2012 Polaris Sportsman 500 400 ATV Service Repair Manual

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🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400/500 Model Variants: • Sportsman 400 H.O. • Sportsman 500 H.O. • Sportsman Touring 500 H.O. • Sportsman Forest Tractor 500 EFI Year: 2012 Codes Chassis Code: Model year 2012 Generation Generation Identifier: Polaris Sportsman (Gen 3/4 500 Series based) 👋 Introduction Market Position Segment: Utility ATV Target Audience: Owners, maintenance personnel, and mechanics working on 2012 Polaris Sportsman 400/500 models for work, hunting, trail riding, and utility tasks. Competitive Analysis Competitors At Time: Honda FourTrax, Yamaha Kodiak/Grizzly, Can-Am Outlander/Renegade, Kawasaki Brute Force. Key Features Of Vehicles Atv Features: • On-Demand All-Wheel Drive (AWD) or True All-Wheel Drive (AWD) with VersaTrac. • Independent Rear Suspension (IRS). • Pro-Ride™ front suspension. • Engine braking system. • Heavy-duty racks for cargo. • Optional power steering on some models. • Towing and payload capabilities. 📋 Manual Details Coverage Areas Covered Models: • 2012 Polaris Sportsman 400 H.O. • 2012 Polaris Sportsman 500 H.O. • 2012 Polaris Sportsman Touring 500 H.O. • 2012 Polaris Sportsman Forest Tractor 500 EFI Page Count Total Pages: 432 Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: • Engine: Complete overhaul, disassembly, assembly, bore, piston, rings, crankshaft, camshaft, valve train, cooling system, lubrication system, fuel system (carbureted and EFI), ignition system, exhaust system. • Transmission: Gearbox disassembly, assembly, troubleshooting, lubrication, maintenance. • Drivetrain: Driveshafts, CV joints, differential, clutch system, belt drive maintenance. Chassis And Body: • Suspension: Front and rear suspension, shock absorbers, springs, bushings, adjustment procedures. • Steering: Steering system components, tie rods, steering column, wheel alignment. • Brakes: Hydraulic brake system, calipers, master cylinder, brake pads, brake lines, bleeding procedures. • Wheels and Tires: Tire pressure, tire wear, wheel installation, bolt patterns. • Frame and Bodywork: Plastics, body panels, mounting, removal, seat assembly. Electrical: • Wiring Diagrams: Comprehensive electrical schematics. • Ignition System: Spark plugs, coils, CDI unit. • Charging System: Stator, rectifier/regulator, battery maintenance. • Starting System: Starter motor, starter solenoid. • Lighting: Headlights, taillights, brake lights, auxiliary lighting. • Instrumentation: Speedometer, odometer, fuel gauge, warning lights. • Accessories: Winch operation, hand warmers, other electrical accessories. Cooling System: Radiator, coolant, fan operation, thermostat, hoses, bleed procedures. Lubrication System: Oil pump, oil filter, oil passages, oil cooler (if applicable). Procedures Included Maintenance: • Regular scheduled maintenance. • Oil and filter changes. • Coolant checks and changes. • Spark plug replacement. • Air filter cleaning and replacement. • Battery maintenance and charging. • Brake fluid checks and replacement. • Lubrication points and schedules. Repair And Troubleshooting: • Engine diagnostics and repair. • Transmission and drivetrain troubleshooting. • Suspension and steering repair. • Brake system repair. • Electrical system troubleshooting. • Component disassembly and reassembly. • Troubleshooting guides for common problems. Troubleshooting Guides: Detailed flowcharts and symptom-based diagnostics for common issues across all systems. Assembly Disassembly: Step-by-step instructions for complete component disassembly and reassembly, including torque specifications. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance and basic repairs to complete engine and transmission overhauls, including detailed troubleshooting steps and diagnostic procedures. Suitable for both DIY enthusiasts and professional technicians. Electrical Diagnostics: Component testing, voltage checks, continuity testing, troubleshooting electrical faults. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (typical for quality PDF manuals) Printable: Yes File Size: Variable, but typically optimized for download (e.g., 30-100MB). Print Quality Quality: High resolution, clear diagrams and text. Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 400: 4-stroke, SOHC, 2-valve, single-cylinder Engine Type 500: 4-stroke, SOHC, 2-valve, single-cylinder Displacement 400: 375cc (approx.) Displacement 500: 499cc (approx.) Bore X Stroke 500: Approx. 93.25 mm x 73.0 mm (specific values covered in manual) Cooling System: Liquid-cooled Ignition System: CDI (Capacitor Discharge Ignition) Performance Horsepower 500: Approx. 33 HP (specific values covered in manual) Torque 500: Approx. 29.6 lb-ft (specific values covered in manual) Fuel System Fuel Delivery 400 Ho: Carburetor (e.g., Mikuni BSR42) Fuel Delivery 500 Ho Efi: Electronic Fuel Injection (EFI) - Specifics covered in manual Recommended Fuel: Unleaded gasoline (Octane rating as specified in manual, typically 87+) 🔧 Transmission Standard Transmission Type: Automatic (PVT - Polaris Variable Transmission) with Engine Braking Drive Selection: High, Low, Neutral, Reverse Features Clutch System: Centrifugal clutch and drive/driven pulleys. Belt maintenance and replacement procedures covered. Final Drive: Sealed chain, AWD or 2WD selectable. 📐 Dimensions Exterior Length: Approx. 83 in. (standard models) / Approx. 85.5 in. (Touring) Width: Approx. 46 in. Height: Approx. 48 in. (standard models) / Approx. 49.5 in. (Touring) Weights Dry Weight: Approx. 650-700 lbs (varies by model) Towing Capacity: 1500 lbs (680 kg) Rack Capacity Front: 100 lbs (45 kg) Rack Capacity Rear: 200 lbs (90 kg) 🛡️ Safety Features Ratings Rollover Protection: Not applicable for ATVs in the...

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Sku: 60192

Collections: ALL ATV Powersports

Availability: In stock

Tags: 2012 ATV Polaris Powersports Sportsman 400 Sportsman 500

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Description

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400/500

Model Variants:

• Sportsman 400 H.O.

• Sportsman 500 H.O.

• Sportsman Touring 500 H.O.

• Sportsman Forest Tractor 500 EFI

Year:

Codes

Chassis Code:

Model year 2012

Generation

Generation Identifier:

Polaris Sportsman (Gen 3/4 500 Series based)

👋 Introduction

Market Position

Segment:

Utility ATV

Target Audience:

Owners, maintenance personnel, and mechanics working on 2012 Polaris Sportsman 400/500 models for work, hunting, trail riding, and utility tasks.

Competitive Analysis

Competitors At Time:

Honda FourTrax, Yamaha Kodiak/Grizzly, Can-Am Outlander/Renegade, Kawasaki Brute Force.

Key Features Of Vehicles

Atv Features:

• On-Demand All-Wheel Drive (AWD) or True All-Wheel Drive (AWD) with VersaTrac.

• Independent Rear Suspension (IRS).

• Pro-Ride™ front suspension.

• Engine braking system.

• Heavy-duty racks for cargo.

• Optional power steering on some models.

• Towing and payload capabilities.

📋 Manual Details

Coverage Areas

Covered Models:

• 2012 Polaris Sportsman 400 H.O.

• 2012 Polaris Sportsman 500 H.O.

• 2012 Polaris Sportsman Touring 500 H.O.

• 2012 Polaris Sportsman Forest Tractor 500 EFI

Page Count

Total Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

• Engine: Complete overhaul, disassembly, assembly, bore, piston, rings, crankshaft, camshaft, valve train, cooling system, lubrication system, fuel system (carbureted and EFI), ignition system, exhaust system.

• Transmission: Gearbox disassembly, assembly, troubleshooting, lubrication, maintenance.

• Drivetrain: Driveshafts, CV joints, differential, clutch system, belt drive maintenance.

Chassis And Body:

• Suspension: Front and rear suspension, shock absorbers, springs, bushings, adjustment procedures.

• Steering: Steering system components, tie rods, steering column, wheel alignment.

• Brakes: Hydraulic brake system, calipers, master cylinder, brake pads, brake lines, bleeding procedures.

• Wheels and Tires: Tire pressure, tire wear, wheel installation, bolt patterns.

• Frame and Bodywork: Plastics, body panels, mounting, removal, seat assembly.

Electrical:

• Wiring Diagrams: Comprehensive electrical schematics.

• Ignition System: Spark plugs, coils, CDI unit.

• Charging System: Stator, rectifier/regulator, battery maintenance.

• Starting System: Starter motor, starter solenoid.

• Lighting: Headlights, taillights, brake lights, auxiliary lighting.

• Instrumentation: Speedometer, odometer, fuel gauge, warning lights.

• Accessories: Winch operation, hand warmers, other electrical accessories.

Cooling System:

Radiator, coolant, fan operation, thermostat, hoses, bleed procedures.

Lubrication System:

Oil pump, oil filter, oil passages, oil cooler (if applicable).

Procedures Included

Maintenance:

• Regular scheduled maintenance.

• Oil and filter changes.

• Coolant checks and changes.

• Spark plug replacement.

• Air filter cleaning and replacement.

• Battery maintenance and charging.

• Brake fluid checks and replacement.

• Lubrication points and schedules.

Repair And Troubleshooting:

• Engine diagnostics and repair.

• Transmission and drivetrain troubleshooting.

• Suspension and steering repair.

• Brake system repair.

• Electrical system troubleshooting.

• Component disassembly and reassembly.

• Troubleshooting guides for common problems.

Troubleshooting Guides:

Detailed flowcharts and symptom-based diagnostics for common issues across all systems.

Assembly Disassembly:

Step-by-step instructions for complete component disassembly and reassembly, including torque specifications.

Technical Depth

Depth:

Comprehensive: Covers everything from routine maintenance and basic repairs to complete engine and transmission overhauls, including detailed troubleshooting steps and diagnostic procedures. Suitable for both DIY enthusiasts and professional technicians.

Electrical Diagnostics:

Component testing, voltage checks, continuity testing, troubleshooting electrical faults.

📊 Manual Specifications

File Format

Format:

Searchable:

Yes (typical for quality PDF manuals)

Printable:

File Size:

Variable, but typically optimized for download (e.g., 30-100MB).

Print Quality

Quality:

High resolution, clear diagrams and text.

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type 400:

4-stroke, SOHC, 2-valve, single-cylinder

Engine Type 500:

4-stroke, SOHC, 2-valve, single-cylinder

Displacement 400:

375cc (approx.)

Displacement 500:

499cc (approx.)

Bore X Stroke 500:

Approx. 93.25 mm x 73.0 mm (specific values covered in manual)

Cooling System:

Liquid-cooled

Ignition System:

CDI (Capacitor Discharge Ignition)

Performance

Horsepower 500:

Approx. 33 HP (specific values covered in manual)

Torque 500:

Approx. 29.6 lb-ft (specific values covered in manual)

Fuel System

Fuel Delivery 400 Ho:

Carburetor (e.g., Mikuni BSR42)

Fuel Delivery 500 Ho Efi:

Electronic Fuel Injection (EFI) - Specifics covered in manual

Recommended Fuel:

Unleaded gasoline (Octane rating as specified in manual, typically 87+)

🔧 Transmission

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission) with Engine Braking

Drive Selection:

High, Low, Neutral, Reverse

Features

Clutch System:

Centrifugal clutch and drive/driven pulleys. Belt maintenance and replacement procedures covered.

Final Drive:

Sealed chain, AWD or 2WD selectable.

📐 Dimensions

Exterior

Length:

Approx. 83 in. (standard models) / Approx. 85.5 in. (Touring)

Width:

Approx. 46 in.

Height:

Approx. 48 in. (standard models) / Approx. 49.5 in. (Touring)

Weights

Dry Weight:

Approx. 650-700 lbs (varies by model)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Ratings

Rollover Protection:

Not applicable for ATVs in the traditional sense; adherence to safe operating practices outlined in the manual is crucial.

Active Features

Braking System:

Hydraulic disc brakes, front and rear.

Engine Braking:

Standard feature integrated with the PVT transmission.

Traction Control:

AWD system.

Passive Features

Lighting:

Dual headlights, tail/brake light.

Operator Safety:

Manual strongly emphasizes safe operating procedures, protective gear, and awareness of terrain.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital LCD display with speedometer, odometer, trip meter, tachometer, fuel gauge, clock, hi-temp light, and AWD indicator. (Specific features may vary by trim).

Driver Assistance

Power Steering:

Available as an option on some 2012 Sportsman 500 models (e.g., High Lifter, Touring EPS).

Connectivity

Charging Port:

Often includes a 12V accessory outlet for charging electronics.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or annually, whichever comes first (refer to manual for exact specifications).

Gearcase Oil Change:

Annually or every 200 hours.

Coolant Check And Change:

Check monthly, change annually or as recommended.

Spark Plug Replacement:

Every 12 months or as needed, depending on conditions.

Drive Belt Inspection:

Inspect every 50 hours, replace as needed (wear indicators in manual).

Fluid Specifications

Engine Oil Type Recommendation:

SAE 0W-40 Synthetic Oil or SAE 5W-50 (refer to manual for precise Polaris specification and API rating).

Engine Oil Capacity:

Approx. 2.0 quarts (1.9 L) with filter change (verify in manual).

Transmission Gearcase Oil:

Polaris Demand Drive Fluid or SAE 75W-90 Synthetic Gearcase Lube (verify in manual).

Coolant:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Polaris recommends specific coolant type.

Brake Fluid:

DOT 4 Brake Fluid (verify in manual for specific type).

Known Issues

Common Wear Items:

• Drive belt fatigue/wear.

• Front and rear suspension bushings.

• CV joint boots.

• Brake pads and rotors.

• Battery terminals and connections.

• Wheel bearings.

Efi Component Care:

Importance of clean fuel and regular checks of fuel injectors and sensors for EFI models.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries, founded in 1954, a pioneer in snowmobiles and later ATVs.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone for Polaris, known for its utility and comfort. The 500cc engine platform has been a long-standing bestseller, evolving through various generations. The 400 series served as a capable, more budget-friendly option.

2012 Updates:

While the core platform was established, 2012 models would have featured Polaris's latest refinements in suspension, ergonomics, and potentially EFI improvements on relevant models.

Production

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Market Reputation:

The Polaris Sportsman line has consistently been recognized for its utility, comfort, and capability in the utility ATV segment. While specific awards for the 2012 models might not be readily available, the platform's long-standing success indicates strong market acceptance.