The Sportsman 400 H.O. and Sportsman 500 H.O. are versatile All-Terrain Vehicles (ATVs) produced for the 2012 and 2013 model years. These ATVs are engineered for a blend of utility and recreational riding, offering robust performance and signature comfort features, including Independent Rear Suspension (IRS) and the Variable Transmission (PVT). With their substantial towing capacity and cargo rack capabilities, they are well-suited for tasks such as hauling, hunting, and trail exploration. The H.O. designation signifies enhanced power output for their respective classes, making them capable performers in challenging terrains. This comprehensive workshop service repair manual provides detailed guidance for maintaining and repairing your Sportsman 400/500 H.O. ATV. It covers a wide array of systems, including engine overhaul, transmission service, drivetrain maintenance, suspension and brake system repairs, and electrical troubleshooting. Within its pages, you will find step-by-step procedures for routine maintenance tasks, assembly and disassembly instructions, and critical technical specifications such as torque values and fluid capacities. This manual is an essential resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 H.O. Model Variant: H.O. (High Output) Vehicle Type: ATV (All-Terrain Vehicle) Codes Product Identifier: Polaris Sportsman 400 500 H.O. ATV Complete Workshop Service Repair Manual 2012 2013 PDF Download 👋 Introduction Market Position Positioning: The Polaris Sportsman 400/500 H.O. models are positioned as versatile, mid-size ATVs catering to utility and recreational riders, known for their robust performance and Polaris's signature comfort features. Competitive Analysis Competitors: Competes with models from Can-Am (Outlander series), Honda (FourTrax Rancher/Rubicon), Yamaha (Grizzly), and Kawasaki (Brute Force). Key Features Features: Independent Rear Suspension (IRS), Polaris Variable Transmission (PVT), On-Demand AWD, powerful engine options for their class, comfortable seating, and ample carrying capacity. 📋 Manual Details Coverage Areas Years Covered: 2012, 2013 Page Count Estimated Pages: Likely 300-500+ pages (typical for a complete workshop manual) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Engine overhaul, tuning, diagnostics, cooling system, lubrication system, fuel system (carbureted/EFI), ignition system, starting system, exhaust system. Transmission: PVT (Polaris Variable Transmission) operation, clutch inspection and adjustment, drive belt service, gearbox maintenance and repair. Drivetrain: All-Wheel Drive (AWD) system, front and rear differentials, axle shafts, U-joints, drive shafts, final drive units. Suspension: Front and rear suspension components, shocks, struts, control arms, bushings, bearings, alignment procedures. Brakes: Hydraulic brake system, master cylinder, calipers, brake pads, brake lines, parking brake, bleeding procedures. Electrical: Battery, charging system (stator, regulator/rectifier), starting system (starter motor), lighting, ignition switch, CDI unit, wiring diagrams, troubleshooting electrical faults. Fuel System: Fuel tank, fuel pump, fuel filter, fuel lines, carburetor (if applicable) or EFI system components (injectors, throttle body). Steering: Handlebar assembly, steering shaft, tie rods, ball joints, steering knuckle, troubleshooting steering play or stiffness. Bodywork: Body panels, fenders, racks, seat, plastics, trim removal and installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, lubrication points, tire pressure checks, battery maintenance, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common problems, fault finding based on symptoms, error code interpretation (if applicable). Repair Overhaul: Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper rebuild, electrical component replacement. Assembly Disassembly: Step-by-step instructions for disassembling and reassembling major vehicle components and systems. Technical Specifications: Torque specifications for fasteners, clearances, gap settings, fluid capacities, electrical system specifications. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: High-resolution, enabling clear viewing of diagrams and text. Designed for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve, Single Cylinder (Liquid-Cooled) Bore X Stroke 400: Approximately 83mm x 71.6mm (150cc class variant may differ slightly) Bore X Stroke 500: Approximately 92.9mm x 71.6mm (499cc class) Displacement 400: Typically around 297cc (specific H.O. designation might refer to tuning or slight displacement variation) Displacement 500: 499cc Performance Horsepower 400 Est: Approx. 25-30 HP Horsepower 500 Est: Approx. 34-39 HP Torque Est: Varies by model, but designed for strong low-end and mid-range torque for utility and trail riding. Fuel System Fuel Delivery: Carbureted (likely Mikuni) or Electronic Fuel Injection (EFI) depending on specific sub-model/trim. Manual will cover both if applicable. Fuel Type: Unleaded Gasoline (87 Octane or higher recommended) 🔧 Transmission Standard Type: Polaris Variable Transmission (PVT) with Engine Braking Optional Options: N/A (PVT is standard) Features Gear Selection: High, Low, Neutral, Reverse, Park Drive Belt Service: Crucial maintenance item covered in detail, including inspection, tension, and replacement procedures. 📐 Dimensions Exterior Length: Approx. 83 in. (210.8 cm) Width: Approx. 46 in. (116.8 cm) Height: Approx. 48 in. (121.9 cm) (Seat height...