Segment:
Entry-level to mid-range utility ATV (All-Terrain Vehicle).
Target Audience:
DIY enthusiasts, property owners, recreational riders seeking reliable and maintainable ATVs.
Competitors:
Competed against models like Honda FourTrax, Yamaha Wolverine, Kawasaki Bayou during its production era.
Value Proposition:
Offered a balance of performance, durability, and relative affordability, making it a popular choice for utility tasks and recreational riding.
Ease Of Maintenance:
Highlighted for its straightforward design facilitating home maintenance and repairs.
Durability:
Known for robust construction suitable for various terrains and work applications.
Versatility:
Suitable for a range of tasks from farm work to trail riding.
Systems Covered:
Engine, Cooling, Fuel, Oil, Air Intake, Exhaust, Drive Train (Front & Rear), Suspension, Steering, Brakes (Front & Rear), Electrical, Controls, Chassis Components, Bodywork (Cab, Racks, Bumpers, Seat), Decals, Tool Kit
Engine Mechanical:
Detailed exploded diagrams and part numbers for Piston, Crankshaft, Crankcase, Cylinder, Oil Pump, Carburetor, Recoil Starter, Magneto, Starting Motor.
Fuel And Oil Systems:
Components for Fuel Tank, Oil Tank, Air Box, and Carburetor assembly.
Cooling System:
Exploded views and part numbers for all cooling system components, including radiator and hoses (if applicable to this model, though not explicitly listed, it's a standard ATV component).
Drivetrain:
Comprehensive coverage of Front Drive, Front Tightener, CV Joints, Front Wheel Drive, Rear Wheel Drive, Drive Clutch, Driven Clutch, Clutch Cover, Gearcase, and Drive Chain assembly.
Suspension And Steering:
Detailed parts breakdown for Front Strut, A-Arm/Strut Mounting, Center Tightener, Swing Arm/Shock Mounting, and Steering Post, Handlebar, and Headlight Pod.
Brakes:
Coverage for Front Brake, Rear Brake, Master Cylinder, and Brake Line components.
Controls:
Parts for Throttle Assembly/Cable, and Master Cylinder/Brake Line controls.
Chassis And Body:
Detailed diagrams for Front Cab, Rear Cab and Seat, Rear Rack Mounting, Front Rack and Bumper Mounting, and Decals.
Electrical System:
Components related to the Electrical/Taillight system.
Part Identification:
Primary function is to identify all parts with corresponding OEM part numbers via exploded diagrams.
Assembly Disassembly Aid:
Facilitates correct reassembly and identification of components during disassembly.
Maintenance Planning:
Assists in identifying wear items and necessary replacements during routine maintenance.
Repair Guidance:
Essential for sourcing correct replacement parts for any repair scenario.
Depth:
Detailed OEM part numbers and exploded views for complete component identification. Does not include repair procedures or diagnostic steps, but is critical for parts procurement.
File Type:
Portable Document Format (PDF)
Searchability:
Likely text-searchable if digitally created, aiding in quick part number lookup.
Printability:
Designed for printing specific pages as needed, offering cost-effectiveness and reduced paper usage.
Binding:
N/A (Digital PDF format)
Paper Recommendation:
N/A (Digital PDF format, print on demand)
Engine Type:
4-Stroke, Liquid-Cooled, Single Cylinder
Bore X Stroke:
Refer to specific Polaris workshop manual for exact dimensions; typically around 83mm x 64.5mm for similar Polaris engines.
Valve Configuration:
Overhead Valve (OHV), 2-Valve (typical for this era)
Horsepower:
Estimated 18-20 HP (at crankshaft, typical for this displacement and class).
Torque:
Estimated 17-19 lb-ft (at crankshaft, typical).
Fuel Delivery:
Carburetor (specific model and size indicated in manual, likely Mikuni or Keihin).
Fuel Type:
Unleaded Gasoline (87 Octane minimum recommended).
Oil Type:
SAE 10W-30 or 10W-40 API SG or higher, specifically formulated for 4-stroke motorcycles/ATVs.
Oil Capacity:
Approximately 2.0 quarts (1.9 Liters) with filter change. Consult manual for exact capacity.
Ignition System:
Electronic CDI (Capacitor Discharge Ignition) with Magneto primary ignition source.
Cooling Method:
Liquid-Cooled
Coolant Type:
Ethylene Glycol based antifreeze mixed with distilled water (50/50 ratio recommended).
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft Drive (Rear Wheel Drive or AWD depending on specific model variant).
Gear Selection:
High/Low range, Neutral, Reverse (typically lever operated).
Clutch Type:
Variable speed drive and driven clutch (CVT).
Gearcase Fluid:
Polaris recommended ATV gearcase lubricant (e.g., 75W-90 synthetic). Consult manual for exact specification.
Length:
Approximately 76 inches (193 cm) - Varies slightly by model variant.
Width:
Approximately 44 inches (112 cm) - Varies slightly by model variant.
Height:
Approximately 47 inches (119 cm) - Varies slightly by model variant.
Dry Weight:
Approximately 530 lbs (240 kg) - Varies slightly by model variant.
Ground Clearance:
Approximately 5.5 inches (14 cm) - Varies slightly by model variant.
Towing Capacity:
Typically around 660 lbs (300 kg) for utility ATVs of this class.
Rack Capacity Front:
Typically around 50 lbs (22.7 kg).
Rack Capacity Rear:
Typically around 100 lbs (45.4 kg).
Front Tire Size:
Typically 22x8-10 or 23x8-10.
Rear Tire Size:
Typically 22x10-10 or 23x10-10.
Wheel Bolt Pattern:
Typically 4x110mm or 4x115mm. Consult manual for exact specifications.
Safety Certification:
No formal crash test ratings like automobiles; adherence to industry safety standards (e.g., ANSI/SVIA).
Braking System:
Hydraulic disc brakes (front and rear) for reliable stopping power.
Engine Braking:
CVT system provides some engine braking effect downhill.
Throttle Limiter:
Often equipped with adjustable throttle limiter for new riders.
Parking Brake:
Integrated parking brake mechanism.
Infotainment System:
N/A (Basic utility ATV, no infotainment system).
Driver Assistance Features:
N/A (No electronic driver assistance features typical of modern vehicles).
Connectivity Options:
N/A (No connectivity features).
Oil Change Interval:
Typically every 100 hours or annually, whichever comes first. Consult manual for precise hours.
Air Filter Cleaning:
Check every 20-40 hours, clean/replace as needed. More frequently in dusty conditions.
Spark Plug Replacement:
Typically every 100-200 hours or annually. Specific plug type and gap are critical.
Gearcase Fluid Change:
Typically every 200-400 hours or annually. Inspect for leaks and contamination.
Clutch Inspection:
Inspect drive and driven clutches for wear on belt, sheave condition, and roller/weight condition every 100-200 hours.
Engine Oil Specification:
SAE 10W-30 or 10W-40 API SG or higher.
Gearcase Oil Specification:
Polaris recommended ATV gearcase lubricant (e.g., 75W-90 synthetic).
Coolant Specification:
50/50 mix of ethylene glycol antifreeze and distilled water.
Common Wear Items:
Drive belt wear, suspension bushings, wheel bearings, brake pads, and CV joint boots are common wear items requiring regular inspection.
Carburetor Issues:
Carburetor can be prone to clogging from stale fuel or debris, requiring cleaning or rebuilding.
Cooling System Maintenance:
Regular flushing and replacement of coolant is essential to prevent corrosion and maintain cooling efficiency.
Starter System:
Recoil starter can wear over time; electric starter motor and solenoid are common maintenance points.
Heritage:
Polaris Industries, founded in 1954, has a long history in powersports, initially known for snowmobiles and later expanding into ATVs, UTVs, and motorcycles.
Predecessors:
The Sportsman line evolved from earlier Polaris ATV models, incorporating advancements in suspension and engine technology.
Development Focus:
The 335cc engine was a popular choice for a balance of power and efficiency in the utility ATV segment.
Manufacturing Location:
Produced in the USA by Polaris Industries.
Production Years:
The 335cc engine was utilized in various Polaris models through the late 1990s and early 2000s.
