🏷️ Basic Information Identification Make: Polaris Model: Sportsman 500 HO Touring Model Variant: Touring Model Trim: HO (High Output) Production Years Covered: 2012, 2013 Codes Chassis Code: AWD/2WD configurations, standard for this model Engine Code: Likely A90 (refer to VIN for precise engine type) 👋 Introduction Market Position Vehicle Segment: Premium all-terrain, multi-purpose ATV, designed for rider and passenger comfort and capability. Competitive Analysis Competitors 2012 2013: Can-Am Outlander MAX, Yamaha Grizzly 550/700, Arctic Cat TRV. Key Features Vehicle Touring Capability: Extended wheelbase for enhanced rider and passenger comfort, integrated passenger seat and backrest. Engine Power: 500cc HO engine providing robust power for hauling, towing, and trail riding. Suspension System: Independent front and rear suspension for superior ride quality and control over varied terrain. Manual Utility Target Audience: Professional mechanical technicians, experienced DIY enthusiasts, and owners seeking in-depth maintenance and repair knowledge. Value Proposition: Enables owners to perform maintenance and repairs effectively, reducing reliance on external service centers and extending vehicle lifespan. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual Language: English Format: PDF Download Page Count Estimated Page Count: Varies by specific edition, typically 500-700 pages for this type of detailed manual. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, and reassembly of the engine; cylinder head, piston, crankshaft, valve train, timing systems. Fuel System: Carburetor (likely Mikuni BST40 for this model) tuning, cleaning, and rebuilding; fuel pump operation; fuel tank and lines. Ignition System: CDI unit, ignition coil, spark plug diagnosis, stator and rotor inspection. Cooling System: Radiator, fan, thermostat, coolant flow, water pump. Transmission And Drivetrain: PVT (Polaris Variable Transmission) system, drive clutch, driven clutch, belt inspection and replacement, final drive gears, differential, driveshafts, CV joints. Suspension: Front and rear suspension components, shock absorbers, A-arms, bushings, ball joints, wheel bearings. Brakes: Hydraulic brake system, master cylinders, brake calipers, brake pads, brake lines, bleeding procedures, parking brake. Steering: Handlebar assembly, steering post, tie rods, steering rack/mechanism. Electrical System: Wiring diagrams, battery, charging system (alternator/stator), starter motor, lighting (headlights, taillights, brake lights), instrumentation, switches, fuses, relays. Chassis And Body: Frame inspection, body panels, fenders, seat, rack systems, removal and installation procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug maintenance, air filter cleaning/replacement, lubrication points. Troubleshooting Guides: Diagnostic charts and procedures for common and uncommon problems across all systems. Repair Procedures: Step-by-step instructions for component removal, repair, and installation. Overhaul Procedures: Detailed guidance for complete engine or transmission rebuilds. Adjustment Procedures: Carburetor tuning, valve lash adjustments, brake adjustments, clutch adjustments. Special Tool Requirements: Identification of and instructions for using specific tools required for certain repairs. Technical Depth Depth Of Coverage: Comprehensive, ranging from basic owner maintenance to advanced mechanical and electrical diagnostics and repairs. Diagnostic Capabilities: Detailed diagnostic flowcharts and troubleshooting for ignition, fuel, electrical, and mechanical issues. Rebuild Specifications: Includes all necessary torque specifications, tolerances, and clearances for major component rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick information retrieval. Print Quality Image Resolution: Typically high-resolution for clear diagrams and photographs. Binding Type Physical Format Analogy: Not applicable (digital download), but professionally laid out for print if desired. Paper Type Digital Equivalent: High-resolution digital pages, suitable for on-screen viewing or printing. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Single Cylinder, SOHC, liquid-cooled Displacement: 499cc (30.4 cu. in.) Bore X Stroke: 92.0 mm x 75.0 mm (3.62 in. x 2.95 in.) Compression Ratio: Typically 9.0:1 or similar for this era 500cc engine. Performance Horsepower Rated: Approx. 38-40 HP (specific rating can vary slightly by test conditions and model year, manual will confirm exact figures). Torque Rated: Not explicitly stated in product description, but ample for its class. Fuel System Carburetor Model: Likely Mikuni BST40, 40mm Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: Typically 3.25 gallons (12.3 L) 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Optional Gearing: High and Low range, Neutral, Reverse Features Drive System: On-Demand True All-Wheel Drive (AWD) / 2WD Final Drive: Shaft Drive 📐 Dimensions Exterior Wheelbase: 57 inches (144.8 cm) Length: 83 inches (210.8 cm) Width: 46 inches (116.8 cm) Height: 50 inches (127 cm) Cargo Front Rack Capacity: 100 lbs (45.4 kg) Rear Rack Capacity: 200 lbs (90.7 kg) Weights Dry Weight: Approx. 661 lbs (299.8 kg) Towing Capacity: 1,500 lbs (680.4 kg) ગ운 Capacity: 300 lbs (136 kg) 🛡️ Safety Features Ratings Atv Safety Standards: Designed to meet ANSI standards for recreational ATVs. Active Features Braking System: Hydraulic disc brakes front and rear. Engine Braking: Integrated into the PVT system for downhill control. Passive Features Lighting: Dual headlights, taillight/brake light. Passenger Safety: Integrated passenger seat with handholds and backrest. 💡 Technology Features Infotainment Instrumentation: Digital instrumentation cluster typically includes speedometer, odometer, trip meter, tachometer, fuel gauge, and indicator lights....