POLARIS SPORTSMAN 335 ATV Full Service & Repair Manual 1999-2000

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UGS: 150360

Mots clés: 1999 2000 ATV Polaris Powersports SPORTSMAN 335 Sportsman Series

Variantes de produits

Description

The Polaris Sportsman 335 is an All-Terrain Vehicle (ATV) produced between 1999 and 2000. Known for its robust engineering and reliability, this model was designed to handle diverse off-road conditions, making it suitable for recreational trail riding, utility work, and general outdoor exploration. The Sportsman line is recognized for its capability and comfort, and the 335 model was a notable contributor to this reputation during its production years, offering a strong performance in its class. This factory service repair workshop manual provides comprehensive guidance for the maintenance and repair of your 1999-2000 Polaris Sportsman 335 ATV. It covers all essential systems, including the engine, fuel, ignition, cooling, exhaust, transmission, suspension, braking, steering, and electrical systems. The manual details routine maintenance procedures, component overhauls, assembly and disassembly steps, and troubleshooting guides, all supported by hundreds of photos and diagrams. This resource is designed to empower owners and technicians with the accurate, factory-level information needed to keep the Sportsman 335 in optimal condition.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 335

Year:

1999-2000

Vehicle Type:

All-Terrain Vehicle (ATV)

Codes

Chassis Code:

A00CH33AA, A00CH33AB (approximate, verify with VIN)

👋 Introduction

Market Position

Target Audience:

Polaris Sportsman 335 owners and independent repair shops.

Competitive Analysis

Advantage:

Provides factory-level repair information, equivalent to what professional mechanics use, offering a significant cost-saving advantage over dealership service.

Key Features

Authenticity:

Factory authorized content, ensuring accuracy and completeness.

Accessibility:

Instant download and multi-device compatibility for immediate use.

Value Proposition:

Lifetime access without extra fees, making it a one-time investment for ongoing maintenance and repair needs.

📋 Manual Details

Coverage Areas

Primary Coverage:

1999 Polaris Sportsman 335, 2000 Polaris Sportsman 335

Page Count

Estimated Page Count:

Hundreds (as stated in product description, exact count not provided but implies a comprehensive volume)

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF (instant download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of engine components, including cylinder head, piston, crankshaft, camshaft, valves, and timing.

Fuel System:

Carburetor overhaul, adjustment, fuel pump, fuel lines, fuel tank, and associated components.

Ignition System:

Ignition timing, spark plugs, ignition coil, CDI unit, and wiring diagrams.

Cooling System:

Radiator, fan, thermostat, coolant hoses, and fluid specifications.

Exhaust System:

Muffler, exhaust pipes, and heat shields.

Transmission And Drivetrain:

CVT (Continuously Variable Transmission) service, belt inspection and replacement, drive clutch and driven clutch maintenance, final drive, differential, and axles.

Suspension System:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, and alignment specifications.

Braking System:

Hydraulic brake system, brake calipers, brake pads, brake discs, master cylinder, brake lines, and bleeding procedures.

Steering System:

Handlebars, steering shaft, tie rods, ball joints, and steering column.

Electrical System:

Battery, starter motor, alternator (if applicable), lighting, electrical harness, switches, fuses, relays, and diagnostic troubleshooting.

Frame And Bodywork:

Chassis inspection, body panel removal and installation, fenders, racks, seat, and plastic components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, air filter cleaning/replacement, lubrication points, tire pressure checks, and chain adjustment (if applicable).

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting guides, and corrective actions.

Component Overhaul:

Detailed instructions for overhauling major components like the carburetor, transmission, and brake calipers.

Assembly Disassembly:

Step-by-step instructions for removing and installing all major parts and sub-assemblies.

Technical Data And Specs:

Torque specifications for fasteners, electrical resistance values, fluid capacities, and engine settings.

Technical Depth

Depth:

Comprehensive (covers all repairs, servicing, and troubleshooting from basic maintenance to complete rebuilds).

Diagrams And Photos:

Includes hundreds of detailed photos and exploded diagrams for visual guidance.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable PDF (standard for professional manuals).

Print Quality

Printability:

Printable (individual pages or entire manual).

Binding Type

Digital Binding:

N/A (digital download)

Paper Type

Digital Paper Type:

N/A (digital download)

Licensing

Usage License:

Unlimited (can be used on multiple devices, no expiry dates or renewal fees).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, single-cylinder, SOHC

Displacement:

335cc

Bore X Stroke:

83 mm x 64 mm (approximate, verify with manual)

Compression Ratio:

9.0:1 (approximate, verify with manual)

Performance

Horsepower:

Approximately 22-24 HP (estimated, actual may vary slightly by year/tuning)

Torque:

Not explicitly stated in product info, but typically in the range of 20-22 ft-lbs

Fuel System

Carburetor Type:

Mikuni BSR32 (typically)

Fuel Type:

Unleaded gasoline, 87 octane minimum

Engine Oil

Oil Type:

SAE 20W-50 motorcycle oil meeting API SG or higher specifications.

Oil Capacity:

Approximately 1.9 US quarts (1.8 liters) with filter change (verify in manual).

🔧 Transmission

Standard

Transmission Type:

Automatic, Polaris Variable Transmission (PVT) with continuously variable ratio (CVT).

Optional

Gear Reduction:

Not applicable (CVT provides variable ratios).

Features

Drive Modes:

High (H), Low (L), Neutral (N), Reverse (R), Park (P).

Fluid Specifications

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent SAE 80W-90 gear oil.

Fluid Capacities

Transmission Fluid Capacity:

Approximately 0.75 US quarts (0.7 liters) for the final drive (verify in manual).

📐 Dimensions

Exterior

Length:

81 inches (205.7 cm)

Width:

46 inches (116.8 cm)

Height:

47 inches (119.4 cm)

Weights

Dry Weight:

565 lbs (256 kg)

Ground Clearance:

10.5 inches (26.7 cm)

Cargo

Front Rack Capacity:

50 lbs (22.7 kg)

Rear Rack Capacity:

100 lbs (45.4 kg)

Towing

Towing Capacity:

1200 lbs (544 kg)

Tires

Front Tire Size:

AT25x8-12

Rear Tire Size:

AT25x11-10

🛡️ Safety Features

Ratings

Atv Safety:

As an ATV, safety is paramount. The manual will cover essential safety precautions, proper riding techniques, and recommended gear (e.g., helmets, protective clothing).

Active Features

Braking:

Hydraulic disc brakes on all wheels for reliable stopping power.

Passive Features

Chassis Design:

Designed for stability with a low center of gravity and independent front suspension.

💡 Technology Features

Infotainment

Features:

Basic controls, no advanced infotainment features. Focus is on functionality and off-road performance.

Driver Assistance

Features:

No electronic driver assistance systems. Mechanical operation of all functions.

Connectivity

Features:

N/A (no electronic connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 1 year, whichever comes first.

Air Filter Cleaning:

Every 50 hours or more frequently in dusty conditions.

Spark Plug Inspection:

Every 100 hours or 1 year.

Transmission Fluid Change:

Every 200 hours or 2 years.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Cvt Belt Wear:

CVT drive belts can wear over time and require regular inspection and replacement. Overheating can accelerate wear.

Carburetor Gumming:

If the ATV sits for extended periods, the carburetor can develop varnish and clog, requiring cleaning.

Cooling System Leaks:

Hose connections and radiator seals can degrade and leak over time, requiring inspection and tightening/replacement.

📚 Vehicle History

Brand Heritage

Polar Heritage:

Polaris Industries has a long history in powersports, known for its innovation in snowmobiles and ATVs. The Sportsman line is one of their flagship ATV series.

Model Evolution

Sportsman Line:

The Sportsman 335 was part of Polaris's evolution towards more versatile and user-friendly ATVs, preceding larger displacement models and introducing features that became standard.

Production

Manufacturing Origin:

USA (Polaris manufacturing facilities).

🏆 Awards & Recognition

Recognitions

Industry Standing:

The Polaris Sportsman line has consistently received positive reviews for its capability and comfort in the ATV market. The 335 model was a strong contender in its class during its production years.