🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Year: 2012 Product Name: Polaris Sportsman 400 HO 2012 Factory Service Repair Manual PDF Download Generation Vehicle Generation: Fourth Generation Sportsman (2009-2014) 👋 Introduction Market Position Vehicle Segment: Mid-size Utility All-Terrain Vehicle (ATV) Target Demographic: Recreational riders, hunters, farmers, and general utility users seeking a capable and reliable ATV. Competitive Analysis Key Competitors: Honda Foreman, Yamaha Kodiak, Suzuki KingQuad, Can-Am Outlander. Key Features Versatility: Known for its versatility in various terrains and applications, from trail riding to farm work. On Demand AWD: Features Polaris's Automatic On-Demand All-Wheel Drive system for enhanced traction. Independent Suspension: Equipped with independent front and rear suspension for a smoother ride and better handling. Engine Power: Provides sufficient power for its class with the 400cc High Output engine. 📋 Manual Details Coverage Areas Manual Coverage Summary: Comprehensive factory service and repair information for the 2012 Polaris Sportsman 400 HO. Page Count Manual Page Count: Hundreds of pages (specific count not provided in product description, but implies extensive detail). Manual Type Manual Type: Factory Service Repair Manual Language Manual Language: English Format Manual Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service And Repair: Detailed procedures for engine disassembly, assembly, troubleshooting, diagnostics, and repair, including carburetor, ignition, cooling, and lubrication systems. Drivetrain Service And Repair: Covers primary drive, drive clutch, driven clutch, final drive, and all-wheel-drive (AWD) system maintenance and repair. Suspension And Steering Service And Repair: Detailed instructions for servicing front and rear suspension components, steering system, tie rods, and wheel alignment. Braking System Service And Repair: Includes procedures for servicing hydraulic brake systems, brake calipers, brake lines, master cylinder, and brake fluid replacement. Electrical System Service And Repair: Comprehensive coverage of the electrical system, including wiring diagrams, battery, charging system (stator, regulator/rectifier), starter, lighting, and accessories. Fuel System Service And Repair: Detailed information on the fuel tank, fuel pump, fuel lines, and carburetor (Mikuni BSR34) servicing. Cooling System Service And Repair: Procedures for radiator, fan, coolant, and hoses inspection and replacement. Exhaust System Service And Repair: Guidance on exhaust pipe, muffler, and heat shield inspection and replacement. Body And Frame Service And Repair: Includes procedures for body panel removal, installation, and frame inspection. Procedures Included Routine Maintenance And Inspections: Detailed steps for oil changes, filter replacements, spark plug checks, tire pressure, chain/belt adjustments (where applicable), and pre-ride inspections. Diagnostic Troubleshooting: Systematic approaches to diagnosing and resolving common and complex mechanical and electrical issues. Component Disassembly And Assembly: Step-by-step instructions for taking apart and putting back together all major vehicle components. Torque Specifications: Precise torque values for all critical fasteners and bolts to ensure proper assembly and prevent damage. Special Tool Requirements: Identification of any specialized tools needed for specific repair or maintenance procedures. Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including interpreting fault codes and understanding system operations. Rebuild Instructions: Comprehensive guides for complete engine rebuilds, transmission overhauls, and suspension component replacements. Specification Data: Detailed technical specifications for all components, including tolerances, clearances, and performance parameters. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke SOHC Displacement: 398.7 cc Bore X Stroke: 92 mm x 76 mm Cooling System: Liquid-Cooled Performance Horsepower: Approximately 29 HP (Manufacturer figures vary slightly, service manual provides definitive data) Torque: Estimated 25 lb-ft (Service manual provides specific figures) Fuel System Fuel Delivery: Mikuni BSR34 Carburetor Fuel Type: Unleaded Gasoline, 87 Octane Minimum Ignition Ignition System: CDI (Capacitor Discharge Ignition) Lubrication Oil Type: SAE 10W-40 Synthetic ATV Oil (Refer to manual for specific API classification and Polaris recommendations) Oil Capacity: Approx. 1.7 L (1.8 US qt) with filter change (Verify with manual) 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Drive System: Shaft Drive Gear Selection: High, Low, Neutral, Reverse, Park Features On Demand AWD: Automatic On-Demand All-Wheel Drive Clutch System: Dual Clutch (Primary and Secondary) 📐 Dimensions Exterior Length: 83 in (210.8 cm) Width: 46 in (116.8 cm) Height: 47 in (119.4 cm) Wheelbase: 50.5 in (128.3 cm) Ground Clearance: 11.25 in (28.6 cm) Cargo Front Rack Capacity: 100 lbs (45.4 kg) Rear Rack Capacity: 200 lbs (90.7 kg) Weights Dry Weight: 640 lbs (290.3 kg) Towing Capacity: 1,500 lbs (680.4 kg) Hitch Receiver Size: 2 in (50 mm) 🛡️ Safety Features Ratings Atv Safety Standards: Adheres to ANSI and SAE standards for ATVs. Active Features Braking System Type: Hydraulic Disc Brakes (Front and Rear) Engine Braking: Integrated engine braking provided by the PVT system. Passive Features Lighting: Dual 25W headlights, 8W brake light. Seatbelt Compatibility: N/A (ATVs are typically ridden without seatbelts, use of helmet and protective gear...