POLARIS SPORTSMAN 335 SPORTSMAN 500 ATV Full Service & Repair Manual 1999

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Art.-Nr: 149228

Stichworte: 1999 ATV Polaris Powersports SPORTSMAN 335 SPORTSMAN 500 Sportsman Series

Produktvarianten

Beschreibung

Welcome to the service and repair manual for the 1999 Sportsman 335 and Sportsman 500. These models are renowned for their comfort, capability, and innovative all-wheel-drive system. Engineered for a wide range of uses, from utility work to recreational trail riding, the Sportsman line embodies a commitment to quality and reliability. With powerful liquid-cooled engines, automatic PVT transmissions, and robust suspension systems, these ATVs are built to perform in demanding environments. This comprehensive manual provides professional-level repair and maintenance information for your Sportsman. It covers all aspects of servicing, from routine maintenance procedures and fluid specifications to in-depth troubleshooting and complete component rebuilding. You will find step-by-step instructions, detailed photos, diagrams, and exploded views to guide you through every task, ensuring your ATV remains in optimal condition and delivers peak performance. This resource is invaluable for professional mechanics, technicians, and experienced DIY enthusiasts alike.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 335 / Sportsman 500

Year:

Product Type:

Service and Repair Manual

👋 Introduction

Market Position

Target Audience:

Professional Mechanics, Technicians, and experienced DIY enthusiasts

Key Features

Licensing:

No extra fees, no expiry dates, lifetime use

Content Type:

Factory Service Repair Workshop Manual

Competitive Analysis

Manual Value Proposition:

Provides professional-level repair information at a fraction of the cost of dealership service, empowering owners to maintain and repair their ATVs.

📋 Manual Details

Coverage Areas

Manual Coverage:

Complete Factory Service Repair Workshop Manual

Page Count

Page Count:

Hundreds of pages

Manual Type

Manual Type:

Professional Service Repair Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF compatible)

📖 Manual Coverage

Systems Covered

Systems Covered:

All repairs, servicing, and troubleshooting procedures

Engine Mechanical:

Engine disassembly, inspection, repair, and reassembly of all internal components (pistons, rings, valves, crankshaft, etc.)

Engine Fuel System:

Carburetor tuning, cleaning, rebuilding, and troubleshooting

Cooling System:

Radiator, fan, water pump, thermostat, coolant hoses, and bleeding procedures

Exhaust System:

Muffler, exhaust pipe inspection and replacement

Pvtsystem:

Drive clutch, driven clutch, belt inspection, replacement, and adjustment; roller and spring maintenance

Drivetrain:

Front and rear differentials, driveshafts, universal joints, final drive inspection and repair

Suspension:

Front and rear suspension components, shock absorbers, bushings, ball joints, tie rods, alignment

Steering:

Handlebar, steering post, steering rack, tie rod ends, troubleshooting steering play

Brakes:

Brake caliper service, pad replacement, rotor inspection, brake fluid flush, bleeding procedures, master cylinder service

Electrical System:

Battery maintenance, starter motor, ignition system, lighting system, charging system (stator, regulator/rectifier), wiring diagrams, troubleshooting electrical faults

Frame And Body:

Frame inspection, body panel removal and installation, seat, fenders, racks

Procedures Included

Procedures Included:

Step-by-step instructions for all repairs and maintenance

Troubleshooting Charts:

Comprehensive diagnostic guides for common problems and symptoms

Preventative Maintenance:

Detailed maintenance schedules and procedures for optimal performance and longevity

Torque Specifications:

Precise torque values for critical fasteners

Technical Bulletins:

Information equivalent to factory service bulletins (implied by 'factory service')

Rebuild Procedures:

Detailed instructions for complete component rebuilding (e.g., engine, transmission, differentials)

Technical Depth

Technical Depth:

Highly detailed, including detailed photos & diagrams; exploded diagrams

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely searchable text within the PDF format

Print Quality

Print Capability:

Print single pages or entire manual

Binding Type

Device Compatibility:

Compatible with computers, tablets, and smartphones

Paper Type

Computer Compatibility:

Fully compatible with Windows & MAC computers

⚙️ Engine Specifications

Primary Engine 335

Engine Type 335:

4-stroke, Liquid-cooled, SOHC, 4-valve

Displacement 335:

335 cc

Cooling System 335:

Liquid-cooled

Primary Engine 500

Engine Type 500:

4-stroke, Liquid-cooled, SOHC, 4-valve

Displacement 500:

499 cc

Cooling System 500:

Liquid-cooled

Performance

Bore X Stroke 335:

70 mm x 72 mm (Approx.)

Bore X Stroke 500:

92 mm x 75 mm (Approx.)

Fuel System

Carburetor 335:

Mikuni BSR42

Carburetor 500:

Mikuni BSR42

🔧 Transmission

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission)

Features

Drive System:

Shaft Drive; AWD (All-Wheel Drive) or 2WD depending on model variant

Gearbox:

High/Low range, Neutral, Reverse

📐 Dimensions

Weights

Dry Weight 335:

615 lbs (279 kg) (Approx.)

Dry Weight 500:

675 lbs (306 kg) (Approx.)

Towing Capacity:

1500 lbs (680 kg) (Approx.)

Rack Capacity Front:

150 lbs (68 kg) (Approx.)

Rack Capacity Rear:

300 lbs (136 kg) (Approx.)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic Disc Brakes (Front & Rear)

Passive Features

Lighting:

Halogen Headlights, Taillight, Brake Light

💡 Technology Features

Infotainment

Instrumentation:

Digital speedometer, odometer, trip meter, tachometer, fuel gauge, engine temperature gauge, AWD indicator.

Driver Assistance

Drive System Technology:

Polaris Variable Transmission (PVT) with Engine Braking System (EBS) (on some models).

Connectivity

Charging System:

12V Electrical System with Alternator

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific mileage/hours (typically 100 hours or annual)

Spark Plug Interval:

Refer to manual for specific mileage/hours

Fluid Specifications

Engine Oil Type:

SAE 20W-50 Polaris 4-Stroke ATV Oil (or equivalent API SG or higher)

Engine Oil Capacity:

Refer to manual (typically around 1.6-1.9 quarts)

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant (or equivalent)

Transmission Fluid Capacity:

Refer to manual

Coolant Type:

Ethylene Glycol-based Antifreeze with corrosion inhibitors (e.g., 50/50 mix with distilled water)

Known Issues

Common Wear Item:

Drive belt in PVT system

Typical Maintenance Focus:

Regular inspection and adjustment of PVT system, brake system maintenance, and fluid checks.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Inc.

Model Evolution

Significance:

The Sportsman line is renowned for its comfort, capability, and Polaris's innovative AWD system.

Production

Model Designation:

Polaris Sportsman 335 and Sportsman 500 are distinct models within the same generation.