This manual covers the 2012 Sportsman 400 H.O., Sportsman 500 H.O., Sportsman Touring 500 H.O., and Sportsman Forest Tractor 500 EFI all-terrain vehicles (ATVs). The Sportsman line is renowned for its comfortable ride, robust chassis, and strong towing capabilities, making these models versatile for both work and recreational pursuits. Engineered for durability and performance, these utility ATVs offer a reliable platform for various demanding applications, building on a long-standing reputation in the powersports industry. This comprehensive Factory Service Manual provides detailed information essential for the maintenance, repair, and troubleshooting of your 2012 Sportsman ATV. It covers all major systems, including engine overhaul, drivetrain, braking, suspension, steering, and electrical systems. With step-by-step procedures, diagnostic guides, technical specifications, and torque values, this manual empowers owners and technicians to effectively maintain and repair their vehicles, ensuring optimal performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 H.O. / Sportsman 500 H.O. / Sportsman Touring 500 H.O. / Sportsman Forest Tractor 500 EFI Year: 2012 Vehicle Type: All-Terrain Vehicle (ATV) 👋 Introduction Market Position Market Segment: Mid-range to high-performance utility ATVs. Competitive Analysis Competitors: Honda Foreman, Yamaha Grizzly, Can-Am Outlander. Key Features Vehicle Strengths: Polaris Sportsman line is known for its comfortable ride, robust chassis, and strong towing capabilities, making them versatile for work and recreation. Manual Value Proposition Manual Benefit: Provides comprehensive, factory-level repair and maintenance information, empowering owners and technicians to perform a wide range of tasks, reducing reliance on expensive dealership service. 📋 Manual Details Coverage Areas Models Covered: • 2012 Polaris Sportsman 400 H.O. • 2012 Polaris Sportsman 500 H.O. • 2012 Polaris Sportsman Touring 500 H.O. • 2012 Polaris Sportsman Forest Tractor 500 EFI Page Count Page Count: 432 pages Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine overhaul, disassembly, assembly, lubrication, cooling system (coolant, radiator), fuel system (fuel injection, fuel pump, carburetor, pilot jet, main jet, mixture screw), ignition system (stator, magneto, coil, spark plug, electronic ignition), exhaust system, intake system, cylinder, piston, connecting rod, crank, crankshaft, flywheel, camshaft, valve clearance, timing. Drivetrain Systems: Drive train, primary reduction gear, transmission, clutch (primary, secondary), drive shaft, rear axle, front drive components, differentials, gearshift operation. Braking Systems: Brakes (front and rear), brake pads, brake rotors, hydraulic brake system components, brake fluid specifications, bleeding procedures. Suspension Steering Suspension And Steering: Front suspension (struts, forks), rear suspension (swingarm, linkage, struts), steering system, EPS (Electronic Power Steering) if applicable, steering handle, bogey system. Electrical Systems Electrical Systems: Electrical system overview, charging system (rectifier, battery, regulator), starter motor, lighting system (headlights, taillights), switches, fuses, wiring diagrams, schematics. Bodywork Chassis Bodywork And Chassis: Frame, body panels, fenders, plastic components, seat, storage, hull structure. Procedures Included Maintenance And Inspection: Scheduled maintenance, lubrication, fluid changes (engine oil, coolant, brake fluid), filter replacement, tire pressure checks, spark plug maintenance. Troubleshooting And Diagnostics: Problem identification, troubleshooting guides, error code explanations, no spark diagnosis, performance issues. Repair And Rebuild: Complete tear down and rebuild procedures for all major components, part replacement, assembly instructions, specific repair techniques. Installation: Installation guides for various accessories or replacement parts. Technical Depth Technical Depth: Comprehensive coverage from basic maintenance and troubleshooting to complete engine and transmission rebuilds. Includes detailed torque specifications, part diagrams, and exploded views. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Printable (no restrictions) Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Features Searchability: Searchable text for quick information retrieval. Navigation: Clickable chapters for easy navigation. Saving Options: Save/burn to disc capability (no restrictions). ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke Engine Configuration: Single-cylinder (likely SOHC or OHV depending on specific 500cc variant). Displacement: 400cc (for Sportsman 400 H.O.), 499cc (for Sportsman 500 H.O. models). Performance Horsepower: Approx. 29 HP (Sportsman 400 H.O.), Approx. 32 HP (Sportsman 500 H.O.) - exact figures vary. Torque: Not explicitly stated in product info, but typically around 25-30 ft-lbs for 400cc and 30-35 ft-lbs for 500cc models. Fuel System Fuel Delivery: EFI (Electronic Fuel Injection) for 500 EFI models; Carburetor for other models. Manual covers both fuel injection and carburetor tuning/repair. Recommended Fuel: Unleaded gasoline (minimum octane rating specified in manual, typically 87). Lubrication Engine Oil Type: Specified in manual; typically a high-quality synthetic or semi-synthetic 0W-40 or 10W-40 motorcycle/ATV oil meeting specific API/JASO standards. Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol based antifreeze with corrosion inhibitors (specified in manual). 🔧 Transmission Standard Transmission Type: Automatic (CVT - Continuously Variable Transmission) Transmission Features: High/Low range, Neutral, Reverse, Park (depending on model). Features Clutch Type: Primary and Secondary Clutch System (CVT belt drive). Transmission Fluid: Specified in manual; typically a dedicated CVT fluid or specific AWD fluid. 📐 Dimensions Exterior Length: Varies by model,...