This manual covers the 2012 Sportsman 400 H.O. and Sportsman 500 H.O. All-Terrain Vehicles (ATVs). The Sportsman line is renowned for its versatility, catering to recreational riders, farm work, and light trail exploration. These ATVs are recognized for their robust engineering, comfortable ride, and capable performance, featuring technologies such as On-Demand All-Wheel Drive and Independent Rear Suspension on the 500 H.O. model. With a strong heritage in powersports, the company consistently delivers reliable and innovative off-road vehicles. This comprehensive factory service manual provides essential information for the maintenance, diagnosis, and repair of your 2012 Sportsman ATV. It details procedures for all major systems, including the engine, fuel, ignition, transmission, chassis, suspension, and electrical components. Within its pages, you will find step-by-step instructions for routine maintenance, troubleshooting common issues, detailed diagnostic techniques, and complete repair and overhaul guidelines. This resource is designed to assist owners, mechanics, and technicians in ensuring the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 H.O. / Sportsman 500 H.O. Year: 2012 Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Segment: Mid-size utility ATV segment, known for its versatility in recreational riding, farm work, and light trail use. Competitive Analysis Competitors: Competes with models from Honda (FourTrax series), Yamaha (Grizzly series), Can-Am (Outlander series), and Kawasaki (Brute Force series) in the same displacement class. Key Features Features Vehicle: Independent Rear Suspension (IRS) on 500 H.O. model, On-Demand All-Wheel Drive (AWD), powerful Polaris engine, comfortable seating, ample cargo capacity, electronic fuel injection (EFI on 500 H.O. likely). 📋 Manual Details Coverage Areas Primary Models Covered: 2012 Polaris Sportsman 400 H.O., 2012 Polaris Sportsman 500 H.O. Page Count Estimated Pages: Refer to actual manual; typically 400-800 pages for comprehensive repair manuals. Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (400 H.O. / 500 H.O. variants), fuel system, ignition system, exhaust system, transmission (PVT - Polaris Variable Transmission), drive shafts, differentials, axles. Chassis And Body: Frame, suspension (front and rear), steering system, braking system (hydraulic disc), wheels, tires, body panels, racks, seats. Electrical: Battery, charging system (alternator/stator), starting system, lighting (headlights, taillights, brake lights), instrumentation, wiring diagrams, fuses, relays, ignition switch, kill switch, winch system (if applicable). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements (oil, air, fuel), spark plug replacement, valve adjustments, lubrication points, brake fluid flush, coolant flush. Diagnostics And Troubleshooting: Diagnostic procedures for engine performance issues, electrical faults, fuel delivery problems, starting issues, braking system irregularities. Fault code lookup and interpretation. Repair And Rebuild: Complete disassembly and reassembly of engine components, transmission service, suspension component replacement, steering linkage repair, brake system overhaul, electrical component diagnosis and replacement. Technical Depth Depth: Comprehensive, covering routine maintenance, troubleshooting, diagnostics, and full mechanical/electrical repair and overhaul procedures. Includes detailed torque specifications, clearances, and service limits. 📊 Manual Specifications File Format Format: Searchable PDF Print Quality Quality: High-resolution digital scans, suitable for printing individual pages or the entire manual. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Sportsman 400 H.O.: 375cc, liquid-cooled, 4-stroke, SOHC, single-cylinder. Electronic fuel injection (EFI). Sportsman 500 H.O.: 499cc, liquid-cooled, 4-stroke, SOHC, single-cylinder. Electronic fuel injection (EFI). Performance Horsepower 500 Ho: Approximately 36-40 HP (estimate, specific figures vary by tuning and conditions). Torque 500 Ho: Approximately 28-30 lb-ft (estimate). Fuel System Injection Type: Electronic Fuel Injection (EFI) for both models. Fuel Type: Unleaded Gasoline, Octane Rating 87 or higher. Cooling System Type: Liquid-Cooled 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with engine braking. Optional Gearing: High, Low, Neutral, Reverse, Park. Features Drive System: Shaft Drive; On-Demand All-Wheel Drive (AWD). Fluid Type Specification: Polaris AGL Premium Gearcase Lubricant (or equivalent SAE 10W-50 Synthetic Gear Oil). 📐 Dimensions Exterior Length 500 Ho: Approx. 83 in. (210.8 cm) Width 500 Ho: Approx. 48 in. (121.9 cm) Height 500 Ho: Approx. 49.5 in. (125.7 cm) Wheelbase 500 Ho: Approx. 50.5 in. (128.3 cm) Weights Dry Weight 500 Ho: Approx. 660 lbs (299 kg) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet ANSI standards for recreational off-highway vehicles. Active Features Braking System: Hydraulic disc brakes front and rear. Engine Braking: Standard feature on Polaris Variable Transmission (PVT) for downhill control. Passive Features Lighting: Dual Halogen Headlights, LED Tail/Brake Light. Roll Over Protection: Not equipped with a roll cage; riders must adhere to safe operating practices and wear appropriate safety gear. 💡 Technology Features Infotainment Display Features: Digital odometer, trip meter, high beam indicator, neutral indicator, reverse indicator, oil/coolant/battery indicators. Driver Assistance Driving Modes: On-Demand AWD system automatically engages front wheels when rear wheels slip. Connectivity Charging Ports:...