8

9

10

26

4


1 7661013 2 Pin, Clevis2 5431107 2 Bushing3 5020850 1 Tube, Pivot4 7542122 1 Nut, Nylok5 7517386 5 Screw

6 ------ -- -- -- -- 2 Rod End, LH(See Gear Selector Pg. D2, Ref. 16)

7 7512144 1 Screw8 1040494-067 1 Pivot, Shift9 5131277 1 Arm, Shift10 7661103 2 Pin, Cotter

10/99

C3

A-ARM/STRUT MOUNTINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


1 45

6

7

8

103

121314

15

1617

19

1820

22

26

27

2524

23

2829

29 28

2423

21

3130

2

14

12

9

11


1 7542403 2 Nut, FLEXLOC2 5333367 1 Bushing3 1820805 2 Asm., Tie Rod (Incl. 4-10)4 5411291 2 Boot, Seal, Rod End5 7061034 2 Rod End, RH6 7542711 2 Nut7 5020926 2 Tie Rod8 7547028 2 Nut, LH9 7517674 2 Screw10 7061054 2 Rod End, LH11 5411920 1 Boot, Seal, Rod End12 7556099 4 Washer, Flat13 7546904 2 Nut14 7661203 4 Pin, Cotter15 ------ -- -- -- -- -- 1 Asm., Hubstrut, Heavy

(See Front Strut Pg. B7, Ref. 16)16 7080927 2 Joint, Ball

17 5211121 2 Bracket, Ball Joint18 7512284 4 Screw19 5410548 2 Boot, Rubber20 7542438 2 Nut21 5431837

543183811

Shield, CV Joint, LHShield, CV Joint, RH

22 7512084 4 Screw23 5433066 4 Bushing, A-Arm, Long24 5020677 4 Bushing25 5020681 2 Shaft, A-Arm26 2201607

220160811

Kit - A-Frame, LHKit - A-Frame, RH

27 7080433 2 Fitting, Lubrication28 7512492 4 Screw29 7552603 4 Washer, Spring Lock30 7517527 1 Screw31 7515415 1 Screw

10/00

C4

DRIVE CLUTCHSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


14

1 2

13 12

5

11

3 4 5

6

10

9

78


1 7512176 6 Bolt2 7552801 6 Washer, Spring Lock3 5430945 6 Washer, Multilube4 1321457 3 Roller and Bushing5 5430768 6 Button, Guide6 5210752

52107535210754

ARARAR

Spacer (.020)Spacer (.032)Spacer (.050)

7 5630279 3 Weight, Shift, 16

8 7512266 3 Bolt, Shoulder9 7541906 3 Nut, FLEXLOC10 3576504 1 Bearing, Moveable, 1/2”11 5020795 3 Pin, Spider12 7041157 1 Spring, Clutch13 3576510 1 Cover, Bearing14 1321632 1 Asm., Drive Clutch, ATV-06

(Incl. All Less 7,12)

1/99

C5

DRIVEN CLUTCHSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


7

3

45

6

8

12

13

14

16

1718

3

12

9

15

1011


1 5010409 1 Spacer, Driven Clutch2 7556401 AR Bushing3 1322182 1 Asm., Driven Clutch, 3-Angle, Heavy

Return (Incl. 8-18)4 5220646 1 Washer, Domed5 7552901 1 Washer, Spring Lock6 7515327 1 Bolt7 3211077 1 Belt, Drive8 7555898 AR Washer (.020)9 7556804 AR Washer

10 7556076 AR Washer11 3576504 1 Bearing, 1/2”12 3576511 1 Bearing, 1”13 7041198 1 Spring, Clutch14 5132344 1 Ramp, Stationary15 5210752 1 Spacer16 7710448 1 Ring, Retaining17 7511854 3 Bolt18 5430766 3 Button, Ramp

1/00

C6

CLUTCH COVERSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


4

8

3

10

1113

14

15

12

1817

21

2223

24

28

27

16

2620

25

1

19

2

19

5

9

76

20


1 1040519-067 1 Bracket, Clutch Cover, Rear2 7512240 2 Bolt3 5410489

541190111

Seal, Cover Case (If built before 3/13/00)Seal, Cover Case (If built after 3/13/00)

4 2201160 1 Kit - Inner Clutch Cover (Incl. 13,16,25)5 7555748 3 Washer, Rubber6 7552605 3 Washer, Split Lock7 7512247 1 Bolt8 7512277 1 Bolt9 7512278 1 Screw10 5521301 1 Seal, Clutch Cover11 5433540

5433451-32811

Cover, Clutch, Outer (If built before 3/13/00)Cover, Clutch, Outer (If built after 3/13/00)

12 7670051 1 Clip, Clutch Cover13 7512093 5 Screw (If built before 3/13/00)(Use

7512094 if built after 3/01/00)14 7078689 1 Decal - Warning, Clutch Cover

15 7074782 1 Decal - “Automatic Transmission”16 7512094 2 Screw (Use 9 if built after 3/13/00)17 5411489 1 Boot, Duct18 7080761 2 Cable Tie19 7512232 2 Screw20 7555935 2 Washer21 5432947

543398011

Duct, Clutch Outlet (If built before 3/13/00)Duct, Clutch Outlet (If built after 3/13/00)

22 ------ -- -- -- 3 Screw and Washer(See Crankcase Pg. D3, Ref. 6)

23 5240409-067 1 Bracket, Retainer, Seal24 5410575 1 Seal, Cover Case25 7512095 1 Screw26 5241156-067 1 Bracket, Clutch Cover27 7080511 1 Clamp, Narrow Band28 ------ -- -- -- -- 1 Duct, Air Inlet, Clutch

(See Air Box Pg. B3, Ref. 7)3/00

C7

ELECTRICAL/TAILLIGHTSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


1

2

4 5

6

78

910 13

12

11

23

15

14

28

22

1617 18

19

20

2124

1211

26

25

30

31

29

15

34

27 27

33

32

3


1 2460770 1 Harness, Main Wire2 2200593 1 Kit - Circuit Breaker, 20 AMP3 2201795 1 Kit - Circuit Breaker, 10 AMP4 2432034 1 Asm., Taillight w/Brake Light (Incl.

5-10)5 4032046 1 Lens, Taillight6 4032029 2 Screw, Taillight7 4030043 1 Bulb, Taillight8 4032045 1 Gasket, Taillight9 4032064 1 Backing, Taillight/Brake Light10 7670054 2 Nut11 7541925 4 Nut, Nylok12 7571602 3 Washer13 7512027 2 Screw14 5810290 3 Pad, Battery15 4010094 1 Cable, Battery/Solenoid, Red16 2200361 1 Kit - Battery Bolt, Short17 4010095 1 Cable, Battery/Engine, Black

18 7010032 2 Hook, Battery Strap19 5410424 1 Strap, Battery Holddown20 5432077 AR Tube, Vent, Battery21 4140006 1 Battery22 5431769 1 Cover, Battery23 4010093 1 Cable, Solenoid/Starter24 7512007 2 Bolt25 5810455 2 Pad, Rack Mount26 5241416 1 Bracket, CDI27 7512024 4 Screw28 4010249 1 Switch, LR-6029 7512018 3 Screw30 4060191 1 Rectifier, Regulator, LR-3531 5131036 1 Sink, Heat32 7670109 2 Clip, Routing33 4020149 5 Clip, Rosebud34 7080138 3 Cable Tie

1/00

C8

REAR WHEEL DRIVESPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


78

1011

1

12

6

9

2

3

5

4


1 7661404 2 Pin, Cotter2 7542459 8 Nut3 5131649 2 Hub, Rear Wheel4 ------ -- -- -- -- 2 Carrier, Bearing, Wheel (See Rear

Suspension Pg. C11, Ref. 41)5 7710440 2 Ring, Retaining6 7515513 8 Stud7 5411710 2 Tire, Titan (24x11.5-10)

8 1525017 2 Valve, Rim9 1520217-067

1520217-11722

Rim, Rear, Black (AC)(AE)(AG)Rim, Rear, Silver(A00CH33AD)(A00CH33AF)

10 7555796 2 Washer, Cone11 7543005 2 Nut, Castle12 5411164 2 Cover, Dust, Hub

6/00

C9

REAR BRAKE/FOOT PEDALSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


4

1315

12

22

18

21 20

10

16

5

8

19

11

79

14

1514

32

17

9

16

23


1 7515497 2 Screw2 7552603 2 Washer, Spring Lock3 7555806 2 Washer, Flat4 1910366

191044122011812201180

1

111

Asm., Caliper, Brake(A00CH33AC)(A00CH33AD)Asm., Caliper, Brake(AE)(AF)(AG)Piston, Stepped, BoreKit, Seal

5 1930853 1 Line, Rear Brake6 1910305 1 Line, Brake, Caliper w/Fittings7 7512111 1 Bolt8 1930854 1 Reservoir, Rear Brake9 7080003 2 Clamp, Hose10 7542153 1 Nut11 1910315 1 Hose, Reservoir12 7542122 2 Nut, Nylok13 7041750 1 Spring

14 7555919 2 Washer15 5431107 2 Bushing, Pivot, Pedal16 1910280-067 1 Rod, Brake17 7661401 1 Pin, Cotter18 2201178

191030111

Kit - Master Cylinder, OverhaulCylinder, Master, Rear

19 7512247 2 Screw20 1910188

191044011

Brake Disc (A00CH33AC)(A00CH33AD)Brake Disc (AE)(AF)(AG)

21 7571620 1 Washer, Spring22 7547046 1 Nut, Nylok23 2201093

2201399

19103391930860

1

1

11

Kit - Brake Pad (Incl. Pin and Spacer)(A00CH33AC)(A00CH33AD)Kit - Brake Pad (Incl. Pin and Spacer)(AE)(AF)(AG)SpacerPin

6/00

C10

REAR SUSPENSIONSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


27

28

29

26

24

44

10

219

18

11

33

3231

38

17

3536

37

41

43

30

34

22

2

19

13

15

1

3 14

16

7

6

5

4

3

1

16

1415

9

9 9

10

1010

11

11

11

11

11

2020

18

17

1031

18

38

98

20

6

54

9

20

5

8

8

1817

17

25

24

23

18

12

65

42

12 12

6

10

39

40

20

C11

REAR SUSPENSIONSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN



1 7512329 6 Bolt2 1580107-067 2 Arm, Stabilizer Bar3 7542303 6 Nut, FLEXLOC4 7517231 4 Screw5 7555761 8 Washer, Flat6 5432598 8 Bushing, Stabilizer7 5020827 2 Rod, Linkage, Stabilizer8 5020826 6 Shaft, A-Arm, Short9 5433063 12 Bushing, A-Arm, Short10 5020677 12 Bushing11 7080433 12 Fitting, Lubrication12 7515472 6 Screw13 5333393-067 1 Bar, Stabilizer Tube14 7555939 4 Washer, Flat15 5433413 2 Bushing, Stabilizer Tube16 7558402 8 Washer17 7512492 12 Screw18 7552603 16 Washer, Spring Lock19 1541322-067 1 Support, Stabilizer20 7542439 10 Nut, Nylok21 5242077-067 2 Bracket, A-Arm Pivot22 7515433 2 Screw23 7542321 2 Nut24 7515321 4 Bolt

25 5224667-067 1 Support, Transmission, Upper26 7552901 2 Washer, Spring Lock27 5630885 2 Retainer, Spring28 7041453-067 2 Spring, Compression, Rear29 5630883 2 Cam, Adjusting30 7041454 2 Shock, Rear31 5433066 4 Bushing, A-Arm, Long32 5020681 2 Shaft, A-Arm33 1012717-067

1012718-06711

Arm, Control, Lower, LHArm, Control, Lower, RH

34 7515415 2 Screw35 7517297 4 Screw36 7555936 4 Washer37 5131883 4 Bushing, Bearing Carrier38 5433065 8 Bushing, Control, Lower39 5433098-070

5433099-07011

Shield, LHShield, RH

40 7512084 4 Screw41 5131738 2 Carrier, Bearing, Wheel42 3585502

771044022

Bearing, Carrier, WheelRing, Retaining

43 7080586 2 Fitting, Lubrication44 1040730-067

1040731-06711

Arm, Control, Upper, LHArm, Control, Upper, RH

10/00

C12

FRONT HOUSINGSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


12

34

56

78

9 1011

12

13

14

15

16

17

18

1920 21

22

2324

25

2627

282

1


1341323 1 Asm., Front Gearcase (Incl. 1-12,16-26)1 3233252 12 Screw2 3233248 2 Seal3 3233701 1 Cover, Input, Front Housing4 3233700 1 O-Ring5 3233699 1 Ring, Retaining6 3233589 1 Bearing, Ball7 3233726 1 Pinion, Input, 14T8 3233541 1 Bushing9 3233319 1 Seal10 3233697 1 Bushing11 3233324 1 Washer12 3233711 1 Plug13 7080756 1 Clamp14 8450003-1525 AR Line, Fuel

15 7080307 1 Clamp, Hose16 3233524 1 Tube, Vent17 3233696 1 Gearcase18 3233725 1 Shaft, Output, 29T19 3233020 1 Bearing20 3233554 AR Shim21 3233693 1 O-Ring22 3233724 1 Cover, Output23 3233583 AR Shim24 3233582 1 Button, Thrust25 3233254 1 Washer26 3233253 1 Plug, Drain27 7552603 4 Washer, Spring Lock28 7512492 4 Screw

10/99

C13

GEARCASE (Internal Components)SPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


10

98

76

12

17

4

14

1920

21

22

23

24 18 16 15

29

31

34

36

37

46

42

43

3

3839

2827

10

98

7

65

19

3

25

26

5

11

26

3

1

13

3332

30

45

44 41 40

35

215

16

18

1819

C14

GEARCASE (Internal Components)SPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN



1341331 1 Asm., Gearcase (Incl. 1-46 on Pg.C14 and 1-8,11-36 on Pg. D1)

1 3233019 1 Bearing2 3233571 1 Shaft, Input, 15T3 3233018 3 Bearing4 3233661 1 Shaft, Shift5 3233548 2 O-Ring6 3233040 2 Washer7 3233045 2 Ring, Retaining8 3233153 2 Bellcrank, HLR9 3233054 6 Washer10 3233055 2 Nut11 3233662 1 Shaft, Shift12 3233664 1 Fork, Shift, H/R13 3233036 1 Chain, Silent, 34P14 3233663 1 Fork, Shift, Low15 3233177 1 Ring, Retaining16 3233176 1 Washer, Thrust17 3233745 1 Gear, 36T18 3233718 3 Bearing, Needle19 3233720 3 Ring, Retaining20 3233732 1 Engagement Dog, Low21 3233746 1 Shaft, Reverse, 26T22 3233719 1 Sprocket, 24T

23 3233743 1 Engagement Dog, High/Rev.24 3233744 1 Gear, 30T25 3233033 2 Screw26 3233308 2 Pin, Interlock27 3233309 1 Bracket, Interlock28 3233189 1 Spring29 3233020 2 Bearing30 3233715 1 Shaft, Center Drive31 3233566 1 Gear, 103T32 3233262 4 Screw33 7552901 4 Washer, Spring Lock34 3233263 1 Cover, Center Drive Bearing35 3233364 1 Ring, Retaining36 3233265 1 Bearing, Ball37 3233365 1 Gear, 16T38 3233282 2 Screw39 3233669 1 Deflector, Oil40 3233434 1 Cam, Chain Tensioner41 3233433 1 Shoe, Chain Tensioner42 3233432 2 Pin, Dowel43 3233431 1 Spring, Torsion44 3233268 2 Bearing, Ball45 3233670 1 Sprocket, 60T46 3233430 1 Chain, Silent

10/99

D1

GEARCASE (Cases and Snorkel)SPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


14

36

29

28

3032

26

16

18

19

202221

23

34

1 2 6

5

7

135

4

33

4

31

27

8

2425

15

15

17

3

11

13

129

10


-- -- -- -- -- -- -- 1 Asm., Gearcase (See Gearcase - In-ternal Components Pg. C14)

1 3233256 2 Seal2 3233252 2 Screw3 3233636 1 Decal - Switch4 3233248 3 Seal5 3233716 1 Gearcase, LH6 3233247 3 Pin, Dowel7 3233037 1 Vent8 3233475 1 Dipstick9 8360009-600 AR Line, Fuel10 7052095 1 Fitting, 90 Degree11 3233691 8 Screw12 3233617 1 Switch, 2 Position13 3233635 1 Switch, 3 Position14 3233442 2 Screw15 ------ -- -- -- -- Washer (See Gearcase - Internal

Components Pg. C14, Ref. 9)16 3233352 1 Washer17 ------ -- -- -- -- Bearing, Ball (See Gearcase - Internal

Components Pg. C14, Ref. 29)18 3233446 1 Shaft, Snorkel19 3233302 1 O-Ring

20 3233303 1 Snorkel21 3233305 1 Bearing, Ball22 3233353

3233354323335532333563233357

11111

Spacer (1.180x.995x.010)Spacer (1.180x.995x.025)Spacer (1.180x.995x.040)Spacer (1.180x.995x.005)Spacer (1.180x.995x.008) NOTE:Ref. 22 indicates choices, may also beused in combinations.

23 3233306 1 Ring, Retaining24 3233476 1 Gear, 31T, Snorkel25 3233444 1 Gear, Snorkel, Bolt Lock26 3233351 1 Screw27 3233293 1 Seal28 3233292 1 Bushing29 3233291 2 Nut, FLEXLOC30 3233294 1 Stamping, Cover Plate31 3233296 4 Screw32 3233295 4 Washer, Lock33 3233253 1 Plug, Drain34 3233254 1 Washer35 3233672 1 Gearcase, RH36 3233026 18 Screw

10/99

D2

GEAR SELECTORSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


2

4

3

5

7

8

6

112310

22

1

13

21

9

12

1011

1420

1916

18

17

15

18

14 16


1341271 1 Asm., Gear Selector (Incl. 1-13,21-23)1 3233195 1 Asm., Knob2 7512024 1 Screw3 3233649 4 Screw4 3233131 1 Strap, Wire5 3233648 1 Boot, Gear Selector6 3233658 1 Handle, Gear Selector7 3233646 1 Sphere, Plastic8 3233754 1 Pin, Groove9 3233644 1 Pin, Dowel10 3233642 2 Spring, Detent11 3233060 2 Bullet, Detent

12 3233076 2 O-Ring13 3233639 1 Slide, Low14 7061014 2 Rod End, RH15 7546701 2 Nut, RH16 7061013 2 Rod End, LH17 5020824 1 Rod, Shift Linkage, Low-Range18 7546707 4 Nut, FLEXLOC19 5020823 1 Rod, Shift Linkage, Hi-Range20 7546702 2 Nut, LH21 3233640 1 Slide, High/Reverse22 3233641 1 Body, Gear Selector23 3233643 1 Spring, Centering

9/00

D3

CRANKCASESPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


2

4

10

11

2

20 21

1

75

16

3

1817

9

1514

1213

22

6

5

23

8

19


1 3083669 1 Bushing, Starter2 3085849 1 Asm., Crankcase

(Incl. 1,4,5,7,8,10,11,16,21,23)3 3084838 2 Pin, Straight4 3080676 3 Bearing, Ball5 3084840 2 Pin, Dowel6 3084205 5 Screw and Washer7 3084839 1 Seal, Oil8 3085850 1 Pipe9 3084842 2 Union10 3084834 2 Bearing, Ball11 3084835 1 Bearing, Ball

12 3084845 1 Plug13 3084846 1 Gasket, Aluminum14 3084844 1 Spring, One Way Valve15 3086810 1 Valve, One Way16 3084841 10 Bolt, Flange17 3082956 1 Gasket18 3083453 1 Plug19 3083568 4 Bolt, Flange20 3085761 1 Cover, Crankcase21 3084836 1 Seal, Oil22 3084847 1 O-Ring23 3080103 2 Pin, Dowel

7/99

D4

CYLINDERSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


5

22

2124

30

4

4

18

13

17

29

76

25

9

10

12

20

11

11

14

28

819

31

1 2

271516

3 8

26

23 20


1 3083166 1 Asm., Band, Adapter (Incl. 2)2 3081497 1 Screw3 3081330 2 Bolt4 3084994 2 Guide, Valve5 3084858 1 Seal, Intake Valve6 3084867 1 O-Ring7 3084866 1 Adapter, Camshaft8 3084877 3 Bolt, Flange9 3084875 1 Bolt, Cylinder Head10 3085767 1 Cover, Rocker11 3084874 15 Bolt, Flange12 3085831 1 Gasket, Rocker Cover13 3084859 1 Seal, Exhaust Valve14 3085832 3 Bolt, Head15 3080285 2 Nut16 3080530 2 Washer, Lock

17 3084862 1 Plug, Blind18 3085326 2 Stud19 3084838 2 Pin, Straight20 3084873 2 Bolt, Flange21 3084849 1 Union, Oil Pump22 3086847 1 Cylinder23 3082206 2 Washer24 3085827 1 Gasket, Cylinder25 3085830 1 Cover, Camshaft26 3086850 1 Gasket, Cover Cam27 3085075 1 Gasket, Exhaust28 3084215 2 Bolt, Flange29 3085829 1 Gasket, Head30 3086849 1 Head, Cylinder (Incl. 4,5,13,17,18)31 3084879 1 Adapter

7/99

D5

CRANKSHAFT and PISTONSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


10

15

3

1

12

14

2

21

16

13

20

1817

1

5 5

19 11

9 87

6 4


1 3085534 2 Clip2 3086851

30868523086853

111

Asm., Piston (Std.) (Incl. 1)Asm., Piston (0.25 mm O/S) (Incl. 1)Asm., Piston (0.50 mm O/S) (Incl. 1)

3 308577430857753085776

111

Ring, Piston (Std.)Ring, Piston (0.25 mm O/S)Ring, Piston (0.50 mm O/S)

4 3085340 1 Crankshaft 25 3085344 2 Spacer, Crank Pin6 3085341 1 Pin, Crank7 3085342 1 Rod, Connecting8 3085400 1 Bearing, End, Large9 3085024 1 Ball, Steel10 3084881

308533911

Asm., Crankshaft (Incl. 4-11,19)Crankshaft 1

11 3085852 1 Balancer, Gear 1

12 3085404 1 Shaft, Balancer13 3084895

30848963084897

111

Spacer (0.8)Spacer (1.0)Spacer (1.2)

14 3240088308489230848933084894

1111

Spacer (0.6)Spacer (0.8)Spacer (1.0)Spacer (1.2)

15 3084882 1 Sprocket 116 3085528 1 Nut, Slit17 3083904 1 Washer18 3083905 1 Nut, Lock19 3085346 1 Pin, Dowel20 3081447 1 Key21 3080130 1 Key, Woodruff

7/99

D6

INTAKE and EXHAUSTSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


13

17

14

1516

24

25

12 11 10

9

21

5

18

6

19

23

4

3

2

1

26

20

27

22

67 8

7

1110

12


1 3084845 1 Plug2 3084920 1 Gasket, Plug3 3086839 1 Spring, Tensioner4 3086813 1 Asm., Tensioner (Incl. 1-3)5 3085836 1 Washer, Wave6 3084912 2 Nut7 3084911 2 Screw, Adjusting8 3084910 2 Asm., Rocker Arm, Intake (Incl. 6,7)9 3085780 1 Shaft, Rocker10 3084908 4 Valve Collet11 3084907 2 Retainer, Spring12 3084906 2 Spring, Valve13 3085853 1 Camshaft (Incl. 14-17)14 3086838 1 Pin, Dowel

15 3085348 1 Lever, Release16 3085076 1 Spring, Return17 3084899 1 Pin, Dowel18 3084914 1 Sprocket 219 3084916 1 Guide, Chain20 3081657 3 Bolt and Washer21 3084915 1 Chain, Timing22 3084924 1 Bolt, Pivot, Lever23 3084917 1 Lever24 3085778 1 Valve, Intake25 3086441 1 Valve, Exhaust26 3084922 1 Gasket, Tensioner27 3084874 2 Bolt, Flange

7/99

D7

CARBURETORSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


9

19

23

48

6

50

7

12

51

49

15

14

18

20

222145

22

44

43

34

36

28

3130

27

46

47

52

33

35

42

40

37

41

16

38

5

1312

11

43

1017

24

25

26

29

39

8

32

D8

CARBURETORSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN



1 3130507 1 Ring2 3130508 1 E-Ring3 3130541 2 Screw4 3130540 2 Washer, Spring5 3130592 4 Screw6 3130503 1 Cover7 3130505 1 Spring8 3084205 2 Screw and Washer9 3130904 1 Asm., Carburetor (Incl. 1-13,18-52)10 3130625 1 Jet, Air (#160)11 3130593 1 Plunger12 3130538 1 Spring13 3130199 1 Holder, Guide14 3130512 1 O-Ring15 3130511 1 Cover16 3130535 4 Screw17 3130543 1 Guide, Cable18 3130513 1 Shaft, Throttle19 3130501 2 Screw20 3130514 1 Ring21 3130589 1 Spring22 3130515 2 Seal23 3130502 1 Valve, Throttle (100)24 3130544 1 Spring25 3130545 1 Ring26 3130546 1 Screw, Adjust

27 3130624 1 Jet, Pilot (#40)28 3130522 1 O-Ring29 3130523 1 Washer30 3130525 1 Spring31 3130524 1 Adjuster32 3130905 1 Plug33 3130529 1 Float34 3130521 1 Screw35 3130590 1 Body, Float36 3130520 4 Screw37 3130532 1 O-Ring38 3130591 2 Screw39 3130594 1 Plate40 3130668 1 Valve, Needle (1.5)41 3130533 1 O-Ring42 3130361 1 Pin, Float43 3130519 1 Cap44 3130518 1 E-Ring45 3130517 1 Packing46 3130569 1 Jet, Main (#150)47 3130014 1 Washer48 3130504 1 Block, Jet49 3130731 1 Jet, Needle (P-9)50 3130732 1 Diaphragm51 3130752 1 Ring52 3130730 1 Needle, Jet (5F81-3)

1/99

D9

RECOIL STARTERSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


14

1

3

10

42

5

6

15

9

11

7

8

12

13

7

8


1 3084822 1 Reel2 3083463 1 Spring, Return3 3083378 1 Ratchet4 3083379 1 Spring, Friction5 3084744 1 Plate, Friction6 3085266 1 Bolt and Washer7 3083453 2 Plug8 3082956 2 Gasket

9 3083669 1 Bushing, Starter10 3083185 1 Spring, Power11 3084750 1 Bushing12 3084933 1 Gasket, Recoil13 3084877 9 Bolt, Flange14 3085652

308565311

Asm., Recoil (Incl.1-6,9-11,14,15)Case, Starter (Incl. 11)

15 3085083 1 Asm., Rope

1/99

D10

OIL PUMPSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


4

1

10

3

2

11

12

15

87

6

13

14

5

16

17

9


1 3084946 1 Pump, Oil, Case 22 3084949 1 Rotor, Outer (Feed)3 3084948 1 Rotor, Inner (Feed)4 3085782

308494511

Asm., Oil Pump (Incl. 1-7,10-15)Pump, Oil, Case 1

5 3085535 1 Screw6 3084955 2 Pin, Dowel7 3084954 2 Pin, Dowel8 3084953 1 Washer9 3084962 3 Bolt and Washer

10 3084947 1 Pump, Oil, Case 311 3084950 1 Rotor, Inner (Scav)12 3084951 1 Rotor, Outer13 3084956 1 Unit, Oil Strainer14 3084205 3 Screw and Washer15 3085783 1 Shaft, Pump16 3084958 1 Gear, Pump, 217 3084959

30849603084961

ARARAR

Spacer (0.8)Spacer (1.0)Spacer (1.2)

1/99

D11

OIL FILTERSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


1

5

4

3

3

3

2

2

2

2

2


1 3084963 1 Filter, Oil2 3084846 8 Gasket, Aluminum3 3086815 4 Bolt, Banjo

4 3085638 1 Pipe 2, Oil Delivery5 3084964 1 Pipe 1, Oil Delivery

1/99

D12

MAGNETOSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


206

5

8

9

10

11

12

15

13

4

7

1

2

16

19

3

1418 17


1 30859213085922

11

Asm., Ignition Coil (Incl. 1,2)Coil, Ignition

2 3084980 1 Cap, Spark Plug3 3085784 1 Plug, Spark4 3084978 1 O-Ring5 3084972 1 Metal, Bearing6 3086859

308497111

Asm., Plate (Incl. 5,6,8-13,15)Plate

7 3081657 5 Bolt and Washer8 3084973 1 Seal, Oil9 3086860 1 Stator (Incl. 14)

10 3081342 3 Screw and Washer11 3085554 1 Band, Pulse12 3084976 2 Screw and Washer13 3084977 1 Clamp14 3085360 1 Coil, Pulser15 3081256 3 Screw and Washer16 3085639 1 C.D.I. System17 3083073 2 Nut18 3080077 2 Washer, Spring19 3085521 1 Switch, Magnetic20 3086857 1 Flywheel w/Ring Gear

7/99

D13

STARTING MOTORSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


9

12

1

5

10

3

2

11 13

17

16

15

14

6

4

8

7

1


3084981 1 Asm., Starting Motor(Incl. 1-5,7-10,12)

1 3084982 1 Washer, Set2 3084406 1 Brush3 3083649 2 Nut, Flange4 3085034 1 Asm., Bracket, Rear5 3084408 3 O-Ring6 3082038 2 Bolt and Washer7 3085353 1 Armature8 3085033 1 Asm., Front Bracket (Incl. 9)

9 3240114 1 O-Ring10 3084983 2 Asm., Set Bolt (Incl. 5)11 3085394 1 Asm., Gear Shaft (Incl. 13-17)12 3084405 2 Ring, Rubber13 3083737 1 Washer, Gear Shaft14 3084412 1 Clip15 3084411 1 Spring, Weight16 3084410 1 Spring, Return17 3084409 1 Clip

1/99

D14

FUEL PUMPSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


4

1

3 2

2

4


3085275 1 Asm., Fuel Pump (Incl. 1-4)1 3084999 1 Screw and Washer2 3085356 2 Screw and Washer

3 3084591 4 Screw4 3084998 1 Diaphragm, Gasket Set

1/99

E1

TOOL KITSPORTSMAN 335 A00CH33AC and SPORTSMAN 335 A00CH33AD and SPORTSMAN 335 A00CH33AE and SPORTSMAN


3

11

4

5

6

7

8

9

10

1

2


1 99152999915770

11

Manual, Owner’s, ’00 ATVSupplement, Owner’s Manual, ’00 Sports-man 335

2 2871515 1 Lube, U-Joint, 3 oz., Case3 3085544 1 Kit - Tool (Incl. 5-10)4 2870725 1 Gauge, Tire Pressure5 3085001 1 Wrench, Open, 8-10mm

6 3085002 1 Wrench, Open, 12-14mm7 3085567 1 Wrench, Box8 3085569 1 Puller, Spark Plug (Wrench Handle)9 3082657 1 Screw Driver10 2690016 1 Pouch, Tool Kit11 2871095-067 1 Wrench, Spanner (Order from Victor Tools)

10/99

PRINTED IN THE USA PARTS MANUAL PN 9915990 and MICROFICHE PN 9916574 3/00

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SPORTSMAN 335 Model #A00CH33AC Model #A00CH33AD …pi54.com/corp/manuals/Parts/9915990r03.pdf · A6 REARCABand SEAT SPORTSMAN335A00CH33ACandSPORTSMAN335A00CH33ADandSPORTSMAN335A00CH33AEandSPORTSMAN