Polaris Sportsman 400 500 HO Touring Forest Tractor ATV Complete Workshop Service Repair Manual 2012 2013

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Touring Forest Tractor Model Year: 2012, 2013 Codes Product Identifier: Polaris Sportsman 400 500 HO Touring Forest Tractor ATV Complete Workshop Service Repair Manual 2012 2013 PDF Download 👋 Introduction Market Position Positioning: Targeted at owners and technicians of the Polaris Sportsman 400 HO Touring Forest Tractor ATV, providing essential technical information for maintenance and repair. The 'Forest Tractor' designation suggests a focus on utility and durability in demanding environments. Competitive Analysis Competitors: Competes with other utility ATVs from manufacturers like Can-Am (Outlander series), Honda (FourTrax series), Yamaha (Grizzly series), and Kawasaki (Mule series). This manual provides specific expertise for Polaris models. Key Features Manual Value: Comprehensive coverage, detailed diagrams, troubleshooting guides, and specifications crucial for maintaining the performance and longevity of the ATV. Essential for cost-effective repairs and proactive maintenance. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, Maintenance, Troubleshooting, Diagnostics, Wiring Diagrams, Specifications, Exploded Views Specific Components: Engine, Transmission, Drivetrain, Suspension, Brakes, Steering, Electrical System, Fuel System, Cooling System, Chassis, Bodywork, Accessories Page Count Estimated Pages: Extensive (typical for complete workshop manuals covering multiple years and models; exact page count not specified in product description but expected to be several hundred) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, inspection, internal component specifications, piston rings, crankshaft, camshaft, valve train, cylinder head, block, oil pump, timing system. Fuel System: Carburetor (or EFI system if applicable), fuel pump, fuel filter, fuel lines, tank, venting system, emissions control. Cooling System: Radiator, fan, water pump, thermostat, coolant hoses, coolant specifications, bleeding procedures. Ignition System: Ignition coil, spark plugs, CDI unit, stator, ignition timing, troubleshooting. Drivetrain: All-Wheel Drive (AWD) system, 2WD/4WD engagement, differential systems (front and rear), axle shafts, CV joints, drive shafts. Transmission Drivetrain: Automatic Transmission (PVT - Polaris Variable Transmission), clutch system (drive clutch, driven clutch), belt inspection and replacement, gear case lubrication, shifting mechanisms. Suspension: Front and rear suspension components, shock absorbers, springs, bushings, control arms, alignment specifications, adjustment procedures. Steering: Handlebar assembly, steering linkage, tie rods, steering column, steering stops, troubleshooting steering play or binding. Braking System: Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, brake discs, parking brake, bleeding procedures, fluid specifications. Electrical System: Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, wiring diagrams, fuse box, diagnostic connectors. Chassis Frame: Frame inspection, welds, mounts, protective components, skid plates, hitch systems. Bodywork Plastics: Body panels, fenders, racks, seat assembly, dashboard, removal and installation procedures. Procedures Included Basic Maintenance: Oil changes, filter replacements, chain adjustment (if applicable), spark plug replacement, air filter cleaning/replacement, tire pressure checks, lubrication points. Routine Service: Scheduled maintenance checks, belt inspection, brake fluid flush, coolant flush, valve clearance adjustment (if applicable). Engine Repair: Complete engine rebuilds, piston and ring replacement, crankshaft and connecting rod repair, cylinder head gasket replacement, timing chain/belt service. Transmission Service: PVT belt replacement, clutch service, transmission oil change, gear case rebuilds (if applicable). Drivetrain Repair: CV joint boot replacement, axle shaft replacement, differential service, AWD system troubleshooting. Suspension And Steering Repair: Shock absorber replacement, bushing replacement, wheel bearing replacement, tie rod end replacement, steering system adjustment. Brake System Overhaul: Brake pad replacement, caliper rebuild, master cylinder replacement, brake line replacement, bleeding the hydraulic system. Electrical Diagnostics: Troubleshooting starting issues, charging system problems, lighting faults, using wiring diagrams to trace circuits. Troubleshooting Guides: Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting tables. Wiring Diagrams: Detailed electrical schematics for all systems, including color coding and component identification. Technical Depth Depth: Comprehensive: Covers everything from basic preventive maintenance and fluid changes to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. Suitable for both DIY enthusiasts and professional technicians. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely searchable text (if created from original digital source), allowing for quick keyword searches. Print Quality Quality: High-resolution scans or original digital files, ensuring clarity of text, diagrams, and illustrations. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke Single Cylinder (likely SOHC or OHC) Engine Displacement: 400cc and 500cc HO (High Output) variants. Bore X Stroke: Specifications vary by exact engine displacement, but typical for this class. Manual will contain precise measurements. Cooling System: Liquid-Cooled Engine Oil Type: Polaris PS-4 4-stroke synthetic oil (typically SAE 0W-40 or 10W-40, refer to manual for specific viscosity and API service classification) Engine Oil Capacity: Approx. 2.0-2.5 quarts (1.9-2.4 liters) with filter. Manual will confirm exact capacity. Spark Plug Type: NGK CR7HSA or equivalent (verify with manual) Performance Horsepower: Approx. 27-30 HP for 400cc, Approx. 32-35 HP for 500 HO (estimated, exact figures in manual)...

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Type: Atv

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Sku: 74486

Collections: ALL ATV Powersports

Availability: In stock

Tags: 2012 2013 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500 HO Touring Forest Tractor

Product variants

Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 HO Touring Forest Tractor

Model Year:

2012, 2013

Codes

Product Identifier:

Polaris Sportsman 400 500 HO Touring Forest Tractor ATV Complete Workshop Service Repair Manual 2012 2013 PDF Download

👋 Introduction

Market Position

Positioning:

Targeted at owners and technicians of the Polaris Sportsman 400 HO Touring Forest Tractor ATV, providing essential technical information for maintenance and repair. The 'Forest Tractor' designation suggests a focus on utility and durability in demanding environments.

Competitive Analysis

Competitors:

Competes with other utility ATVs from manufacturers like Can-Am (Outlander series), Honda (FourTrax series), Yamaha (Grizzly series), and Kawasaki (Mule series). This manual provides specific expertise for Polaris models.

Key Features

Manual Value:

Comprehensive coverage, detailed diagrams, troubleshooting guides, and specifications crucial for maintaining the performance and longevity of the ATV. Essential for cost-effective repairs and proactive maintenance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service, Repair, Maintenance, Troubleshooting, Diagnostics, Wiring Diagrams, Specifications, Exploded Views

Specific Components:

Engine, Transmission, Drivetrain, Suspension, Brakes, Steering, Electrical System, Fuel System, Cooling System, Chassis, Bodywork, Accessories

Page Count

Estimated Pages:

Extensive (typical for complete workshop manuals covering multiple years and models; exact page count not specified in product description but expected to be several hundred)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, inspection, internal component specifications, piston rings, crankshaft, camshaft, valve train, cylinder head, block, oil pump, timing system.

Fuel System:

Carburetor (or EFI system if applicable), fuel pump, fuel filter, fuel lines, tank, venting system, emissions control.

Cooling System:

Radiator, fan, water pump, thermostat, coolant hoses, coolant specifications, bleeding procedures.

Ignition System:

Ignition coil, spark plugs, CDI unit, stator, ignition timing, troubleshooting.

Drivetrain:

All-Wheel Drive (AWD) system, 2WD/4WD engagement, differential systems (front and rear), axle shafts, CV joints, drive shafts.

Transmission Drivetrain:

Automatic Transmission (PVT - Polaris Variable Transmission), clutch system (drive clutch, driven clutch), belt inspection and replacement, gear case lubrication, shifting mechanisms.

Suspension:

Front and rear suspension components, shock absorbers, springs, bushings, control arms, alignment specifications, adjustment procedures.

Steering:

Handlebar assembly, steering linkage, tie rods, steering column, steering stops, troubleshooting steering play or binding.

Braking System:

Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, brake discs, parking brake, bleeding procedures, fluid specifications.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlights, taillights, indicators), horn, wiring diagrams, fuse box, diagnostic connectors.

Chassis Frame:

Frame inspection, welds, mounts, protective components, skid plates, hitch systems.

Bodywork Plastics:

Body panels, fenders, racks, seat assembly, dashboard, removal and installation procedures.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, chain adjustment (if applicable), spark plug replacement, air filter cleaning/replacement, tire pressure checks, lubrication points.

Routine Service:

Scheduled maintenance checks, belt inspection, brake fluid flush, coolant flush, valve clearance adjustment (if applicable).

Engine Repair:

Complete engine rebuilds, piston and ring replacement, crankshaft and connecting rod repair, cylinder head gasket replacement, timing chain/belt service.

Transmission Service:

PVT belt replacement, clutch service, transmission oil change, gear case rebuilds (if applicable).

Drivetrain Repair:

CV joint boot replacement, axle shaft replacement, differential service, AWD system troubleshooting.

Suspension And Steering Repair:

Shock absorber replacement, bushing replacement, wheel bearing replacement, tie rod end replacement, steering system adjustment.

Brake System Overhaul:

Brake pad replacement, caliper rebuild, master cylinder replacement, brake line replacement, bleeding the hydraulic system.

Electrical Diagnostics:

Troubleshooting starting issues, charging system problems, lighting faults, using wiring diagrams to trace circuits.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common and uncommon issues, symptom-based troubleshooting tables.

Wiring Diagrams:

Detailed electrical schematics for all systems, including color coding and component identification.

Technical Depth

Depth:

Comprehensive: Covers everything from basic preventive maintenance and fluid changes to complete engine and transmission rebuilds, electrical system diagnostics, and chassis repairs. Suitable for both DIY enthusiasts and professional technicians.

📊 Manual Specifications

File Format

Format:

PDF (Portable Document Format)

Searchability:

Likely searchable text (if created from original digital source), allowing for quick keyword searches.

Print Quality

Quality:

High-resolution scans or original digital files, ensuring clarity of text, diagrams, and illustrations.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke Single Cylinder (likely SOHC or OHC)

Engine Displacement:

400cc and 500cc HO (High Output) variants.

Bore X Stroke:

Specifications vary by exact engine displacement, but typical for this class. Manual will contain precise measurements.

Cooling System:

Liquid-Cooled

Engine Oil Type:

Polaris PS-4 4-stroke synthetic oil (typically SAE 0W-40 or 10W-40, refer to manual for specific viscosity and API service classification)

Engine Oil Capacity:

Approx. 2.0-2.5 quarts (1.9-2.4 liters) with filter. Manual will confirm exact capacity.

Spark Plug Type:

NGK CR7HSA or equivalent (verify with manual)

Performance

Horsepower:

Approx. 27-30 HP for 400cc, Approx. 32-35 HP for 500 HO (estimated, exact figures in manual)

Torque:

Specifications not readily available, but designed for low-end torque for utility. Manual will provide torque figures for engine components.

Fuel System

Fuel Delivery:

Carburetor (likely Keihin or Mikuni for this era) or Throttle Body Fuel Injection (EFI) for some variants. Manual specifies exact system.

Fuel Type:

Unleaded Gasoline, 87 Octane Minimum

🔧 Transmission

Standard

Transmission Type:

Automatic (Polaris Variable Transmission - PVT)

Drive System:

Shaft Drive with Automatic All-Wheel Drive (AWD) engagement.

Optional

Optional Transmissions:

None typically offered for this model.

Features

Gear Reduction:

High and Low range gearing plus Reverse.

Clutch System:

Centrifugal Drive Clutch and Driven Clutch (Primary and Secondary).

Transmission Fluid Type:

Polaris Synthetic Gearcase Lubricant (refer to manual for specific SAE viscosity and part number)

Transmission Fluid Capacity:

Approx. 0.5 quarts (0.47 liters) for rear gearcase. Manual will confirm.

📐 Dimensions

Exterior

Length:

Approx. 85.1 inches (2161 mm) for Touring models (verify specific model variant in manual).

Width:

Approx. 46 inches (1168 mm) (verify specific model variant in manual).

Height:

Approx. 49.6 inches (1260 mm) (verify specific model variant in manual).

Wheelbase:

Approx. 57 inches (1448 mm) for Touring models (verify specific model variant in manual).

Cargo

Front Rack Capacity:

Approx. 100 lbs (45 kg) (verify specific model variant in manual).

Rear Rack Capacity:

Approx. 200 lbs (90 kg) (verify specific model variant in manual).

Weights

Dry Weight:

Approx. 660 lbs (299 kg) for standard models, Touring heavier. Manual will provide exact specifications.

Towing Capacity:

1500 lbs (680 kg) (verify specific model variant in manual).

Payload Capacity:

Approx. 465 lbs (211 kg) (verify specific model variant in manual).

Wheels Tires

Front Tire Size:

25 x 8-12 (verify specific model variant in manual).

Rear Tire Size:

25 x 10-12 (verify specific model variant in manual).

Wheel Bolt Pattern:

4x110mm (verify in manual)

🛡️ Safety Features

Ratings

Rollover Protection:

No specific ROPS rating; ATVs are designed for off-road use with inherent risks. Follow safe operating procedures.

Active Features

Braking System:

Hydraulic Disc Brakes (Front and Rear). Single lever front brake, thumb lever rear brake, and foot pedal rear brake.

Parking Brake:

Mechanical parking brake, typically integrated into the rear brake caliper or a separate mechanism.

Passive Features

Handlebars:

Contoured handlebars with grip protection for operator safety.

Lighting:

Dual Halogen 50W Headlights, Single 27/8W Tail/Brake Light.

💡 Technology Features

Infotainment

Features:

Typically minimal on utility ATVs of this era, focusing on core functionality. May include analog/digital instrument clusters with speed, RPM, fuel level, and indicator lights.

Driver Assistance

Features:

Active descent control or electronic power steering (EPS) may be available on some higher trim levels, but not standard across all 2012-2013 400/500 HO Touring models. Manual would detail specific features if present.

Connectivity

Features:

No integrated smartphone connectivity or advanced telematics expected for this model year. Focus is on robust mechanical and electrical systems.

🔧 Maintenance

Service Intervals

First Service:

Typically around 10-20 operating hours or 1 month for initial break-in service (oil change, filter check, lubrication). Detailed schedule in manual.

Regular Oil Change:

Every 100 operating hours or 6 months, whichever comes first (verify specific interval in manual).

Air Filter Cleaning:

Every 50 operating hours or as needed based on conditions (more frequent in dusty environments). Manual specifies cleaning/replacement intervals.

Transmission Oil Change:

Every 100 operating hours or annually (verify specific interval in manual).

Belt Inspection:

Every 50 operating hours or annually (verify specific interval in manual). Replacement recommended based on wear and tear.

Fluid Specifications

Engine Oil:

Polaris PS-4 4-stroke synthetic oil (SAE 0W-40 or 10W-40, API SJ or higher). Refer to manual for precise recommendation.

Gearcase Oil:

Polaris Synthetic Gearcase Lubricant (specific viscosity and part number in manual).

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Polaris recommends specific coolant. Manual will list part number and type.

Brake Fluid:

DOT 3 or DOT 4 hydraulic brake fluid. Manual specifies exact type.

Known Issues

Common Wear Items:

PVT belt wear, suspension bushings, wheel bearings, tie rod ends, brake pads, and starter motor reliability can be common wear items on ATVs with heavy use.

Electrical Connections:

Corrosion on electrical connectors can sometimes lead to intermittent issues; proper maintenance and dielectric grease application are key.

Cooling System Maintenance:

Ensuring proper coolant levels and condition is crucial to prevent overheating, especially under heavy load.

📚 Vehicle History

Brand Heritage

Brand History:

Polaris Industries, founded in 1954, is a leading manufacturer of powersports vehicles, including ATVs, snowmobiles, motorcycles, and utility vehicles. They are known for innovation and performance.

Model Evolution

Sportsman Lineage:

The Sportsman line is Polaris's flagship ATV range, known for its comfort, capability, and utility. The Touring models add passenger capability, and the 'Forest Tractor' designation emphasizes its work-oriented features.

Production

Production Period:

2012-2013 model years covered by this manual. The Sportsman platform has been in production for decades with continuous updates.

🏆 Awards & Recognition

Recognitions

Model Recognition:

Polaris Sportsman series generally receives positive reviews for its utility, comfort, and off-road capability. Specific awards for the 2012-2013 400/500 HO Touring Forest Tractor model may vary, but the platform is a recognized leader in its segment.