This manual covers the Sportsman 400 500 HO Touring Forest Tractor ATV models for the 2012 and 2013 model years. There is a strong reputation in the powersports industry, and the Sportsman line is recognized for its utility and off-road prowess. This particular model offers versatility, designed for both recreational touring and demanding utility tasks, featuring a liquid-cooled 4-stroke SOHC engine with displacements of 375cc for the 400 model and 499cc for the 500 HO model. Its robust engineering ensures reliability for various applications, from challenging terrain to extended rides, with features like On-Demand All-Wheel Drive and integrated engine braking enhancing its capabilities. This comprehensive Service Repair Shop Manual provides detailed information for all aspects of maintenance, repair, and troubleshooting for your Sportsman. It covers critical systems including the engine, transmission, chassis, brakes, and electrical system, offering step-by-step instructions for diagnostics, component overhaul, and routine maintenance. The manual includes essential technical specifications, torque values, fluid requirements, and clear wiring diagrams to assist owners and technicians. By utilizing this manual, you can ensure your vehicle remains in optimal condition, maximizing its performance and longevity. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 500 HO Touring Forest Tractor ATV Model Variant: Touring Model Variant Specialty: Forest Tractor Generation Model Years Covered: 2012, 2013 Codes Product Sku Identifier: POL400500HO2012-2013SRMD 👋 Introduction Market Position Segment: Utility ATV, particularly suited for touring and demanding work applications (Forest Tractor designation). Competitive Analysis Competitors: Competes with other multi-purpose ATVs from manufacturers like Can-Am (Outlander), Yamaha (Grizzly), and Kawasaki (Brute Force). Key Features Versatility: Designed for both recreational touring and heavy-duty utility tasks, as indicated by the 'Forest Tractor' designation. Touring Capability: The 'Touring' model implies comfort and stability for longer rides, often with features like passenger seating. 📋 Manual Details Coverage Areas Documentation Scope: Comprehensive service, repair, maintenance, and troubleshooting for all listed models and years. Page Count Estimated Pages: Hundreds (specific count not provided in product info, but typical for full service manuals) Manual Type Type: Service Repair Shop Manual Language Language: English Format Format: Downloadable PDF Compatibility Device Compatibility: PC, MAC, Tablets, Smartphones 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul, tuning, fuel system, lubrication, cooling, ignition, exhaust. Transmission: Service, repair, and adjustments for automatic transmission (CVT), gearboxes, and driveline components. Chassis And Frame: Frame inspection, repair, suspension (front and rear), steering system, wheel alignment. Brakes: Hydraulic brake system diagnosis, caliper and master cylinder repair, brake fluid replacement, bleeding procedures. Electrical System: Wiring diagrams, battery, charging system (alternator/stator), starting system, lighting, instrumentation, ECM diagnostics. Fuel System: Fuel pump, fuel injectors (if applicable), carburetor (for some variants), fuel tank, lines, and filters. Cooling System: Radiator, fan, coolant, hoses, thermostat, water pump, overheat diagnosis. Exhaust System: Muffler, exhaust pipes, catalytic converter (if applicable), leak detection, repair. Body And Trim: Body panel removal/installation, seat removal, accessory mounting (e.g., cargo racks, winches). Wheels And Tires: Tire pressure, rotation, wheel bearing maintenance, rim specifications. Procedures Included Preventative Maintenance: Regular service checks, fluid changes, filter replacements, lubrication points. Troubleshooting: Diagnostic flowcharts, symptom-based repair guidance for common and uncommon issues. Repair And Rebuild: Step-by-step instructions for component disassembly, repair, and reassembly. Adjustments: Carburetor/fuel injection adjustments, throttle cable, brake adjustments. Wiring Diagrams: Detailed electrical schematics for accurate diagnosis and repair. Special Tools: Identification and usage of specific Polaris or aftermarket tools required for certain procedures. Technical Depth Diagnostic Level: Advanced diagnostics including error code interpretation, sensor testing, and ECM analysis. Rebuild Capability: Complete engine and transmission overhaul procedures with detailed specifications. Specification Detail: Torque values, clearances, fluid capacities, and electrical parameters. 📊 Manual Specifications File Format Format Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Image Resolution: Professional quality with clear diagrams and illustrations. Layout: Organized into logical sections for ease of use. Binding Type Binding: N/A (Downloadable PDF) Paper Type Paper Type: N/A (Downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC Displacement 400: 375cc (for the 400 model variant) Displacement 500: 499cc (for the 500 HO model variant) Bore X Stroke 400: Approx. 80mm x 75mm (typical for this displacement range) Bore X Stroke 500: Approx. 92mm x 75mm (typical for this displacement range) Horsepower 400: Estimated 25-30 HP (actual varies by year and tune) Horsepower 500: Estimated 34-38 HP (for HO model, actual varies) Cooling System: Liquid-cooled Ignition System: CDI (Capacitor Discharge Ignition) Performance Torque Characteristics: Designed for strong low-end and mid-range torque for pulling and climbing. Fuel System Fuel Delivery 400: Likely Carbureted (Mikuni or similar) for 2012-2013 400 model. Fuel Delivery 500: Likely Electronic Fuel Injection (EFI) for 500 HO model, for improved performance and cold starts. Fuel Type: Unleaded gasoline (Octane rating specified in manual) 🔧 Transmission Standard Transmission Type: Automatic Polaris Variable Transmission (PVT) with Engine Braking Drive System: On-Demand All-Wheel Drive (AWD) with 2WD/4WD selector. Gear Selection:...