The Polaris Sportsman 400 HO is a robust and versatile All-Terrain Vehicle (ATV) designed for both recreational pursuits and demanding utility tasks. Produced for the 2012-2013 model years, this High Output (HO) ATV is engineered with a focus on reliability and performance, featuring Independent Rear Suspension (IRS) and an On-Demand All-Wheel Drive (AWD) system for superior traction. Its powerful engine and ample rack capacity make it well-suited for trail riding, hunting, and light farm work, offering a compelling blend of capability and comfort that has made the Sportsman line a benchmark in the industry. This workshop service manual provides comprehensive guidance for the maintenance, diagnosis, and repair of the Polaris Sportsman 400 HO. It covers all essential systems, including the engine, fuel system, transmission, drivetrain, brakes, suspension, and electrical components, with detailed procedures for routine maintenance, troubleshooting, and complete overhauls. Technicians and owners will find in-depth instructions, precise specifications, torque values, and clear diagnostic flowcharts to ensure the longevity and optimal performance of their vehicle. 🏷️ Basic Information Identification Make: Polaris Model: Sportsman 400 HO Model Variant: High Output (HO) Year: 2012-2013 Vehicle Type: ATV (All-Terrain Vehicle) 👋 Introduction Market Position Positioning: The Polaris Sportsman 400 HO is positioned as a versatile and capable mid-size ATV, offering a balance of power, comfort, and utility for recreational riders and light-duty farm/ranch work. Competitive Analysis Competitors: Competes with models from Honda (e.g., Rancher), Yamaha (e.g., Kodiak), Can-Am (e.g., Outlander L), and Arctic Cat (e.g., Alterra). Key Features Features: Independent Rear Suspension (IRS), On-Demand All-Wheel Drive (AWD), Electronic Fuel Injection (EFI) on later models (ensure model specific check), powerful HO engine, comfortable seating, ample rack capacity. Manual Value Proposition Value: This comprehensive workshop manual provides DIY mechanics and professional technicians with the essential information to maintain, diagnose, and repair the Polaris Sportsman 400 HO 2012-2013 models, saving time and money. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global markets where Polaris is sold Page Count Total Pages: 432 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, component testing, specifications Fuel System: Fuel pump, injectors, throttle body, fuel lines, fuel tank, carburetor (if applicable to specific sub-models) Ignition System: Ignition coil, spark plugs, ECU, wiring diagrams Transmission: PVT (Polaris Variable Transmission) operation, clutch maintenance, belt replacement, lubrication Drivetrain: AWD system, differentials (front and rear), driveshafts, CV joints, wheel bearings Brakes: Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedures Suspension: Front and rear suspension components, shocks, springs, control arms, bushings, alignment Steering: Handlebars, steering stem, tie rods, steering linkage, steering wheel (if applicable), power steering system (if equipped) Electrical System: Battery, charging system, starter motor, lighting, switches, fuses, relays, wiring diagrams, ECU diagnostics Body And Frame: Body panels, fenders, racks, seat, frame inspection and repair Cooling System: Radiator, fan, coolant, thermostat, hoses Exhaust System: Muffler, exhaust pipe, heat shields Procedures Included Maintenance: Oil changes, filter replacements, lubrication points, tire pressure checks, belt inspection Troubleshooting: Systematic diagnostic procedures for common and uncommon faults, fault code interpretation Repair: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly Rebuilding: Comprehensive instructions for engine and transmission rebuilding Installation: Instructions for installation of accessories and replacement parts Technical Depth Depth: Complete coverage from basic maintenance to advanced diagnostics and complete engine/transmission overhaul Detail Level: Includes detailed torque specifications, clearances, and diagnostic parameters Schematics: Includes detailed electrical wiring diagrams and hydraulic schematics 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable, enhancing usability Print Quality Quality: High-resolution digital reproduction Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Family: Polaris ProStar (4-stroke SOHC) Engine Type: 4-stroke, Liquid-Cooled, DOHC, 4-valve, Single Cylinder Displacement: Approximately 325cc to 455cc depending on specific engine variant within the HO designation for this period. Bore X Stroke: Refer to manual for precise specifications, typically around 85mm x 80mm for similar displacement engines. Compression Ratio: Refer to manual, typically around 10.0:1 to 11.0:1. Cooling Method: Liquid-Cooled Performance Horsepower: Estimated 25-30 HP (varies by year and exact model configuration, consult manual for definitive figures). Torque: Refer to manual for specific torque figures. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) or Carbureted (confirm for specific sub-model and year from manual) Fuel Type: Unleaded gasoline, minimum 87 octane Fuel Tank Capacity: Approximately 3.25 US gallons (12.3 L) Lubrication Oil Type: SAE 10W-40 Synthetic (confirm specific API rating and JASO standard from manual) Oil Capacity: Approximately 2.0 US quarts (1.9 L) with filter change (verify in manual) 🔧 Transmission Standard Transmission Type: Polaris Variable Transmission (PVT) with Engine Braking (EB) Gear Selection: High, Low, Neutral, Reverse, Park Features Clutch System: Primary and secondary clutch system (belt-driven) Drive System: Shaft Drive, On-Demand...