SPORTSMAN 335 Model #A99CH33AA Model #A99CH33AB …

1 PARTS MANUAL PN 9914988 and MICROFICHE PN 9915651 1/99 SPORTSMAN 335 Model #A99CH33 AAModel # a99ch33ab WORKER 335 Model #A99CH33 IARev.

2 01 hi in n i n n TABLE OF CONTENTSSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33 IAParts ManualAA-ARM/STRUT MOUNTING C3.. AIR BOX B3.. CCARBURETOR D9-10.. CLUTCH COVER C7.. CONTROLS - MASTER CYLINDER/BRAKE LINE B11.. CONTROLS - THROTTLE B10.. CRANKCASE D5.. CRANKSHAFT and PISTON D7.. CV JOINT - BTB B4.. CYLINDER D6.. DDECALS A10-11.. DRIVE CLUTCH C4.. DRIVE SHAFT REAR B5.. DRIVEN CLUTCH C5.. EELECTRICAL/TAILLIGHT C8.. ENGINE MOUNTING A13-14.. EXHAUST SYSTEM B1.. FFOOT BRAKE, WORKER 335 C6.. FRAME MOUNTING C2.. FRONT BRAKE B9.. FRONT CAB A7.. FRONT HOUSING C13-14.. FRONT RACK and BUMPER MOUNTING A9.. FRONT STRUT B7.. FRONT WHEEL B8.. FUEL PUMP E2.. FUEL TANK B2.. GGEAR SELECTOR D4.. GEARCASE (CASES & SNORKEL) D3.. GEARCASE (INTERNAL COMPONENTS) D1-2.. HHANDLEBAR and HEADLIGHT POD B13-14.. IINTAKE and EXHAUST D8.. MMAGNETO D14.. OOIL COOLING SYSTEM A12.. OIL FILTER D13.. OIL PUMP D12.. OIL TANK C1.. PPART NUMBER INDEX E4-10.

3 PROP SHAFT B6.. RREAR BRAKE/FOOT PEDAL C10.. REAR CAB and SEAT A5-6.. REAR RACK MOUNTING A8.. REAR SUSPENSION C11-12.. REAR WHEEL DRIVE C9.. RECOIL STARTER D11.. SSTARTING MOTOR E1.. STEERING POST B12.. TTOOL KIT E3.. The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to beused for SPORTSMAN 335 and WORKER 335 SPECIFICATIONSBRAKESType/BrakesType/Brak es - AuxiliaryPark BrakeHydraulic DiscHydraulic DiscHydraulic Lock, All WheelCAPACITIESC oolant Capacity (quarts)Fuel Tank (gallons)Gearcase Oil (ounces)Engine Counter Balance 10W30 Oil (quarts) InjectorOil (quarts) Engine OW40 Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow TRAINTypePVTDRIVE CLUTCHC enter Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color101/2#16 Blue/GreenDRIVEN CLUTCHH elix AngleSpring PositionCompound2-2 DIMENSIONAL FEATURESA pprox. Turning RadiusBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (lbs.)

4 Dry)Wheel Base (inches)Width (inches)65 6x7x14 Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (cc s)Compression RatioCoolingAlternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)Main JetPilot JetNeedle JetCut AwayAir Screw/Pilot ScrewJet NeedleIgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)ExhaustES33 PFE024 Cycle, Single Sump78 x :1 EffectiveAir Cooledw/Fan Assist Oil Cooler200 WStandard1/BST34(CV type)15040P9 @ BKR7 EUSFS TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain TypePRDSide :1N/AN/AShaftGRAPHICSBody StyleBumper Box or BedFender, FrontFender, RearFootwellFrame/SteelFront CoverHandlebar Cover w/DecalHeadlight/Dash PodRack, FrontRack, RearRimsSeat VinylSide PanelSpring, FrontSpring, RearTank CoverTool Box Coverw/lettering ColorGen IVN/AN/AOlive Green ( a99ch33aa )Porsche Red ( a99ch33ab /A99CH33IA)Olive Green ( a99ch33aa )Porsche Red ( a99ch33ab /A99CH33IA)BlackSemi Flat BlackBlack( a99ch33aa )Porsche Red ( a99ch33ab /A99CH33IA)BlackOlive Green/Black ( a99ch33aa )Porsche Red/Black ( a99ch33ab /A99CH33IA)BlackBlackBlack ( a99ch33aa )Aluminum ( a99ch33ab /A99CH33IA)BlackOlive Green ( a99ch33aa )Porsche Red ( a99ch33ab /A99CH33IA)BlackBlackN/AN/AN/A ELECTRICALH eadlight - Handlebar (watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillights (watts)Brake Light (watts)Indicator Bulb1 Single Beam, 60WN/A2 Single Beam, Type -Front Travel (inches)Rear Type -Rear Travel (inches)

5 ShockAdjustmentMacPherson - 1 Bore Gas BagCAMTIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - CenterTitan23x7-1024x11-10N/A55N/APolari s Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its productswithout ATV PUBLICATION NUMBERS MODELMODEL SMANUALOWNER SMANUALSUPPLEMENTPARTSMANUALPARTSMICROFI CHEASSEMBLYINSTRUCTIONSS portsman 335A99CH33AA(AB)991490599149879914988991 56519914598 Worker 335A99CH33IA9914905991498799149889915651 9914598A5 REAR CAB and SEATSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA2736910141315161741401219212235 5434445142371123244381833128323331839272 62534293036202726A6 REAR CAB and SEATSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33 IARef. Part DescriptionRef. Part Description1766164510 Rivet275119302 Bolt375557924 Washer458111071 Foil, Rear Cab, Rear55432117-1915432117-13611 Cab, Rear, Olive Green ( a99ch33aa )Cab, Rear, Porsche Red( a99ch33ab )(A99CH33IA)675419252 Nut, Nylok752245921 Retainer, Seat Latch858113081 Foil, Tape, Rear Cab975122424 Screw1075558594 Washer1175120852 Screw1254317861 Box, Tool1376214032 Rivet1452110332 Bracket, Lever Retainer1510403871 Latch, Seat1670413701 Spring, Latch172682441-0702681747-07058111045811 1051111 SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small1854104148 Bumper, Rubber1975173122 Screw2075557482 Washer2154317871 Cover, Tool Box2254108961 Cap, Drain2376616384 Rivet245241403-0671 Guard, Clutch25 1 Asm.

6 , Gearcase, Front (See Front Hous-ing Pg. C13 for Details)26755260311 Washer27751249211 Bolt281040699-0671 Frame, Main2970806531 Clamp, Hose3075120241 Screw31754212228 Nut, Nylok3254322802 Spacer, Footwell3375173774 Screw3470725331 Decal - Hitch3575173764 Screw365432221-0705433219-07011 Footwell, Black, LHFootwell, Black, RH3758111111 Foil, Foam, Rear Fender3858111062 Foil, Rear Cab, Front3975419292 Nut4070737611 Decal - Carb Information4170774461 Decal - Filter Element4258110871 Foil, Foam43751223212 Screw44767005712 Nut455431797543179611 Guard, Mud, Rear, RHGuard, Mud, Rear, LH1/99A7 FRONT CABSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA5678910113220214181913121415168 1174422 Ref. Part DescriptionRef. Part Description158114911 Foil, Side Panel, Gen. IV, RH258109961 Foil, Foam, Side Panel32620085-1915431809-1912620085-1365 431809-1361111 Panel, Side, RH w/Foil, Olive Green( a99ch33aa )Panel, Side, LH, Olive Green( a99ch33aa )Panel, Side, RH w/Foil, Red( a99ch33ab )(A99CH33IA)Panel, Side, LH, Red( a99ch33ab )(A99CH33IA)4751223210 Screw55432088-0705432088-13611 Cover, Front, Black ( a99ch33aa )Cover, Front, Porsche Red( a99ch33ab )(A99CH33IA)676700852 Clip, Spring72631987-1912631987-13611 Cab, Front, Olive Green w/WarningDecals ( a99ch33aa )Cab, Front, Porsche Red w/WarningDecals ( a99ch33ab )(A99CH33IA)

7 8767005710 Nut976700092 Nut1076616454 Rivet115431799543179811 Guard, Mud, Front, RHGuard, Mud, Front, LH1275419252 Nut, Nylok1375557922 Washer1475120852 Screw1570806931 Clamp, Hose168450073-600 ARLine, Breather1775120171 Screw1875559312 Washer1975421222 Nut, Nylok2076700884 Clip, Dart2158114892 Shield, Deflector2275173122 Screw1/99A8 REAR RACK MOUNTINGSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA54239101214151313107168113 Ref. Part DescriptionRef. Part Description128715011 Kit - Rack Extender, Rear (Incl. 6)275151932 Screw375151944 Screw426701741 Rack, Rear (Incl. 5 & Warning Decal)526700702 Reflector, Red675172086 Screw71040490-0671 Support, Rear Rack85241663-0671 Bracket, Silencer, Frame975123294 Bolt1075423438 Nut, Nylok1176700962 Nut, Chimney121040524-0671040525-06711 Mount, Front, Rear Rack, LHMount, Front, Rear Rack, RH1375584022 Washer145333332-0674 Spacer1575153854 Screw1/99A9 FRONT RACK and BUMPER MOUNTINGSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA1415171819201375910112122232341 24811624725266 Ref.

8 Part DescriptionRef. Part Description175151944 Screw226701801 Rack, Front (Incl. 3 & Warning Decal)326700712 Reflector, Amber475153996 Screw522007751 Kit - Front Rack Mount675470694 Nutsert775423244 Nut, Nylok875584032 Washer95432155-0701 Bumper1075153912 Screw1175153902 Screw1275559542 Washer131040554-0671040555-06711 Support, Front Rack, LHSupport, Front Rack, RH1475122324 Screw15243101424310154030059112 Headlight, LHHeadlight, RHBulb, Replacement, 27W1624606101 Harness, Headlight, Low1775153842 Bolt1875584024 Washer1958104671 Plug, Frame205241398-0675241399-06711 Extension, Frame, LHExtension, Frame, RH215241583-0671 Guard, Brush225240591-0671 Grill, Brush Guard2376213307 Rivet2452412241 Hitch, U-Bolt255211633-0671 Plate, Back Mount2675155472 Screw1/99A10 DECALSSPORTSMAN 335 A99CH33AA1234567910111213147161718519320 21221015 LHRH18 Ref. Part DescriptionRef. Part Description170749542 Decal - Rack270741101 Decal - Load Distribution, 4W370778892 Decal - 4x4 INDY SHAFT DRIVE 470776571 Decal - Side Panel, RH570765022 Decal - SPORTSMAN 670765041 Decal - Tank Side, RH770765012 Decal - POLARIS 870780031 Decal - Headlight Adjustment970749351 Decal - Warning, AWD Switch1070742201 Decal - MacPherson Strut 1170783541 Decal - Discretionary Warning1270757411 Decal - Drain Recoil1370765081 Decal - Demand 4 Drive 1470783151 Logo, 45th Anniversary1570762021 Decal - CE Regulation1670762731 Decal - Override Switch, AWD1770765031 Decal - Tank Side, LH1870782531 Decal - Age Warning, ATV1970776561 Decal - Side Panel, LH2070779201 Decal - Passenger Warning2170758341 Decal - Tire Pressure2270779191 Decal - Warning, General, CPSC1/99A11 DECALSSPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA2122371316121022181568191152041 864141217 LHRH193 Ref.

9 Part DescriptionRef. Part Description170749542 Decal - Rack270741101 Decal - Load Distribution370777491 Decal - Park Lock Warning(A99CH33IA)470778822 Decal - 4X4 INDY SHAFT DRIVE 570776591 Decal - Side Panel, RH67077468707833522 Decal - SPORTSMAN ( a99ch33ab )Decal - WORKER (A99CH33IA)770782531 Decal - Age Warning870766642 Decal - POLARIS 970780031 Decal - Headlight Adjustment1070749351 Decal -Warning AWD Switch1170766661 Decal - Tank Side, RH1270742201 Decal - MacPherson Strut 1370783541 Decal - Discretionary Warning1470757411 Decal - Drain Recoil1570764831 Decal - Demand 4 Drive1670783151 Logo, 45th Anniversary1770762021 Decal - CE Regulation1870762731 Decal - Override Switch, AWD1970766651 Decal - Tank Side, LH2070776581 Decal - Side Panel, LH2170779201 Decal - Passenger Warning2270758341 Decal - Tire Pressure2370779191 Decal - Warning, General, CPSC1/99A12 OIL COOLING SYSTEMSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA7212213456911623815241821455202 1212121212631125101217619 Ref.

10 Part DescriptionRef. Part Description15241355-0671 Bracket, Cooling Fan275118753 Screw375557803 Washer475582013 Washer575421226 Nut, Nylok675583014 Washer731100322 Mount, Rubber85242924-0672 Bracket, Oil Cooler975122402 Screw1075470041 Nut, Nylok1140101621 Switch, Thermister1270801383 Cable Tie1312400391 Cooler, Oil1454330341 Blade, Fan1541700241 Motor, Fan1654330011 Shroud, Fan1775175491 Screw1875122324 Screw1970805732 Clamp, Rubber Coated20 1 Tube, Banjo Return (See Oil Tank Pg. C1,Ref. 9)2170807117 Clamp2212400401 Valve, Thermo2354115141 Hose, Cooler Outlet2454115111 Hose, Cooler Inlet2570804922 Cable Tie2654115151 Hose, Thermo Valve Inlet1/99A13 ENGINE MOUNTINGSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33IA2642443740199315282732211762293 9384125304336334435145101124202883612101 211141776222333161537131817171716637A14 ENGINE MOUNTINGSPORTSMAN 335 a99ch33aa and SPORTSMAN 335 a99ch33ab and WORKER 335 A99CH33 IARef.