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Polaris Sportsman-335-AC-AD-AE-AF Parts Manual 2000 rev-01

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This manual covers the 2000 Sportsman 335, a capable and versatile all-terrain vehicle designed for utility and recreational use. Known for its reliability and ease of maintenance within its class,...
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Type: Atv
Vendor:
Polaris
Sku: 141541
Tags: 2000 ATV Polaris Powersports Sportsman-335-AC Sportsman-335-AD Sportsman-335-AE Sportsman-335-AF
Polaris Sportsman-335-AC-AD-AE-AF Parts Manual 2000 rev-01
This manual covers the 2000 Sportsman 335, a capable and versatile all-terrain vehicle designed for utility and recreational use. Known for its reliability and ease of maintenance within its class, the Sportsman 335 features a full-size chassis, independent rear suspension, and Automatic Variable Transmission. It competed effectively with other mid-size ATVs by offering a balance of power, comfort, and a robust utility focus, making it a dependable choice for various off-road activities. This comprehensive parts manual provides detailed component breakdowns, including exploded views and part numbers, essential for identifying and sourcing the correct replacement parts for your 2000 Sportsman 335. Coverage extends across critical systems such as the engine, fuel system, drivetrain, suspension, brakes, and electrical system. Its primary purpose is to assist owners and technicians in accurately identifying components for maintenance, repair, and part ordering, ensuring the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 335
Model Codes:
AC, AD, AE, AF
Year:
2000
👋 Introduction
Market Position
Market Position:
The Polaris Sportsman 335 was positioned as a capable and versatile all-terrain vehicle (ATV) for utility and recreational use in the late 1990s and early 2000s. It was known for its reliability and ease of maintenance within its class.
Competitive Analysis
Competitive Analysis:
Competed with other mid-size ATVs from manufacturers like Honda (e.g., FourTrax 300/350), Yamaha (e.g., Wolverine/Grizzly), and Kawasaki (e.g., Bayou). The Sportsman line generally emphasized rider comfort and a robust utility focus.
Key Features
Key Features:
Full-size chassis, independent rear suspension (IRS) on some configurations, Polaris's proprietary Automatic transmission (PVT - Polaris Variable Transmission), reliable engine performance for its displacement, robust bodywork and racks for utility.
📋 Manual Details
Coverage Areas
Coverage Areas:
Engine, Fuel System, Ignition System, Drivetrain, Suspension, Brakes, Electrical System, Body Panels, Frame, Steering, Cooling System, Exhaust System, Wheels and Tires, Carburetion, Maintenance, Troubleshooting, Part Identification
Page Count
Page Count:
Estimated 200-300 pages (typical for a comprehensive parts manual of this era, actual count not specified in product info but implied by content)
Manual Type
Manual Type:
Parts Manual (with Exploded Views and Part Numbers)
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine Assemblies (including crankshaft, camshaft, piston, cylinder, valves), Fuel System (carburetor, fuel pump, mixture screw, jets), Ignition System (magneto, coil, starter, battery, charging system), Drivetrain (primary reduction gear, clutch, transmission, drive shaft), Suspension (front forks, rear struts, swingarm), Brakes (rotors, pads, hydraulic system), Electrical System (lights, fuses, rectifier, switches), Chassis and Body (frame, fenders, panels, handle bars), Steering System, Cooling System (radiator, coolant, hoses)
Procedures Included
Procedures Included:
Part Identification, Component Location, Assembly Schematics, Exploded Views, Part Number Cross-referencing, Basic Maintenance Component Identification (e.g., oil type, fluid capacities implied by part listings)
Technical Depth
Technical Depth:
Detailed component breakdown for part ordering and identification. Not a repair or diagnostic manual, but essential for identifying correct replacement parts for various repair and maintenance tasks. Provides part numbers for specific assemblies like carburetor components (jets, screws), engine internals (piston, rings, conrod), and electrical components.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution for clear viewing and printing of diagrams and part numbers.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Compatibility:
All Versions of Windows & Mac
Requirements
Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-Stroke, Liquid-Cooled, SOHC
Displacement:
335cc
Bore X Stroke:
Not specified in product info, but typically around 78mm x 70mm for similar displacements
Compression Ratio:
Not specified in product info, but likely around 9.0:1 to 10.0:1
Performance
Horsepower:
Approx. 26-28 HP (estimated for the 335cc engine of this era)
Torque:
Not specified in product info, but sufficient for utility tasks and moderate trail riding.
Fuel System
Fuel Delivery:
Carburetor (indicated by 'carburetor', 'carb', 'mixture screw', 'main jet', 'pilot jet', 'slow jet' in keywords)
Carburetor Model:
Likely a Mikuni or Keihin, specific model not provided.
Fuel Type:
Unleaded gasoline
Cooling System
Cooling Type:
Liquid-Cooled
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
Ignition Component:
Magneto
🔧 Transmission
Standard
Transmission Type:
Automatic (Polaris Variable Transmission - PVT)
Drive System:
2WD/4WD Selectable (likely, based on Sportsman model history)
Features
Features:
Continuously Variable Transmission (CVT) with High, Low, Neutral, and Reverse gears. Belt-driven system.
📐 Dimensions
Exterior
Length:
Not specified, but typical for a full-size ATV (approx. 80-85 inches)
Width:
Not specified, but typical for a full-size ATV (approx. 46-48 inches)
Height:
Not specified, but typical for a full-size ATV (approx. 48-50 inches)
Weights
Dry Weight:
Not specified, but typically in the range of 550-600 lbs
Payload Capacity:
Not specified, but typically around 200-250 lbs for racks
Towing Capacity:
Not specified, but typically around 1500 lbs
Wheels And Tires
Front Tire Size:
Not specified, but common sizes include 25x8-12 or 25x9-12
Rear Tire Size:
Not specified, but common sizes include 25x10-12 or 25x12-12
Wheel Bolt Pattern:
Not specified, but typical for Polaris is 4/110 or 4/144
🛡️ Safety Features
Ratings
Safety Ratings:
ATVs are not subject to the same crash testing and safety rating systems as automobiles. Riders are advised to always wear appropriate safety gear.
Active Features
Active Features:
Brake system (front and rear), Handlebar controls for throttle and steering.
Passive Features
Passive Features:
Durable frame construction, ergonomic seat, handguards (often optional or accessory).
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic Utility/Recreational ATV with no advanced infotainment features)
Driver Assistance
Driver Assistance Features:
N/A
Connectivity
Connectivity Options:
N/A
Lighting
Lighting System:
Halogen headlights, taillight, and brake light. Part numbers for bulbs and lenses would be in this manual.
🔧 Maintenance
Service Intervals
Service Intervals:
While this is a parts manual, typical service intervals for a 2000 Polaris Sportsman 335 would include: Oil changes every 50-100 hours or annually. Gearcase lubricant changes every 100-200 hours. Spark plug replacement every 100 hours. Air filter cleaning/replacement as needed based on operating conditions. Belt inspection and replacement based on wear.
Fluid Specifications
Engine Oil Type:
Typically SAE 10W-40 or 20W-50 motorcycle/ATV specific oil with API SG or higher classification. Exact specification would be in the owner's manual or a service manual.
Coolant Type:
Ethylene glycol-based antifreeze/coolant suitable for liquid-cooled engines. Specific type and mixture ratio would be in owner's/service manual.
Gearcase Oil:
Polaris recommends specific gearcase lubricant, often a proprietary blend or a heavy-duty gear oil. Part numbers for gearcase lubricant and differential fluid would be in this manual if applicable.
Brake Fluid:
DOT 3 or DOT 4 brake fluid, depending on the original specification.
Known Issues
Known Issues:
Common issues for ATVs of this era can include CVT belt wear and failure, carburetor issues (clogging, jetting), aging electrical components (stator, rectifier), suspension wear (bushings, ball joints), and exhaust system leaks. This parts manual is invaluable for identifying and sourcing replacement parts for these common wear items and failures.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Polaris Industries Inc. is a long-standing American manufacturer known for its off-road vehicles, including snowmobiles, ATVs, and side-by-sides. Founded in 1954, Polaris has a history of innovation in the powersports industry.
Model Evolution
Model Evolution:
The Sportsman line has been a cornerstone of Polaris's ATV offerings. The 335 model was part of the evolution of Polaris's utility and recreational ATVs, offering a balance of power and capability for its time. It was succeeded by larger displacement models and models with more advanced features as technology progressed.
Production
Production Period:
The Sportsman 335 was produced around the turn of the millennium, with the 2000 model year being specifically covered by this manual. Production likely spanned several years in the late 1990s and early 2000s.
🏆 Awards & Recognition
Recognitions
Recognitions:
Specific awards for the 2000 Polaris Sportsman 335 are not readily available, but the Sportsman line has consistently been recognized for its utility, comfort, and capability in the ATV market.
Ratings
Ratings:
Customer satisfaction and dealer reviews from the period often highlighted the Sportsman's workhorse nature and comfortable ride for its class.
📄 Manual Usefulness
Value Proposition
Value Proposition:
This parts manual is essential for owners and technicians needing to accurately identify and order replacement parts for the 2000 Polaris Sportsman 335. It provides crucial visual aids (exploded views) and specific part numbers for engine components, drivetrain parts, suspension elements, brake assemblies, and electrical systems. This ensures that the correct parts are purchased, minimizing downtime and incorrect installations. Its PDF format makes it easily accessible and searchable.
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