🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400, Sportsman 500, Sportsman Touring 500, Sportsman Forest Tractor 500 Model Variant: H.O., EFI Model Years Covered: 2012, 2013 Codes Manual Product Code: Likely internal company designation, not publicly stated 👋 Introduction Market Position Positioning: The Polaris Sportsman line is a highly regarded and popular series of ATVs, known for their versatility, durability, and off-road capability. This manual caters to owners and technicians working on a key generation of these utility and recreational vehicles. Competitive Analysis Competitors: Competes directly with other major ATV manufacturers like Can-Am (Outlander series), Yamaha (Grizzly series), Honda (FourTrax series), and Suzuki (KingQuad series). Key Features Of Vehicles Features: The 2012-2013 Sportsman models are characterized by their robust chassis, capable suspension systems, reliable engines, and Polaris's signature on-demand AWD for superior traction. 📋 Manual Details Coverage Areas Systems Covered: Engine, Drivetrain (AWD/2WD systems), Transmission, Suspension (Front/Rear), Steering, Braking System, Electrical System (Ignition, Lighting, Accessories), Fuel System, Cooling System, Chassis, Bodywork, Diagnostic Procedures, Troubleshooting, Maintenance, Lubrication, Specifications, Torque Values, Special Tools. Page Count Total Pages: 432 Manual Type Type: Original Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures for engine components including cylinder head, valve train, pistons, connecting rods, crankshaft, lubrication system, and cooling system. Engine Performance: Detailed information on fuel delivery, ignition timing, emissions controls, and diagnostic procedures for optimal performance. Drivetrain: In-depth coverage of the AWD system, including front and rear differentials, drive shafts, CV joints, and engagement mechanisms. Transmission: Repair and maintenance of the Polaris Variable Transmission (PVT), including clutch inspection, belt replacement, and gearcase lubrication. Suspension: Front and rear suspension service, including shock absorber replacement, spring adjustments, A-arm maintenance, and wheel bearing service. Steering: Detailed procedures for steering column, tie rod, and handlebar assembly maintenance and repair. Includes information on EPS (Electronic Power Steering) if applicable to specific models. Braking System: Front and rear brake caliper, rotor, and brake line service. Includes bleeding procedures and fluid specifications. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, voltage regulator), starter motor, lighting system, and accessory circuits. Fuel System: Fuel tank, fuel pump, fuel filter, and fuel injector service (for EFI models). Carburetor service for carbureted models. Chassis Frame: Frame inspection, component mounting, and alignment checks. Bodywork Plastics: Removal, installation, and repair of body panels, fenders, racks, and trim pieces. Procedures Included Maintenance: Scheduled maintenance tasks such as oil changes, filter replacements, spark plug service, air filter cleaning/replacement, and lubrication points. Troubleshooting: Systematic diagnostic flowcharts and common issue resolution for electrical, mechanical, and performance problems. Repair Rebuild: Complete step-by-step instructions for disassembly, inspection, repair, and reassembly of all major vehicle components. Diagnostics: Detailed procedures for identifying and rectifying faults using diagnostic charts and specifications. Wiring Diagrams: Comprehensive electrical schematics for all model year variants covered, illustrating component connections and circuit functions. Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Suitable for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if produced by the manufacturer or a reputable publisher, allowing for quick information retrieval. Print Quality Quality: High-resolution scans of original factory documentation, ensuring clarity of text, diagrams, and illustrations. Binding Type Type: N/A (PDF Download) Paper Type Type: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 4-valve, Single Cylinder, Liquid-Cooled Engine Displacement 400: Approx. 401cc (Actual displacement may vary slightly based on specific H.O. tuning) Engine Type 500: 4-stroke, SOHC, 4-valve, Single Cylinder, Liquid-Cooled Engine Displacement 500: Approx. 499cc Performance Horsepower Estimate 400: Estimated 25-30 HP (Subject to specific tuning and model year) Horsepower Estimate 500: Estimated 30-35 HP (Subject to specific tuning and model year) Torque Characteristics: Designed for strong low-end and mid-range torque for pulling and climbing. Fuel System Fuel Delivery 400 Ho: Fuel Injection (EFI) for most 2012-2013 H.O. models, potentially carbureted for base models or specific configurations not explicitly listed. Fuel Delivery 500 Ho: Fuel Injection (EFI) for most 2012-2013 H.O. models. Fuel Type: Unleaded Gasoline Engine Codes Engine Identifier 400: Likely 'R3A' or similar Polaris internal engine code for the 400cc unit. Engine Identifier 500: Likely 'R3B' or similar Polaris internal engine code for the 500cc unit. Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with Engine Braking Optional Optional Types: N/A for this generation's primary Sportsman models; PVT is standard across the range. Features Gear Selection: High, Low, Neutral, Reverse, Park Drive Modes: 2WD / AWD (On-Demand) Maintenance Fluid Type: Polaris AGL Synthetic Gearcase Lubricant (or equivalent specified in manual) Fluid Capacity: Refer to manual for specific gearcase oil capacity, typically around 0.5 liters. Belt Replacement Interval: Recommended at 2400 miles or 24 months, or sooner if signs of wear are present. 📐...