The 2012 Sportsman 400 HO and Sportsman 500 HO represent a robust line of mid-size utility all-terrain vehicles, engineered for versatility across various terrains and designed for recreational riders, hunters, and those performing light-duty farm or ranch work. Known for their durable build and capable performance, these ATVs feature a liquid-cooled, 4-stroke engine, an automatic PVT transmission with engine braking, and an on-demand AWD system for optimal traction. The Sportsman line is recognized for its comfortable ride and independent rear suspension, making it a reliable choice for demanding conditions and diverse applications. This comprehensive factory service repair manual provides detailed instructions for the maintenance, troubleshooting, and repair of your 2012 Sportsman 400 HO or 500 HO ATV. It covers all essential systems, including the engine, fuel system, drivetrain, transmission, electrical system, chassis, suspension, brakes, and steering. With over 500 pages of in-depth information, including diagnostic procedures, component repair, routine maintenance schedules, and technical specifications with torque values, this manual is an indispensable resource for owners and technicians aiming to keep their vehicle in optimal operating condition. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Model Variant: Sportsman 500 HO Year: 2012 Codes Vin Decoder Reference: Refer to Service Manual for specific VIN decoding. 👋 Introduction Market Position Segment: Mid-size utility ATV, positioned for recreational and light-duty farm/ranch use. Target Audience: Off-road enthusiasts, hunters, farmers, and general recreational riders seeking a reliable and capable ATV. Competitive Analysis Key Competitors: Honda Rancher, Yamaha Kodiak, Kawasaki Brute Force, Can-Am Outlander (competitors in similar displacement and capability classes). Key Features Versatility: Known for its versatile performance across various terrains, including trail riding, mud, and light work applications. Durability: Polaris Sportsman line is generally regarded for its robust build and durability, suitable for demanding conditions. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair for Polaris Sportsman 400 HO and 500 HO ATVs. Specific Systems Covered: Engine, Fuel System, Drivetrain, Transmission, Electrical System, Chassis, Suspension, Brakes, Steering, Bodywork, Accessories. Page Count Estimated Pages: Over 500 pages (typical for a factory service manual of this scope). Manual Type Type: Factory Service Repair Manual / Workshop Manual Language Language: English Format Format: Downloadable Digital File (likely PDF) 📖 Manual Coverage Systems Covered Engine And Drivetrain: Detailed diagrams, specifications, disassembly, assembly, troubleshooting, and repair procedures for the engine, including top-end, bottom-end, cooling system, and oil lubrication. Fuel And Exhaust: Carburetor (or EFI if applicable), fuel pump, fuel lines, fuel filter, and exhaust system maintenance and repair. Transmission And Drive Axles: Maintenance, inspection, and repair of the automatic transmission, PVT (Polaris Variable Transmission), drive shafts, CV joints, and differentials. Electrical System: Wiring diagrams, component testing (starter, alternator/stator, battery, ignition system), lighting, switches, and accessory circuits. Chassis And Suspension: Frame inspection, front and rear suspension (A-arms, shocks, springs, bushings), wheel bearings, and hub assemblies. Brakes And Steering: Brake system inspection, service (pads, rotors, fluid), bleeding procedures, and steering system components (tie rods, steering column, rack and pinion). Body And Plastics: Removal and installation of body panels, fenders, racks, and seat. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points, and general inspections. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts. Component Repair And Rebuild: Detailed instructions for disassembly, inspection, repair, and reassembly of major components. Diagnostic Procedures: Testing of electrical components, fuel system pressures, and ignition timing (if applicable). Specifications And Tolerances: Torque values, clearances, fluid capacities, and material specifications for all serviceable parts. Technical Depth Depth Of Coverage: Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls. Designed for professional technicians and advanced DIY mechanics. 📊 Manual Specifications File Format Format Details: Downloadable digital file, typically a PDF. Offers searchability and zoom capabilities. Print Quality Print Readability: High-resolution scans with clear text and sharp, detailed illustrations and diagrams. Binding Type Digital Binding: N/A (Digital Format) Paper Type Digital Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 4-valve, Single Cylinder Displacement 400: 375cc (approximate) Displacement 500 Ho: 499cc (approximate) Performance Horsepower 400: Approx. 25-28 HP (estimated) Horsepower 500 Ho: Approx. 30-34 HP (estimated) Torque 500 Ho: Approx. 30-32 lb-ft (estimated) Fuel System Fuel Delivery 400: Carburetor (likely Mikuni or Keihin) Fuel Delivery 500 Ho: Electronic Fuel Injection (EFI) - High Output Fuel Type: Unleaded Gasoline (91 Octane Recommended) Cooling System Cooling Method: Liquid-Cooled 🔧 Transmission Standard Transmission Type: Automatic PVT (Polaris Variable Transmission) with Engine Braking Gear Selection: High, Low, Neutral, Reverse, Park Optional Optional Transmissions: N/A for this model year and configuration. Features Drive System: On-Demand AWD/2WD (Activates automatically when front wheels lose traction) Final Drive: Sealed, single-ratio IRS (Independent Rear Suspension) with 2WD/AWD and shaft drive to front and rear wheels. 📐 Dimensions Exterior Length: Approx. 83 in. (210.8 cm) Width: Approx. 46 in....