🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO, Sportsman 400 HO Touring, Sportsman 500 HO, Sportsman 500 HO Forest Tractor, Sportsman 500 EFI Model Variants: 400 HO, 400 HO Touring, 500 HO, 500 HO Forest Tractor, 500 EFI Year: 2012, 2013 Codes Product Type: Service Repair Manual 👋 Introduction Market Position Positioning: The Polaris Sportsman line is a dominant force in the utility ATV market, known for its ruggedness, versatility, and rider comfort. This manual targets owners and technicians who require in-depth knowledge to maintain and repair these popular machines. Competitive Analysis Competitors: This manual covers models that compete with offerings from brands like Can-Am (Outlander), Yamaha (Grizzly), Kawasaki (Brute Force), and Suzuki (KingQuad) in the mid-to-large displacement utility ATV segment. Key Features Manual Benefits: Provides factory-level repair information, essential for accurate diagnostics, efficient repairs, and proper maintenance, ultimately saving time and money compared to guesswork or incomplete online resources. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and maintenance for all listed Polaris Sportsman models and variants. Page Count Estimated Page Count: Likely over 800 pages (based on typical comprehensive factory service manuals for ATVs). Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, transmission, driveline, final drive. Chassis: Frame, suspension (front and rear), steering system, wheels, tires, brakes (hydraulic, parking), body panels, racks. Electrical: Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, instrumentation, wiring diagrams, electronic control modules (ECMs/ECUs), sensors. Accessories & Other: Winch operation (if applicable), accessories installation, fluid capacities and specifications, lubrication points. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, lubrication, valve clearance checks. Troubleshooting: Diagnostic charts, symptom-based troubleshooting, common problem diagnosis and solutions. Repair & Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major systems. Component Specific Procedures: Engine rebuild procedures, transmission overhaul, carburetor/fuel injection adjustment and cleaning, brake caliper servicing, suspension component replacement. Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIY technicians. Covers everything from basic fluid checks to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans, clear diagrams, searchable text (typical for quality digital manuals). Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine 400 Ho Engine: Typically a 375cc, liquid-cooled, 4-stroke engine. Exact horsepower and torque figures vary slightly by year but generally around 25-30 HP. 500 Ho Engine: Typically a 499cc, liquid-cooled, 4-stroke, SOHC, 2-valve engine. Horsepower typically in the range of 30-36 HP, with torque figures around 27-30 lb-ft. 500 Efi Engine: Typically a 499cc, liquid-cooled, 4-stroke, SOHC, 2-valve engine with Electronic Fuel Injection (EFI). Similar performance to the carbureted 500 HO but with improved throttle response and fuel efficiency. Performance Bore Stroke 400: Approx. 82mm x 71.5mm (varies) Bore Stroke 500: Approx. 83mm x 92mm (varies) Fuel System Fuel Delivery 400: Carbureted (likely Mikuni BSR series, e.g., BSR34/36) Fuel Delivery 500 Efi: Electronic Fuel Injection (EFI) with throttle body and fuel pump Ignition System Ignition Type: Electronic CDI (Capacitor Discharge Ignition) Cooling System Cooling Method: Liquid-cooled with fan assist Oil Specifications Engine Oil Type: Typically SAE 5W-50 Synthetic or a high-quality ATV specific oil meeting Polaris standards (e.g., PS-4). 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse. Optional Optional Transmissions: N/A (CVT is standard for all listed models) Features Clutch System: Primary and secondary clutch system for automatic gear changes. Fluid Specs Transmission Fluid Type: Typically Polaris AGL Synthetic Gearcase Oil or equivalent. Check manual for specific part numbers and capacities. 📐 Dimensions Exterior Length: Approximately 83 inches for standard models, longer for Touring variants (e.g., 85-90 inches). Width: Approximately 46 inches. Height: Approximately 45 inches. Weights Dry Weight: Ranging from approximately 600 lbs (400 HO) to 700+ lbs (500 HO Touring). Ground Clearance: Typically around 10.25 inches. Cargo Front Rack Capacity: Typically 100 lbs. Rear Rack Capacity: Typically 200 lbs. Towing Towing Capacity: Typically 1500 lbs (receiver hitch rated). Payload Capacity: Typically 250-300 lbs. 🛡️ Safety Features Ratings Atv Safety Considerations: ATVs are not street legal. Operators must wear helmets and protective gear. Operate responsibly and be aware of terrain. Active Features Braking System: Hydraulically actuated disc brakes on all wheels. Single-lever front braking, foot-actuated rear braking. Parking brake on rear caliper. Traction Control: Standard AWD (All-Wheel Drive) system with Automatic Decoupling (ADC - Automatic Drive Control), which engages front drive when rear wheels slip. Passive Features Lighting: Dual 50W headlights, dual taillight/brake lights. Operator Safety: Anti-kickback steering mechanism, handlebar grips, throttle limiter (adjustable). 💡 Technology Features Infotainment Infotainment Systems: Minimal. Primarily focused...