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  • PARTS MANUAL PN 9914988 and MICROFICHE PN 9915651 1/99

    SPORTSMAN 335Model #A99CH33AAModel #A99CH33AB

    WORKER 335 Model #A99CH33IA

    Rev. 01

  • TABLE OF CONTENTSSPORTSMAN 335 A99CH33AA and SPORTSMAN 335 A99CH33AB and WORKER 335 A99CH33IA

    Parts Manual

    AA-ARM/STRUT MOUNTING C3. . . . . . . . . . . . . . AIR BOX B3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

    CCARBURETOR D9-10. . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER C7. . . . . . . . . . . . . . . . . . . . . . CONTROLS -

    MASTER CYLINDER/BRAKE LINE B11. . . . . CONTROLS - THROTTLE ASM./CABLE 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. . . . . . . . . . . . . . . . . . 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 assembly.

  • 1999 SPORTSMAN 335 and WORKER 335 SPECIFICATIONSBRAKES

    Type/BrakesType/Brakes - AuxiliaryPark Brake

    Hydraulic DiscHydraulic Disc

    Hydraulic Lock, All Wheel

    CAPACITIESCoolant Capacity (quarts)Fuel Tank (gallons)Gearcase Oil (ounces)Engine Counter Balance 10W30Oil (quarts) InjectorOil (quarts) Engine OW40Rack, Front (pounds)Rack, Rear (pounds)Tongue WeightTow HitchTow Weight

    N/A3.75

    32N/AN/A2.25

    9018030

    Standard850

    DRIVE TRAINType PVT

    DRIVE CLUTCHCenter Distance (inches)Clutch Offset (inches)Clutch WeightSpring Color

    101/2#16

    Blue/Green

    DRIVEN CLUTCHHelix AngleSpring Position

    Compound2-2

    DIMENSIONAL FEATURESApprox. Turning RadiusBox, ToolBox (cubic feet)Ground Clearance (inches)Height (inches)Length (inches)Seat Height (inches)Weight (lbs. dry)Wheel Base (inches)Width (inches)

    656x7x14

    N/A10.2545.5

    8133

    67050.50

    46

    ENGINEEngine Model NumberEngine TypeLubrication TypeBore & Stroke (mm)Displacement (ccs)Compression RatioCooling

    Alternator OutputElec. Start w/Recoil Back UpCarburetors (no. of/size)

    Main JetPilot JetNeedle JetCut AwayAir Screw/Pilot ScrewJet Needle

    IgnitionIgnition (Type & Deg. BTDC)Spark Plug Gap (inches)Spark Plug (Type)Exhaust

    ES33PFE024 Cycle, Single Cyl.

    Dry Sump78 x 70mm

    3349.2:1 Effective

    Air Cooledw/Fan Assist Oil Cooler

    200WStandard

    1/BST34(CV type)15040P9

    N/A2.5

    5F14-3CDI

    30 @ 3500.028

    NGK BKR7EUSFS Appr.

    GEARCASETransmissionShift TypeGear Reduction - LowGear Reduction - ReverseGear Reduction - HighFront Drive (ratio)Final Drive (ratio)Center Drive (ratio)Axle to AxleChain Type

    PRDSide Lever

    6.89/15.17/13.56/1

    2:13.16:1

    N/AN/A

    Shaft

    GRAPHICSBody StyleBumper Caps/Polyprop.Cargo Box or BedFender, Front

    Fender, Rear

    FootwellFrame/SteelFront Cover

    Handlebar Cover w/DecalHeadlight/Dash Pod

    Rack, FrontRack, RearRims

    Seat VinylSide Panel

    Spring, FrontSpring, RearTank CoverTool Box Cover

    w/lettering Color

    Gen IVN/AN/A

    Olive Green (A99CH33AA)Porsche Red (A99CH33AB/A99CH33IA)

    Olive Green (A99CH33AA)Porsche Red (A99CH33AB/A99CH33IA)

    BlackSemi Flat Black

    Black(A99CH33AA)Porsche Red (A99CH33AB/A99CH33IA)

    BlackOlive Green/Black (A99CH33AA)

    Porsche Red/Black (A99CH33AB/A99CH33IA)BlackBlack

    Black (A99CH33AA)Aluminum (A99CH33AB/A99CH33IA)

    BlackOlive Green (A99CH33AA)

    Porsche Red (A99CH33AB/A99CH33IA)BlackBlack

    N/AN/AN/A

    ELECTRICALHeadlight - Handlebar (watts)Headlight - Front Hood (watts)Headlight - Grill (watts)Taillights (watts)Brake Light (watts)Indicator Bulb

    1 Single Beam, 60WN/A

    2 Single Beam, 27W8.26W26.9W1.0W

    SUSPENSIONFront Type -

    Front Travel (inches)Rear Type -

    Rear Travel (inches)ShockAdjustment

    MacPherson Strut6.25

    Independent9.5

    2 - 1 Bore Gas BagCAM

    TIRES & WHEELSTire ManufacturerTire Size - FrontTire Size - RearTire Size - CenterTire Pressure - FrontTire Pressure - RearTire Pressure - Center

    Titan23x7-10

    24x11-10N/A

    55

    N/A

    Polaris Industries Inc. reserves the right to make changes in design and specifications and/or to make additions or improvements to its productswithout notice.

  • 1999 ATV PUBLICATION NUMBERS

    MODEL MODEL NO. OWNERSMANUAL

    OWNERSMANUAL

    SUPPLEMENT

    PARTSMANUAL

    PARTSMICROFICHE

    ASSEMBLYINSTRUCTIONS

    Sportsman 335 A99CH33AA(AB) 9914905 9914987 9914988 9915651 9914598

    Worker 335 A99CH33IA 9914905 9914987 9914988 9915651 9914598

  • A5

    REAR CAB and SEATSPORTSMAN 335 A99CH33AA and SPORTSMAN 335 A99CH33AB and WORKER 335 A99CH33IA

    2

    7

    3

    6

    910

    14

    13

    15

    16

    17

    4140

    12

    19

    21

    22

    35

    5

    43

    44

    45

    1

    42

    37

    11

    23

    24

    4

    38

    18

    3

    31

    28

    32

    33

    31

    8

    39

    2726

    25

    34

    2930

    36

    20

    27

    26

  • A6

    REAR CAB and SEATSPORTSMAN 335 A99CH33AA and SPORTSMAN 335 A99CH33AB and WORKER 335 A99CH33IA

    Ref. Part No. Qty. Description Ref. Part No. Qty. Description

    1 7661645 10 Rivet2 7511930 2 Bolt3 7555792 4 Washer4 5811107 1 Foil, Rear Cab, Rear5 5432117-191

    5432117-13611

    Cab, Rear, Olive Green (A99CH33AA)Cab, Rear, Porsche Red(A99CH33AB)(A99CH33IA)

    6 7541925 2 Nut, Nylok7 5224592 1 Retainer, Seat Latch8 5811308 1 Foil, Tape, Rear Cab9 7512242 4 Screw

    10 7555859 4 Washer11 7512085 2 Screw12 5431786 1 Box, Tool13 7621403 2 Rivet14 5211033 2 Bracket, Lever Retainer15 1040387 1 Latch, Seat16 7041370 1 Spring, Latch17 2682441-070

    2681747-07058111045811105

    1111

    SeatCovering, SeatFoil, Seat Base, LargeFoil, Seat Base, Small

    18 5410414 8 Bumper, Rubber19 7517312 2 Screw20 7555748 2 Washer21 5431787 1 Cover, Tool Box22 5410896 1 Cap, Drain

    23 7661638 4 Rivet24 5241403-067 1 Guard, Clutch25 1 Asm., Gearcase, Front (See Front Hous-

    ing Pg. C13 for Details)26 7552603 11 Washer27 7512492 11 Bolt28 1040699-067 1 Frame, Main29 7080653 1 Clamp, Hose30 7512024 1 Screw31 7542122 28 Nut, Nylok32 5432280 2 Spacer, Footwell33 7517377 4 Screw34 7072533 1 Decal - Hitch35 7517376 4 Screw36 5432221-070

    5433219-07011

    Footwell, Black, LHFootwell, Black, RH

    37 5811111 1 Foil, Foam, Rear Fender38 5811106 2 Foil, Rear Cab, Front39 7541929 2 Nut40 7073761 1 Decal - Carb Information41 7077446 1 Decal - Filter Element42 5811087 1 Foil, Foam43 7512232 12 Screw44 7670057 12 Nut45 5431797

    543179611

    Guard, Mud, Rear, RHGuard, Mud, Rear, LH

    1/99

  • A7

    FRONT CABSPORTSMAN 335 A99CH33AA and SPORTSMAN 335 A99CH33AB and WORKER 335 A99CH33IA

    5

    6

    7

    8

    910

    11

    32

    20

    21

    4

    1819

    1312

    14

    1516

    8

    1

    17

    4

    4

    22

    Ref. Part No. Qty. Description Ref. Part No. Qty. Description

    1 5811491 1 Foil, Side Panel, Gen. IV, RH2 5810996 1 Foil, Foam, Side Panel3 2620085-191

    5431809-191

    2620085-136

    5431809-136

    1

    1

    1

    1

    Panel, Side, RH w/Foil, Olive Green(A99CH33AA)Panel, Side, LH, Olive Green(A99CH33AA)Panel, Side, RH w/Foil, Red(A99CH33AB)(A99CH33IA)P

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