This manual covers the 2012 Sportsman 400 H.O. and Sportsman 500 H.O. All-Terrain Vehicles (ATVs), including the Sportsman Touring 500 H.O. and Sportsman Forest Edition 500 EFI variants. A well-established manufacturer of powersports vehicles, designed the Sportsman line for robust utility and off-road performance, renowned for its comfort and capability. These ATVs are equipped with liquid-cooled, 4-stroke SOHC engines, with displacements typically in the 400cc class for the Sportsman 400 H.O. and 500cc class for the Sportsman 500 H.O. models, featuring Electronic Fuel Injection (EFI) on the 500 series. They utilize an automatic Variable Transmission (PVT) system with High, Low, Neutral, and Reverse gear selections, and offer On-Demand All-Wheel Drive (AWD) or 2WD capabilities. This comprehensive factory service manual provides complete vehicle service and repair information in English. It details maintenance procedures, troubleshooting guides, and step-by-step repair instructions for all major components and systems, including the engine, fuel system, cooling system, transmission, clutch, final drive, body and frame, steering and suspension, brakes, and electrical systems. The manual also includes detailed wiring diagrams, specifications, and high-quality images and illustrations to aid in understanding. Its purpose is to empower owners and technicians to perform maintenance, diagnostics, and repairs effectively, ensuring the optimal performance and longevity of their 2012 Sportsman ATVs. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400/500 Model Variants: Sportsman 400 H.O., Sportsman 500 H.O., Sportsman Touring 500 H.O., Sportsman Forest Edition 500 EFI Model Year: 2012 Codes Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Target Audience: Polaris Sportsman ATV owners, technicians, and maintenance professionals Purpose: To provide comprehensive guidance for maintaining, servicing, and repairing 2012 Polaris Sportsman 400 and 500 models. Competitive Analysis Value Proposition: Instant access to factory-level repair information, empowering users to perform their own maintenance and repairs, saving time and money. Key Features Digital Access: Instant download, accessible on computers, tablets, and smartphones Visual Aids: High-quality pictures, diagrams, and illustrations for clear procedural understanding Software Requirement: No special software required, standard PDF viewer 📋 Manual Details Coverage Areas Coverage Scope: Complete vehicle service and repair Specific Models Covered: 2012 Polaris Sportsman 400 H.O., 2012 Polaris Sportsman 500 H.O., 2012 Polaris Sportsman Touring 500 H.O., 2012 Polaris Sportsman Forest Edition 500 EFI Page Count Estimated Page Count: Refer to actual manual for definitive count, typically 300-500 pages for comprehensive ATV manuals Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed engine disassembly, assembly, troubleshooting, diagnostics, timing, lubrication, cooling, and emissions Fuel System: Fuel injection system (EFI), fuel pump, injectors, fuel lines, fuel filter, throttle body, and related sensors Cooling System: Radiator, coolant, fan, thermostat, water pump, and hoses Transmission: Automatic transmission (PVT), gear selector, internal components, fluid maintenance Clutching: Primary and secondary clutch inspection, service, replacement, and belt maintenance Final Drive: Front and rear drive systems, CV joints, differentials, drive shafts, and gear cases Body And Frame: Body panels, plastics, frame inspection, repair, mounting points Steering And Suspension: Handlebars, steering stem, tie rods, A-arms, shocks, springs, bushings, and wheel bearings Brakes: Hydraulic brake system, master cylinders, calipers, rotors, brake lines, pads, and parking brake Electrical: Battery, charging system, ignition system, lighting, starter motor, fuses, relays, and accessories Wiring Diagrams: Comprehensive electrical wiring diagrams for all systems Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication, and general upkeep Troubleshooting: System-specific troubleshooting guides, diagnostic charts, and common problem resolutions Repair: Detailed step-by-step repair instructions for all major components and systems Installation: Procedures for component removal and installation Technical Depth Depth Of Coverage: Comprehensive, covering basic to advanced repair and diagnostics Content Type: Factory-level technical information, diagrams, exploded views, and specifications 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Image Resolution: High-quality images, diagrams, and illustrations Readability: Designed for clear viewing on various devices, printable Binding Type Binding: Digital download (N/A for physical binding) Paper Type Paper Quality: Digital download (N/A for physical paper type) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-Stroke SOHC Engine Displacement 400: 375cc to 400cc class (specific designation '400 H.O.') Engine Type 500: 4-Stroke SOHC Engine Displacement 500: 499cc to 500cc class (specific designation '500 H.O. EFI') Performance Horsepower Range: Approx. 26-36 HP (varies by specific model and tune) Torque Range: Approx. 28-34 lb-ft (varies by specific model) Fuel System Fuel Delivery System: Electronic Fuel Injection (EFI) for 500 models, Carbureted for some 400 variants (manual will cover specifics) Fuel Type: Unleaded Gasoline Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: Automatic (Polaris Variable Transmission - PVT) Gear Selection: High, Low, Neutral, Reverse Features Drive Modes: On-Demand All-Wheel Drive (AWD) / 2WD Engine Braking: Integrated engine braking via PVT system 📐 Dimensions Exterior Overall Length: Approx. 81-83 inches (varies by specific model, e.g., Touring) Overall Width: Approx....