This manual covers the 2012 Sportsman 400 / 500 HO, a versatile utility all-terrain vehicle renowned for its durability and performance. Designed for recreational riders, hunters, farmers, and utility users, the Sportsman offers robust construction and capable off-road handling across various terrains and tasks. Its engineering emphasizes reliability, making it a dependable choice for demanding conditions. Notable features include an On-Demand All-Wheel Drive system for enhanced traction, a powerful liquid-cooled engine available in 360 cc or 499 cc HO variants, and a comfortable design suitable for extended use. This comprehensive service and repair manual provides detailed information for maintaining and repairing your 2012 Sportsman. It covers all essential systems, including engine diagnostics and overhaul, transmission service, drivetrain components, suspension, brakes, electrical systems, and fuel and cooling systems. Within its over 500 pages, you will find step-by-step repair instructions, scheduled maintenance procedures, troubleshooting guides with diagnostic flowcharts, and essential technical specifications such as torque values and fluid capacities. This manual is an invaluable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman Model Variant: 400 / 500 HO Year: 2012 Codes Product Code Reference: SP012 👋 Introduction Market Position Category: Utility All-Terrain Vehicle (ATV) Target Audience: Recreational riders, hunters, farmers, utility users Competitive Analysis Competitors: Can-Am Outlander, Yamaha Grizzly, Honda Foreman, Arctic Cat Prowler Key Features Versatility: Suitable for various terrains and tasks, from trail riding to hauling Durability: Renowned for robust construction and reliability in demanding conditions Performance: Balanced power delivery and capable off-road handling 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: 500+ Manual Type Manual Scope: Factory Authorized Service Manual 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, and overhaul of 400cc and 500 HO engines Transmission: Service and repair of the Automatic Transmission (PVT) and final drive Drivetrain: Front and Rear Drive System, Driveshafts, CV Joints, Differential Suspension: Front and Rear Suspension components, Shock Absorbers, Bushings, Ball Joints Brakes: Hydraulic Brake System, Calipers, Rotors, Master Cylinder, Bleeding Procedures Electrical System: Ignition, Starting System, Charging System, Lighting, ECU, Wiring Diagrams Fuel System: Fuel Injection System (EFI), Fuel Pump, Injectors, Fuel Filter Cooling System: Radiator, Fan, Water Pump, Thermostat, Coolant Specifications Exhaust System: Muffler, Exhaust Pipes, Catalytic Converter (if applicable) Frame And Bodywork: Frame inspection, Body panel removal/installation, Fenders, Racks Steering: Handlebar assembly, Steering shaft, Tie Rods, Rack and Pinion (if applicable) Wheels And Tires: Tire specifications, Wheel torque, Bearing maintenance Procedures Included Maintenance: Scheduled maintenance, Oil changes, Filter replacements, Lubrication Troubleshooting: Diagnostic flowcharts for common problems and symptoms Repair: Step-by-step instructions for component removal, repair, and reinstallation Rebuilds: Complete engine and transmission overhaul procedures Technical Specifications: Torque values, Clearances, Gap settings, Fluid capacities Wiring Diagrams: Detailed electrical schematics for all systems Technical Depth Depth: Comprehensive from basic maintenance to complete engine rebuilds and advanced diagnostics 📊 Manual Specifications File Format Format: Digital PDF Searchability: Searchable text for quick information retrieval Print Quality: High-resolution scans, suitable for printing Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, Single Cylinder Displacement 400: 360 cc Engine Type 500: 4-stroke, SOHC, 4-valve, Single Cylinder, High Output (HO) Displacement 500: 499 cc Performance Horsepower 400: Approx. 30 HP Horsepower 500 Ho: Approx. 39 HP Cooling System: Liquid-Cooled Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 Octane) Ignition Ignition Type: Electronic Ignition 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Automatic Gear Selection: High, Low, Neutral, Reverse, Park Features Drive Modes: On-Demand All-Wheel Drive (AWD) / 2WD Engine Braking: Integrated Engine Braking 📐 Dimensions Exterior Length: 81 in (205.7 cm) Width: 46 in (116.8 cm) Height: 47 in (119.4 cm) Wheelbase: 50.5 in (128.3 cm) Ground Clearance: 11.5 in (29.2 cm) Weights Dry Weight: 660 lbs (299.4 kg) Towing Capacity: 1500 lbs (680.4 kg) Rack Capacity Front: 50 lbs (22.7 kg) Rack Capacity Rear: 100 lbs (45.4 kg) Cargo Cargo Bed Type: Rear Cargo Rack 🛡️ Safety Features Ratings Safety Standard: Meets ANSI/ROHVA standards for recreational off-highway vehicles Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Drive System: On-Demand AWD for enhanced traction Passive Features Lighting: Dual Halogen Headlights, Single LED Taillight Ergonomics: Comfortable seating and handlebar position for extended use 💡 Technology Features Infotainment Instrument Cluster: Digital instrument cluster with speedometer, tachometer, odometer, trip meter, fuel gauge, high beam indicator, neutral indicator, reverse indicator, AWD indicator. Driver Assistance AWD System: On-Demand All-Wheel Drive (AWD) engages front wheels automatically when rear wheels lose traction. Connectivity Charging Port: 12V DC outlet for charging accessories. 🔧 Maintenance Service Intervals Oil Change Interval: Every 100 hours or 6 months (refer to manual for specific...