This manual covers the 2012 All-Terrain Vehicles. These utility ATVs are renowned for their durability, versatility, and robust construction, making them ideal for a wide range of applications including farming, hunting, trail riding, and property maintenance. The line has a strong legacy in the market, consistently recognized for its off-road capability and reliable performance in demanding conditions. This comprehensive factory shop manual provides detailed information essential for the maintenance and repair of your 2012. It includes in-depth coverage of all major systems, such as the engine, transmission, drivetrain, fuel, electrical, cooling, braking, suspension, and chassis. You will find step-by-step procedures for routine maintenance, component diagnosis, overhaul instructions, and troubleshooting guides. This manual is an invaluable resource for owners, mechanics, and technicians seeking to ensure their vehicle operates at peak performance and longevity, with factory-level detail and accuracy. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400/500 Year: 2012 Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Vehicle Segment: Utility ATV, known for its versatility in work and recreational applications. Competitive Analysis Key Competitors: Competed with models from Can-Am (Outlander), Honda (FourTrax/Rancher), Yamaha (Grizzly), and Suzuki (KingQuad) in the utility ATV segment. Key Features Versatility: Designed for a wide range of tasks including farming, hunting, trail riding, and property maintenance. Durability: Polaris Sportsman line is generally recognized for its robust construction and reliability in demanding conditions. Indexing Importance: This manual is crucial for owners and technicians to maintain and repair these capable ATVs effectively, ensuring longevity and optimal performance. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for 2012 Polaris Sportsman 400 and 500 models. Page Count Estimated Page Count: Likely 300-500 pages (typical for a factory shop manual). Manual Type Manual Type: Factory Shop Manual / Service Manual Language Language: English (as indicated by product description and typical for factory manuals). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service: Detailed procedures for engine disassembly, assembly, troubleshooting, and component replacement. Transmission And Drivetrain: Coverage of transmission, differential, axle, and driveshaft maintenance and repair. Fuel System: Information on fuel pump, carburetor/fuel injection, fuel filter, and fuel tank servicing. Electrical System: Wiring diagrams, component testing, troubleshooting for ignition, lighting, charging, and accessories. Cooling System: Radiator, fan, coolant hoses, and thermostat service procedures. Braking System: Hydraulic brake system service, including master cylinder, calipers, lines, and bleeding procedures. Suspension And Steering: Front and rear suspension component inspection, replacement, and wheel alignment. Chassis And Body: Frame inspection, body panel removal and installation, and seat servicing. Maintenance Procedures: Routine maintenance tasks, lubrication points, and inspection schedules. Troubleshooting Guides: Diagnostic charts and common issue resolution for various systems. Procedures Included Preventative Maintenance: Detailed schedules and instructions for oil changes, filter replacements, and fluid checks. Component Diagnosis: Step-by-step diagnostic procedures for identifying faulty components. Overhaul Instructions: Complete disassembly and reassembly instructions for major components like the engine and transmission. Special Tool Identification: Specification of required special tools for specific repair procedures. Technical Depth Depth Of Information: Factory-level detail, suitable for professional technicians and experienced DIY mechanics. Diagnostic Capabilities: Advanced diagnostic procedures, including electrical system testing and fault code interpretation (if applicable). Repair Accuracy: Authoritative information for ensuring repairs are performed to factory specifications. 📊 Manual Specifications File Format File Format: PDF Print Quality Image Resolution: High-resolution illustrations and schematics for clarity. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Likely searchable text within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type 400: Single-cylinder, 4-stroke, SOHC (Sportsman 400 typically used a ~375cc or ~455cc engine depending on variant). Engine Type 500: Single-cylinder, 4-stroke, SOHC, typically around 499cc to 500cc, often carbureted or EFI depending on specific sub-model/region. Performance Horsepower Estimate 400: Estimated 25-30 HP (varies by specific engine configuration). Horsepower Estimate 500: Estimated 30-35 HP (varies by specific engine configuration). Fuel System Fuel Delivery 400: Likely carbureted (e.g., Mikuni or Keihin), though some later 400s may have received EFI. Fuel Delivery 500: Typically electronic fuel injection (EFI) for 2012 models, providing better throttle response and fuel efficiency. Some variants might still be carbureted. Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Optional Drive Modes: Selectable 2WD/4WD, often with AWD (All-Wheel Drive) engagement. Features Gear Selection: High, Low, Neutral, Reverse, Park. Clutch Type: Primary and secondary clutch system for CVT operation. 📐 Dimensions Exterior Length: Approx. 83 inches (210.8 cm) - varies slightly by specific model variant. Width: Approx. 46 inches (116.8 cm). Height: Approx. 45 inches (114.3 cm). Weights Dry Weight: Approx. 600-650 lbs (272-295 kg) - varies by model and equipment. Towing Capacity: Typically 1500 lbs (680 kg). Cargo Capacity Rack Front: Approx. 100 lbs (45 kg). Cargo Capacity Rack Rear: Approx. 200 lbs (90 kg). 🛡️ Safety Features Ratings Atv...