🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 HO Year: 2012 Product Type: Workshop Service Repair Manual 👋 Introduction Market Position Positioning: The Polaris Sportsman line is a benchmark in the utility ATV market, known for its ruggedness, comfort, and capability in various terrains. The 400 and 500 HO models offer a balance of power and versatility for work and recreational use. Competitive Analysis Competitors: Competes with models from Honda (FourTrax), Yamaha (Grizzly), Can-Am (Outlander), and Kawasaki (Brute Force) in the mid-displacement utility ATV segment. Key Features Vehicle Features: Independent Front Suspension (IFS), Polaris Variable Transmission (PVT), On-Demand All-Wheel Drive (AWD), powerful ProStar engines, comfortable seating position, robust chassis. 📋 Manual Details Coverage Areas Primary Coverage: 2012 Polaris Sportsman 400 HO and 2012 Polaris Sportsman 500 HO Page Count Estimated Page Count: 500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed engine overhaul, diagnostics, fuel system, ignition system, lubrication system, cooling system. Transmission: CVT system, clutch inspection and service, gearbox maintenance. Drivetrain: All-Wheel Drive (AWD) system, differential service, driveshafts, U-joints, CV boots. Suspension: Front and rear suspension component inspection, shock absorber service, bushings, ball joints. Brakes: Hydraulic brake system service, caliper rebuild, brake line replacement, bleeding procedures. Electrical: Complete electrical system diagnostics, wiring diagrams, battery service, charging system, starter, lighting, switches, sensors. Fuel System: Fuel pump, fuel filter, carburetor/fuel injection system, fuel tank service. Cooling System: Radiator, fan, coolant hoses, thermostat, water pump service. Body And Frame: Frame inspection, plastic body panel removal/installation, seat service, handlebar maintenance. Steering: Steering column, tie rods, steering rack inspection and service. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, chain/belt adjustments, lubrication points. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides. Repair: Step-by-step repair procedures for all major components and systems. Overhaul: Complete engine and transmission rebuild instructions. Diagnostics: Detailed diagnostic procedures, including testing of electrical components and sensors. Carburetor Adjustment 500 Ho: Detailed procedures for adjusting or rebuilding the carburetor for optimal performance and fuel economy. Fuel Injection Diagnostics: If applicable to specific 400/500 HO variants, comprehensive EFI diagnostic procedures, including sensor testing and ECU codes. Suspension Geometry Adjustment: Information on caster, camber, and toe adjustments for optimal handling and tire wear. Technical Depth Depth: Comprehensive from basic maintenance to advanced engine and electrical system repairs. Suitable for professional mechanics and skilled DIY enthusiasts. Diagnostic Codes: Includes specific diagnostic trouble codes (DTCs) for EFI models and troubleshooting steps associated with them. Specifications Tables: Extensive tables of torque specifications, clearances, fluid capacities, and electrical resistance values. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick information retrieval. Print Quality Printability: Printable for physical use in a workshop environment. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, single-cylinder (specific displacement likely around 330cc-400cc for the 400 HO model, but manual would confirm exact designation and displacement). Engine Type 500 Ho: 4-stroke, SOHC, single-cylinder (Polaris HO - High Output, typically around 499cc). Performance Horsepower Estimation 400: Estimated 27-30 HP (precise figure in manual). Horsepower Estimation 500 Ho: Estimated 34-38 HP (precise figure in manual). Torque Estimation 500 Ho: Estimated 28-30 lb-ft (precise figure in manual). Fuel System Fuel Delivery: Carbureted (likely Mikuni BSR42 for 500 HO, specific carburetor for 400 detailed in manual) or Electronic Fuel Injection (EFI) depending on sub-model/region, which the manual will clarify. Cooling System Cooling Method: Liquid-cooled Ignition System Ignition Type: Electronic Ignition 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking Optional Gear Selection: High, Low, Neutral, Reverse, Park Features Drive System: Shaft Drive, On-Demand All-Wheel Drive (AWD) Fluid Specifications Cv Fluid: Polaris AGL Synthetic Gearcase Lubricant or equivalent (specific part number and capacity in manual). 📐 Dimensions Exterior Length: Approx. 81.9 in (208 cm) Width: Approx. 46 in (117 cm) Height: Approx. 45.3 in (115 cm) Weights Dry Weight: Approx. 660 lbs (299 kg) Ground Clearance: Approx. 11 in (28 cm) Cargo Front Rack Capacity: 100 lbs (45 kg) Rear Rack Capacity: 200 lbs (90 kg) Towing Towing Capacity: 1500 lbs (680 kg) Wheels And Tires Front Tire Size: 25 x 8-12 (typical, manual to confirm exact) Rear Tire Size: 25 x 10-12 (typical, manual to confirm exact) Wheelbase: Approx. 50.5 in (128 cm) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet ANSI standards (specific certification details in manual). Active Features Braking System: Hydraulic disc brakes front and rear. Engine Braking: Standard on PVT for downhill control. Passive Features Handlebars: Rolled and flaired handlebars for rider control and comfort. Footwells: Aggressive floorboard serrations for grip. 💡 Technology Features Infotainment Display Features: Digital odometer, speedometer, trip meter, tachometer, high-beam indicator, neutral indicator, reverse indicator, oil...