🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Year: 2012 Vehicle Type: ATV (All-Terrain Vehicle) Product Name: Polaris Sportsman 400 HO 2012 Workshop Repair Service Manual PDF Download 👋 Introduction Market Position Segment: Mid-size utility ATV segment, known for its versatility and value. Competitive Analysis Competitors: Competes with models from Yamaha (Grizzly 350/450), Can-Am (Outlander 400/500), Honda (Foreman/Rancher 420), Kawasaki (Brute Force 300/400). Key Features Features: Polaris's signature independent rear suspension (IRS), reliable engine, robust chassis, and user-friendly controls. 📋 Manual Details Coverage Areas Covered Models: All Models/Engines/Trim Page Count Page Count: Detailed page count not specified, but professional workshop manuals are typically extensive. Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhauls, diagnostics, component testing, and specifications. Transmission: PVT (Polaris Variable Transmission) system, clutch inspection and adjustment, belt replacement. Drivetrain: All-wheel drive (AWD) system, front differential, rear differential, driveshafts, U-joints. Suspension: Front and rear suspension systems, shock absorbers, A-arms, bushings, wheel bearings. Brakes: Hydraulic brake system, front and rear calipers, master cylinder, brake lines, brake fluid specifications and bleeding procedures. Electrical: Starter system, charging system, battery, ignition system, lighting, switches, fuses, wiring diagrams, diagnostics. Fuel System: Fuel pump, fuel filter, fuel lines, carburetor (if applicable) or fuel injection system, fuel tank inspection. Cooling System: Radiator, fan, coolant specifications, hoses, thermostat, water pump. Steering: Steering column, tie rods, steering linkage, component inspection and adjustment. Bodywork: Body panel removal and installation, plastics, seat, handlebars, rack systems. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, lubrication points, bolt torque specifications. Troubleshooting: Diagnostic charts for common problems, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major systems, including disassembly, assembly, and component replacement. Diagnostics: Detailed diagnostic procedures for electrical and mechanical systems. Specifications: Torque specifications, clearances, fluid capacities, electrical values, engine performance data. Wiring Diagrams: Comprehensive electrical wiring diagrams for all circuits. Technical Depth Depth: Comprehensive coverage for both routine maintenance and in-depth repairs and overhauls. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Likely text-searchable PDF for easy information retrieval. Print Quality Print Quality: Designed for clear printing of text and diagrams. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-Stroke, SOHC, 4-Valve Displacement: 375cc Bore X Stroke: 85 mm x 66 mm Cooling System: Liquid-Cooled Performance Horsepower: Approx. 29 HP (Horsepower, specific rating may vary slightly) Torque: Torque specifications would be detailed in the manual. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) for the 'HO' models, but 2012 400 HO used carburetor. Carburetor Type: Keihin CVK-34 (likely, specific model to be confirmed in manual) Ignition Ignition System: Electronic Ignition 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) Automatic with Engine Braking Features Gear Selection: High (H), Low (L), Neutral (N), Reverse (R), Park (P) Fluid Type Transmission Fluid: Polaris AGL Synthetic Gearcase Lubricant (or equivalent) Clutch System Clutch Type: Sealed On-Demand ATV AWD (Active Descent Control, though ADC is typically found on higher models, it might refer to AWD engagement logic) 📐 Dimensions Exterior Length: 83 in. (210.8 cm) Width: 46 in. (116.8 cm) Height: 47 in. (119.4 cm) Wheelbase Wheelbase: 50.5 in. (128.3 cm) Ground Clearance Ground Clearance: 11.5 in. (29.2 cm) Weights Dry Weight: 625 lbs (283.5 kg) Towing Capacity: 1500 lbs (680.4 kg) Rack Capacity Front: 100 lbs (45.4 kg) Rack Capacity Rear: 200 lbs (90.7 kg) Fuel Capacity Fuel Capacity: 4.25 gal (16.1 L) 🛡️ Safety Features Ratings Safety Standards: Designed to meet ANSI standards for recreational ATVs. (Note: ATV safety ratings are different from automotive crash test ratings). Active Features AWD: On-Demand All-Wheel Drive (AWD) for enhanced traction. Passive Features Braking System: Hydraulic disc brakes front and rear. Lighting: Dual 25W headlights, 35W brakelight/taillight. 💡 Technology Features Infotainment Infotainment System: Basic instrumentation: speedometer, odometer, trip meter, tachometer, fuel gauge, gear indicator, AWD indicator, engine hour meter. Driver Assistance Traction Control: On-Demand AWD system provides enhanced traction. Connectivity Diagnostic Ports: Diagnostic ports for connecting to Polaris diagnostic tools (specific type detailed in manual). 🔧 Maintenance Service Intervals Oil Change Interval: Refer to the manual for specific intervals (typically every 100 hours or annually). Clutch Belt Inspection: Regular inspection and replacement as needed, often recommended at 1500 miles or 2400 hours, but dependent on usage. Air Filter Cleaning: Frequent cleaning or replacement recommended, especially in dusty conditions. Fluid Specifications Engine Oil Type: Polaris Synthetic 2W-50 (or specified SAE 5W-50, API CI-4) Engine Oil Capacity: Approximately 2.0 L (2.1 US qt) with filter change. Coolant Type: Ethylene Glycol-based antifreeze (50/50 mix with distilled water) Brake Fluid Type: DOT 4 Hydraulic Brake Fluid Known Issues Common Wear Items: Tie rod ends, wheel bearings, suspension bushings, brake pads, and the PVT belt are...