The Polaris Sportsman 400, 450, and 500 series ATVs, produced between 2012 and 2013, represent a versatile lineup of utility all-terrain vehicles. These models are engineered to provide a robust balance of signature handling and a practical feature set, making them suitable for a wide range of applications including recreational riding, farming, hunting, and general trail use. They offer a compelling value proposition within their segment, known for their reliable performance and adaptability to various terrains. The engineering quality is evident in their durable construction and the inclusion of features designed for rider comfort and operational efficiency. This electronic service manual provides comprehensive coverage for the complete Sportsman machine, catering to both dealership technicians and experienced owners. It details essential maintenance procedures, systematic troubleshooting guides, critical technical specifications, and important safety guidelines necessary for the upkeep and repair of these ATVs. The manual covers all major systems, including the engine, transmission, drivetrain, brakes, electrical systems, suspension, and chassis, offering step-by-step instructions for everything from routine servicing to complete component overhauls. Its thoroughness ensures that users can effectively maintain their vehicle's performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 450 / 500 Year: 2012-2013 Product Type: Electronic Service Manual 👋 Introduction Market Position Segment: Entry-level to mid-range utility All-Terrain Vehicles (ATVs) Target Audience: Recreational riders, utility users, farmers, hunters, and general trail riders Competitive Analysis Competitors: Yamaha Kodiak, Honda Foreman/Rancher, Can-Am Outlander/Outlander MAX, Kawasaki Brute Force Key Features Value Proposition: Offers a balance of Polaris's renowned handling and feature set at a more accessible price point compared to larger displacement models. Powertrain Flexibility: Covers multiple engine displacements (400, 450, 500cc), indicating common chassis and system designs across these variants. 📋 Manual Details Coverage Areas Overall Coverage: Complete machine Intended User: Dealership technicians and experienced owners Manual Type Type: Factory Electronic Service Manual (ESM) Language Language: English Format Format: Digital (likely PDF or proprietary software) 📖 Manual Coverage Systems Covered Engine: Engine assembly, disassembly, diagnosis, performance tuning, cooling system, lubrication system, fuel system, ignition system, starting system Transmission: PVT (Polaris Variable Transmission) operation, maintenance, belt inspection and replacement, clutch service, gearbox maintenance Drivetrain: All-Wheel Drive (AWD) system, On-Demand AWD, differential service, drive shafts, U-joints, wheel bearings Brakes: Hydraulic brake system, caliper service, pad replacement, master cylinder, brake fluid specifications, bleeding procedures Electrical: Wiring diagrams, lighting system, battery service, charging system, starter motor, ignition switch, accessories, diagnostic trouble codes (DTCs) Suspension: Front and rear suspension components, shock absorber adjustment and replacement, bushings, ball joints, steering components Chassis And Body: Frame inspection, body panel removal and installation, seat, handlebars, racks, plastics Fuel And Emissions: Fuel tank, fuel pump, fuel filter, carburetor/EFI system (depending on model variant), emission control components Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, greasing points, battery care, belt inspection Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides Repair And Overhaul: Detailed step-by-step instructions for component disassembly, repair, reassembly, and calibration Specifications: Torque specifications for all fasteners, clearances, measurements, fluid capacities, electrical specifications Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including electrical diagnostics 📊 Manual Specifications File Format Format: Digital (likely searchable PDF with integrated diagrams and schematics) Print Quality Quality: High-resolution images, clear diagrams, easily readable text (if printed) Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve (typical for these displacements) Displacement 400: Approximately 375cc - 400cc (Polaris often uses nominal figures) Displacement 450: Approximately 455cc Displacement 500: Approximately 499cc Cooling System: Liquid-cooled Bore X Stroke: Varies by specific engine, manual will detail this Compression Ratio: Varies by specific engine, manual will detail this (typically around 9.0:1 to 10.5:1) Performance Horsepower: Estimated 28-32 HP (for 400/450 models), 30-36 HP (for 500 models) - actual figures vary and are detailed in the manual Torque: Estimated 25-30 lb-ft (for 400/450 models), 30-35 lb-ft (for 500 models) - actual figures vary and are detailed in the manual Fuel System Fuel Delivery: Fuel Injection (EFI) for most 2012-13 models, potentially carburetors on earlier 400 variants not covered by this specific manual. Fuel Type: Unleaded gasoline, minimum 87 octane 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) Automatic Gears: High, Low, Neutral, Reverse, Park Features Drive Modes: 2WD/4WD On-Demand Final Drive: Shaft drive Fluid Specifications Fluid Type: Polaris AGL Synthetic Gearcase Lubricant (or equivalent SAE 80W-90 hypoid gear lubricant for specific gearcase applications) Fluid Capacities Gearcase Capacity: Refer to manual for exact capacity, typically around 1.0-1.2 liters 📐 Dimensions Exterior Wheelbase: Approximately 50.5 inches (128.3 cm) Length: Approximately 81 inches (205.7 cm) Width: Approximately 46 inches (116.8 cm) Height: Approximately 48 inches (121.9 cm) Cargo Front Rack Capacity: 200 lbs (90.7 kg) Rear Rack Capacity: 400 lbs (181.4 kg) Weights Dry...