This manual covers the 2012 models, including the Touring and Forest Tractor EFI. These utility ATVs are renowned for their robust engineering, featuring on-demand All-Wheel Drive, Independent Rear Suspension, and powerful SOHC engines. Built for demanding tasks, trail riding, and work, the line offers significant towing and rack capacity, along with a comfortable operator experience. Key features include an engine braking system and heavy-duty racks for cargo transport, embodying a commitment to durable and capable off-road vehicles. This comprehensive service repair manual provides detailed guidance for maintaining and repairing your 2012 ATV. It encompasses all major systems, including the powertrain, chassis, body, and electrical components, offering step-by-step procedures for disassembly, assembly, and troubleshooting. Essential maintenance schedules, fluid specifications, and diagnostic information are clearly outlined. This manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their ATV. 🏷️ 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 Tractor 500 EFI Year: 2012 Codes Chassis Code: Model year 2012 Generation Generation Identifier: Polaris Sportsman (Gen 3/4 500 Series based) 👋 Introduction Market Position Segment: Utility ATV Target Audience: Owners, maintenance personnel, and mechanics working on 2012 Polaris Sportsman 400/500 models for work, hunting, trail riding, and utility tasks. Competitive Analysis Competitors At Time: Honda FourTrax, Yamaha Kodiak/Grizzly, Can-Am Outlander/Renegade, Kawasaki Brute Force. Key Features Of Vehicles Atv Features: • On-Demand All-Wheel Drive (AWD) or True All-Wheel Drive (AWD) with VersaTrac. • Independent Rear Suspension (IRS). • Pro-Ride™ front suspension. • Engine braking system. • Heavy-duty racks for cargo. • Optional power steering on some models. • Towing and payload capabilities. 📋 Manual Details Coverage Areas Covered Models: • 2012 Polaris Sportsman 400 H.O. • 2012 Polaris Sportsman 500 H.O. • 2012 Polaris Sportsman Touring 500 H.O. • 2012 Polaris Sportsman Forest Tractor 500 EFI Page Count Total Pages: 432 Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: • Engine: Complete overhaul, disassembly, assembly, bore, piston, rings, crankshaft, camshaft, valve train, cooling system, lubrication system, fuel system (carbureted and EFI), ignition system, exhaust system. • Transmission: Gearbox disassembly, assembly, troubleshooting, lubrication, maintenance. • Drivetrain: Driveshafts, CV joints, differential, clutch system, belt drive maintenance. Chassis And Body: • Suspension: Front and rear suspension, shock absorbers, springs, bushings, adjustment procedures. • Steering: Steering system components, tie rods, steering column, wheel alignment. • Brakes: Hydraulic brake system, calipers, master cylinder, brake pads, brake lines, bleeding procedures. • Wheels and Tires: Tire pressure, tire wear, wheel installation, bolt patterns. • Frame and Bodywork: Plastics, body panels, mounting, removal, seat assembly. Electrical: • Wiring Diagrams: Comprehensive electrical schematics. • Ignition System: Spark plugs, coils, CDI unit. • Charging System: Stator, rectifier/regulator, battery maintenance. • Starting System: Starter motor, starter solenoid. • Lighting: Headlights, taillights, brake lights, auxiliary lighting. • Instrumentation: Speedometer, odometer, fuel gauge, warning lights. • Accessories: Winch operation, hand warmers, other electrical accessories. Cooling System: Radiator, coolant, fan operation, thermostat, hoses, bleed procedures. Lubrication System: Oil pump, oil filter, oil passages, oil cooler (if applicable). Procedures Included Maintenance: • Regular scheduled maintenance. • Oil and filter changes. • Coolant checks and changes. • Spark plug replacement. • Air filter cleaning and replacement. • Battery maintenance and charging. • Brake fluid checks and replacement. • Lubrication points and schedules. Repair And Troubleshooting: • Engine diagnostics and repair. • Transmission and drivetrain troubleshooting. • Suspension and steering repair. • Brake system repair. • Electrical system troubleshooting. • Component disassembly and reassembly. • Troubleshooting guides for common problems. Troubleshooting Guides: Detailed flowcharts and symptom-based diagnostics for common issues across all systems. Assembly Disassembly: Step-by-step instructions for complete component disassembly and reassembly, including torque specifications. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance and basic repairs to complete engine and transmission overhauls, including detailed troubleshooting steps and diagnostic procedures. Suitable for both DIY enthusiasts and professional technicians. Electrical Diagnostics: Component testing, voltage checks, continuity testing, troubleshooting electrical faults. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (typical for quality PDF manuals) Printable: Yes File Size: Variable, but typically optimized for download (e.g., 30-100MB). Print Quality Quality: High resolution, clear diagrams and text. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, single-cylinder Engine Type 500: 4-stroke, SOHC, 2-valve, single-cylinder Displacement 400: 375cc (approx.) Displacement 500: 499cc (approx.) Bore X Stroke 500: Approx. 93.25 mm x 73.0 mm (specific values covered in manual) Cooling System: Liquid-cooled Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower 500: Approx. 33 HP (specific values covered in manual) Torque 500: Approx. 29.6 lb-ft (specific values covered in manual) Fuel...