This manual provides comprehensive service information for the 2012 Sportsman 400 HO Touring EFI, Sportsman 500 HO, Sportsman Touring 500 HO, and Sportsman Forest Tractor 500 EFI models. A renowned manufacturer in the recreational vehicle market, has engineered these ATVs to offer robust performance for utility and recreational purposes. The Sportsman line is recognized for its evolutionary advancements, providing owners with reliable and capable off-road machines. Key features across these models include Electronic Fuel Injection (EFI) for optimized power delivery and starting, Variable Transmission (PVT), and effective hydraulic disc braking systems. This service repair shop manual is designed as an authoritative resource for maintaining and repairing your 2012 Sportsman ATV. It covers essential areas such as engine and transmission servicing, chassis and suspension diagnostics, electrical system troubleshooting, and bodywork procedures. The manual includes detailed step-by-step instructions, factory specifications, exploded diagrams, and troubleshooting guides for common issues, including advanced diagnostics for the EFI system. It is an indispensable tool for owners and technicians aiming to ensure the longevity and optimal performance of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Touring EFI, Sportsman 500 HO, Sportsman Touring 500 HO, Sportsman Forest Tractor 500 EFI Year: 2012 Codes Product Name: Polaris 2012 Sportsman 400 500 HO Touring EFI Repair Service 👋 Introduction Market Position Market Position: This manual serves the utility and recreational ATV market, catering to owners who perform their own maintenance and repairs on Polaris Sportsman models. Competitive Analysis Competitive Analysis: A vital resource for owners of the 2012 Polaris Sportsman 400/500 HO series, offering factory-level technical data that is often more detailed and accurate than aftermarket alternatives. Key Features Key Features: Factory service data, detailed diagrams, step-by-step instructions, OEM specifications, EFI system coverage, and comprehensive troubleshooting for multiple 2012 Sportsman models. 📋 Manual Details Coverage Areas Applicable Models: Polaris Sportsman 400 HO (2012), Polaris Sportsman 500 HO (2012), Polaris Sportsman Touring 500 HO (2012), Polaris Sportsman Forest Tractor 500 EFI (2012) Page Count Estimated Page Count: Varies by specific model variant; typically 500-800+ pages for a comprehensive service manual. Manual Type Manual Type: Service Repair Shop Manual Language Language: English Format Format: Digital PDF Download Access Method: Digital download link via email within hours of payment confirmation. Usage Rights: Printable and copyable to multiple devices (computers, smartphones, tablets, flash drives, hard drives). 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission (PVT - Polaris Variable Transmission), Drive Train, Differentials, Axles, Final Drive Chassis: Frame, Suspension (Front and Rear), Steering System, Brakes (Hydraulic Disc), Wheels and Tires Electrical: Ignition System, Lighting, Starting System, Charging System, Battery, Instrumentation, Wiring Diagrams, EFI System Components Bodywork: Body Panels, Fenders, Racks, Seat, Controls, Handlebars Fuel System: Fuel Tank, Fuel Pump, Fuel Injectors, EFI Control Module, Fuel Lines Lubrication Cooling: Engine Oil System, Cooling System (Radiator, Fan, Coolant) Steering: Complete steering system diagnosis, repair, and adjustment procedures, including tie rods, steering shafts, and handle bar assembly. Shocks: Information on front and rear shock absorber service, adjustment, and replacement. Fuel System: Detailed EFI system components: ECU, sensors (TPS, MAP, IAT, ECT), fuel injectors, fuel pump, and pressure regulator. Procedures Included Maintenance: Scheduled Maintenance, Lubrication Points, Fluid Changes (Engine Oil, Transmission Fluid, Brake Fluid), Filter Replacements, Spark Plug Service, Tire Pressure Checks Repair: Engine Rebuilds (Top-end and Bottom-end), Transmission Overhaul, Brake System Repair, Suspension Component Replacement, Steering System Service, Electrical Component Diagnosis and Replacement Diagnostics: Troubleshooting Guides for Common Issues, EFI System Diagnosis, Electrical System Fault Finding, DTC (Diagnostic Trouble Code) Interpretation Assembly Disassembly: Complete Step-by-Step Procedures for Component Removal and Installation, Exploded Diagrams for Part Identification and Reassembly Engine Removal Installation: Detailed instructions for removing and reinstalling the engine, including all associated components and connections. Intake Exhaust: Procedures for servicing the air intake system, carburetor (if applicable to specific sub-models not detailed in description but common in the era), and exhaust system. Troubleshooting: Extensive 'Advanced Troubleshooting' section covering electrical, fuel, and mechanical issues. Technical Depth Technical Depth: Comprehensive coverage for professional technicians and knowledgeable DIY enthusiasts, including detailed procedures, OEM specifications, and diagnostic information. Oem Specifications: Includes critical OEM specifications such as torque values for fasteners, compression test ranges, piston ring end gap, valve clearances, and electrical connector pinouts. Diagnostic Charts: Includes diagnostic flowcharts and troubleshooting trees to systematically identify and resolve issues. Manual Type Manual Purpose: Factory authorized repair, maintenance, and diagnostic procedures for servicing the specified Polaris Sportsman models. 📊 Manual Specifications File Format File Format: PDF (.pdf) Print Quality Print Quality: Printable. High-resolution digital images and text for clear reproduction. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-Stroke Single Cylinder SOHC, Electronic Fuel Injection (EFI) Engine Type 500: 4-Stroke Single Cylinder SOHC, Electronic Fuel Injection (EFI) Performance Bore Stroke 400: Refer to manual for specific...