OWNER’S MANUAL SUPPLEMENT
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1999 SPORTSMAN 335
IMPORTANT: This is a supplement to your owner’s manual. This information should remain with your owner’s
manual at all times.
Specifications
Sportsman 335
Body Style Gen IV
Gross Vehicle Weight 1200 Lbs.
Fuel Capacity 3.75 U.S. Gallons
Gearcase Oil 32 oz.
Oil Capacity 2.25 U.S. Quarts
Front Rack
(Maximum - Capacity)
C
Rear Rack
A
(Maximum - Caacity)
P
Tongue Weight 30 Lbs.
A
C
Tow H it ch Standard
I
Tow Capacity 850 Lbs
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I
Turn Radius 65²
E
Ground Clearance 9.5²
S
Height 45.5²
Length 81²
Seat Height 34²
Weight 670 Lbs.
Wheel Base 50.50²
Width 46²
Drive System Type PVT
D
Shift Type Side Lever (L, R, H/F)
R
I
Gear Reduction - Low 6.89:1
Gear Reduction - Reverse 5.17:1
E
Gear Reduction - Foward 3.56:1
Front Drive (ratio) 2:1
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S
Final Drive (ratio) 3.16:1
Center Drive (ratio) Not Applicable
E
M
Drive Chain Not Applicable
T
Front Tire 23 x 7 - 10
I
Rear Tire 24 x 11 - 10
R
E
Tire Pressure (front) 5
S
Tire Pressure (rear) 5
90 Lbs.
180 Lbs.
1
Sportsman 335
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A
N
G
C
O
N
G
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Front Susp. - Mac Strut 6.25² Travel
S
Rear Susp. - Mono Progressive Rate Fully
U
Shock Adjustment CAM
P
Front Brake Fixed Disc Hydraulic
B
R
Rear Brake Single Lever Hydraulic Caliper
Auxiliary Brake Hydraulic Disc
K
E
S
Park Brake Hydraulic Lock / All Wheel
Engine Model Number ES33PFE01
Engine Type 4 Cycle, Single Cylinder
Lubrication Dry Sump
Bore x Stroke 78 x 70 mm
E
Displacement 334 cc
Compression Ratio 9.2:1 Effective
G
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Engine Cooling Air Cooled with Fan Assisted
N
E
Alternator Output (watts) 200
&
Carburetion 1/BST34 (CV Type)
Main Jet 150
C
O
Pilot Jet 40
Needle Jet P-9
L
I
Cut Away Not Applicable
Air Screw 2.5
G
Valve Seat
Jet Needle 5F14-3
Ignition CDI
Timing 30° @ 3500
Spark Plug Gap .028
Spark Plug Type BKR7E (NGK)
Exhaust UFSF Approved
LIHeadlight (watts) 60 (1 pod headlight) (2 grill
Independent with Anti-Roll Bar
Floating Caliper
Dual Floating Caliper
Oil Cooler
headlights)
Taillight (watts) 8.26
H
Brake Light (watts) 26.9
S
2
3-Point Hitch Accessory
F
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E
Battery 12V 14AH
DC Plug In - Rear Standard
DC Socket - Forward Standard
F
E
Electric Start Standard
High Beam Indicator Standard
T
U
High Temp Indicator Standard
Windshield Accessory
E
S
Low Oil Light Not Available
Neutral Indicator Standard
Reverse Indicator Standard
Speedometer Standard
Tool Kit Standard
SPORTSMAN 335
(Engine - ES-33PFE-01)
Carburetor Jetting
Sportsman 335
Altitude Ambient
Meters
(Feet)
Temperature
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700
(6000-9000)
2700-3700
(9000-12000)
(Below --18°C)
- Pilot screw in 1/2 turn
- Pilot screw out 1/2 turn
Clutching
Altitude Shift
Meters
(Feet)
0-900
(0-3000)
900-1800
(3000-6000)
1800-2700
(6000-9000)
2700-3700
(9000-12000)
Below 0°F
0° to 40°F
(--18°Cto
+5°C)
+40° to +80°F
(+5°Cto
+26°C)
+80°F&Above
(+26°C&
Above)
162.5 155 150 145
155 150 145 137.5
147.5 142.5 137.5 132.5
140 135 130 125
Weight
Clutch
Spring
16 Blue/Green 2-2
16 Blue/Green 2-1
16 mod Blue/Green 2-2
16 mod Blue/Green 2-2
Driven
Helix
Carrying Loads
Model Total Load Capacity
(includes driver & cargo)
Sportsman 335 470 lbs.
(213 kg)
3
Front Rack
Cargo Maximum
90 lbs.
(41 kg)
Rear Rack
Cargo Maximum
180 lbs.
(82 kg)
Optional Suspension Springs
SOFT FIRM
Sportsman 335 4x4 - Rear Compression Spring 7041517-067
Sportsman 335 4x4 - Front Strut Spring 7041238-067
OPTION
80 lb/in
OPTION
61 lb/in
Air Filter Service
1. Remove seat.
2. Remove wingnuts securing the airbox lid and remove lid.
3. Pull foam breather filter out.
4. Loosen clamp and remove filter.
5. Remove foam pre-cleaner from main filter.
6. Wash the pre-filter in soapy water and dry it.
7. Install dry pre-filter over new main filter and reinstall.
8. Push foambreather filter straightdown intoairbox untilflush withupper edge of box. Make certain foam is flush with front edge of airbox
so air cannot enter engine breather fitting hole without first passing
through the foam.
Main Filter
7041546-067
STANDARD
100 lb/in
7041375-067
STANDARD
64/113 lb/in
Foam
Pre--cleaner
7041519-067
OPTION
140 lb/in
7041450-067
OPTION
101 lb/in
Breather Filter and Hose
1. Remove the clamps and pull the filter out of the hoses. NOTE: It
be necessary to remove the lower hose from the engine.
will not
2. Inspect filter for debris. Blow through gently in direction of arrowon
filter to check for clogging. Replace as needed.
3. Check hoses for cracks, deterioration, abrasion,or leaks. Replace
as needed.
4. Reinstall filter and clamps with arrow pointing toward engine.
NOTE: The breather filter is intended to be used with airbox
pre-filter in place. Without the pre-filter, the breather filter can clog
quickly. Never operate the ATV without the pre-filter.
PN 9914987 Rev 02 12/98
Printed in U.S.A.
Breather
Filter
4
5
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