The Polaris Sportsman 400 and 500 are robust All-Terrain Vehicles (ATVs) designed for a wide range of applications, from recreational riding to demanding utility tasks. Produced for the 2012-2013 model years, these ATVs are recognized for their ruggedness, versatility, and reliable performance across varied terrain. The Sportsman line, a cornerstone of ATV offerings, has a reputation for engineering quality and has been a significant player in the market. These mid-size utility ATVs are targeted at recreational riders, farmers, hunters, and other users who require dependable performance and durability. This comprehensive Factory Service Manual (FSM) provides essential information for the maintenance, troubleshooting, and repair of the Polaris Sportsman 400 and 500 ATVs from model years 2012-2013. It covers all major systems, including the powertrain, chassis, and electrical components, detailing procedures from basic scheduled maintenance, such as oil changes and filter replacements, to complex overhauls and advanced diagnostic steps. The manual includes detailed technical specifications, high-resolution illustrations, and guidance on special tools, empowering owners and technicians to maximize the lifespan and performance of their vehicles. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 / 500 Product Type: Service Repair Manual Download Codes Vehicle Generation Identifier: Model Years 2012-2013 👋 Introduction Market Position Segment: Mid-size utility ATV Target Audience: Recreational riders, farmers, hunters, and utility users Competitive Analysis Key Competitors: Can-Am Outlander 400, Honda Foreman 400/500, Suzuki KingQuad 400/500, Yamaha Grizzly 450/550 Key Features Vehicle Usp: Reputation for ruggedness, versatility, and reliable performance in varied terrain Manual Value Proposition: Provides essential knowledge for owners to maintain, troubleshoot, and repair their ATVs, maximizing lifespan and performance. 📋 Manual Details Coverage Areas Applicable Models: Polaris Sportsman 400 (2012-2013), Polaris Sportsman 500 (2012-2013) Market Segments: All-Terrain Vehicle (ATV) Page Count Estimated Pages: Comprehensive (Exact count not specified, but implied extensive for FSM) Manual Type Type: Factory Service Manual (FSM) Subtype: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Lubrication System, Cooling System, Transmission, Drivetrain Chassis: Suspension, Steering, Brakes, Wheels and Tires Electrical: Ignition System, Lighting System, Charging System, Battery, Wiring Diagrams, Instruments and Gauges Body And Frame: Frame, Body Panels, Seat, Handlebars, Racks Procedures Included Maintenance: Scheduled Maintenance, Oil Changes, Filter Replacements, Lubrication Points Diagnostics: Troubleshooting Guides, Diagnostic Codes, Symptom Analysis Repair: Component Removal and Installation, Assembly and Disassembly, Specific Repair Procedures Overhaul: Engine Rebuilding, Transmission Overhauling, Suspension Component Rebuilding Adjustment: Carburetor Adjustment, Valve Clearance Adjustment, Brake Adjustment Technical Depth Depth: Comprehensive (from basic checks to complete engine rebuilds) Diagnostics Level: Advanced diagnostic procedures, including electrical circuit testing Special Tools: Identification of required special tools for specific procedures 📊 Manual Specifications File Format File Type: Portable Document Format (.pdf) Searchability: Likely text-searchable, facilitating quick information retrieval Print Quality Image Resolution: High-resolution illustrations and diagrams for clarity Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, Liquid-Cooled, SOHC Sportsman 400 Displacement: 455cc Sportsman 500 Displacement: 499cc Bore X Stroke 400: 92mm x 82mm (approximate, specific to 455cc) Bore X Stroke 500: 92mm x 92mm (approximate, specific to 499cc) Compression Ratio: Approx. 9.5:1 (Typical for these displacements) Horsepower 400: Approx. 30-33 HP (Varies slightly by year/tuning) Horsepower 500: Approx. 34-37 HP (Varies slightly by year/tuning) Performance Torque Peak 500: Approx. 28-30 lb-ft @ 5000 RPM (estimated) Fuel System Fuel Delivery: Carburetor (Likely Keihin CVK) Carburetor Size: Approx. 34mm (Typical for this class) Fuel Type: Unleaded Gasoline, 87 Octane Minimum Cooling System Type: Liquid-Cooled Coolant Type: Antifreeze/Coolant Mixture (e.g., 50/50 Ethylene Glycol) Lubrication System Oil Type: SAE 10W-40, API SG or higher (Check manual for specific Polaris recommendation) Oil Capacity: Approx. 2.2 US quarts (2.1 liters) with filter change (Verify in manual) Oil Filter Part Number: Polaris Part # 3083722 or equivalent aftermarket (Verify in manual) 🔧 Transmission Standard Type: Automatic (CVT - Continuously Variable Transmission) Drive System: Shaft Drive, On-Demand AWD (All-Wheel Drive) Gearing: High, Low, Neutral, Reverse, Park Features Cvts Belt Inspection: Manual details critical inspection and replacement intervals for the drive belt. Final Drive Fluid Type: Polaris Demand Drive Fluid or equivalent (Verify in manual) Final Drive Fluid Capacity: Front Gearcase: Approx. 5.8 oz (170 ml), Rear Gearcase: Approx. 7.7 oz (227 ml) (Verify in manual) 📐 Dimensions Exterior Length: Approx. 83 inches (210.8 cm) Width: Approx. 46 inches (116.8 cm) Height: Approx. 48 inches (121.9 cm) to handlebars Weights Dry Weight: Approx. 650-680 lbs (295-309 kg) Ground Clearance: Approx. 10.5 inches (26.7 cm) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) 🛡️ Safety Features Ratings Atv Safety Standards: Compliance with ANSI/SVIA standards recommended for ATVs. Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Parking Brake: Hand-operated brake lever or thumb lever engaging rear brake Passive Features Lighting:...