Vehicle Segment:
Utility ATV, known for its versatility in work and recreational applications.
Key Competitors:
Competed with models from Can-Am (Outlander), Honda (FourTrax/Rancher), Yamaha (Grizzly), and Suzuki (KingQuad) in the utility ATV segment.
Versatility:
Designed for a wide range of tasks including farming, hunting, trail riding, and property maintenance.
Durability:
Polaris Sportsman line is generally recognized for its robust construction and reliability in demanding conditions.
Indexing Importance:
This manual is crucial for owners and technicians to maintain and repair these capable ATVs effectively, ensuring longevity and optimal performance.
Coverage Scope:
Comprehensive service and repair for 2012 Polaris Sportsman 400 and 500 models.
Estimated Page Count:
Likely 300-500 pages (typical for a factory shop manual).
Manual Type:
Factory Shop Manual / Service Manual
Language:
English (as indicated by product description and typical for factory manuals).
Engine Service:
Detailed procedures for engine disassembly, assembly, troubleshooting, and component replacement.
Transmission And Drivetrain:
Coverage of transmission, differential, axle, and driveshaft maintenance and repair.
Fuel System:
Information on fuel pump, carburetor/fuel injection, fuel filter, and fuel tank servicing.
Electrical System:
Wiring diagrams, component testing, troubleshooting for ignition, lighting, charging, and accessories.
Cooling System:
Radiator, fan, coolant hoses, and thermostat service procedures.
Braking System:
Hydraulic brake system service, including master cylinder, calipers, lines, and bleeding procedures.
Suspension And Steering:
Front and rear suspension component inspection, replacement, and wheel alignment.
Chassis And Body:
Frame inspection, body panel removal and installation, and seat servicing.
Maintenance Procedures:
Routine maintenance tasks, lubrication points, and inspection schedules.
Troubleshooting Guides:
Diagnostic charts and common issue resolution for various systems.
Preventative Maintenance:
Detailed schedules and instructions for oil changes, filter replacements, and fluid checks.
Component Diagnosis:
Step-by-step diagnostic procedures for identifying faulty components.
Overhaul Instructions:
Complete disassembly and reassembly instructions for major components like the engine and transmission.
Special Tool Identification:
Specification of required special tools for specific repair procedures.
Depth Of Information:
Factory-level detail, suitable for professional technicians and experienced DIY mechanics.
Diagnostic Capabilities:
Advanced diagnostic procedures, including electrical system testing and fault code interpretation (if applicable).
Repair Accuracy:
Authoritative information for ensuring repairs are performed to factory specifications.
Engine Type 400:
Single-cylinder, 4-stroke, SOHC (Sportsman 400 typically used a ~375cc or ~455cc engine depending on variant).
Engine Type 500:
Single-cylinder, 4-stroke, SOHC, typically around 499cc to 500cc, often carbureted or EFI depending on specific sub-model/region.
Horsepower Estimate 400:
Estimated 25-30 HP (varies by specific engine configuration).
Horsepower Estimate 500:
Estimated 30-35 HP (varies by specific engine configuration).
Fuel Delivery 400:
Likely carbureted (e.g., Mikuni or Keihin), though some later 400s may have received EFI.
Fuel Delivery 500:
Typically electronic fuel injection (EFI) for 2012 models, providing better throttle response and fuel efficiency. Some variants might still be carbureted.
Cooling Method:
Liquid-cooled
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive Modes:
Selectable 2WD/4WD, often with AWD (All-Wheel Drive) engagement.
Gear Selection:
High, Low, Neutral, Reverse, Park.
Clutch Type:
Primary and secondary clutch system for CVT operation.
Length:
Approx. 83 inches (210.8 cm) - varies slightly by specific model variant.
Width:
Approx. 46 inches (116.8 cm).
Height:
Approx. 45 inches (114.3 cm).
Dry Weight:
Approx. 600-650 lbs (272-295 kg) - varies by model and equipment.
Towing Capacity:
Typically 1500 lbs (680 kg).
Cargo Capacity Rack Front:
Approx. 100 lbs (45 kg).
Cargo Capacity Rack Rear:
Approx. 200 lbs (90 kg).
Atv Safety Standards:
Designed to meet industry safety standards for ATVs.
Braking System:
Hydraulic disc brakes on all wheels.
Engine Braking:
CVT system provides engine braking on deceleration.
Ergonomics:
Designed with rider comfort and control in mind.
Frame Construction:
Steel frame for durability and strength.
Instrument Cluster:
Digital instrument cluster displaying speed, RPM, fuel level, gear indicator, trip meters, and diagnostic lights.
Efi System:
Electronic Fuel Injection (EFI) on 500 model enhances performance and cold starts.
Charging System:
12V DC charging system with alternator for battery charging and accessory power.
Engine Oil Change:
Typically every 100 hours or annually, whichever comes first.
Gearcase Oil Change:
Typically every 100 hours or annually.
Differential Oil Change:
Typically every 100 hours or annually.
Engine Oil Type:
SAE 5W-50 synthetic or premium conventional motorcycle oil (API SG or higher).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Cvt Fluid Type:
Polaris specified CVT fluid or equivalent (manual will specify exact type).
Cv Boots:
CV joint boots can be prone to tearing due to exposure, requiring regular inspection and replacement.
Battery Performance:
Ensure battery terminals are clean and connections are tight, as voltage drops can affect EFI systems.
Throttle Response:
EFI models may require occasional sensor cleaning or recalibration for optimal throttle response.
Polaris Atv Legacy:
Polaris has a long history of ATV manufacturing, beginning with the Polaris ATCs in the 1980s and evolving into the dominant Sportsman line.
Sportsman Line Development:
The Sportsman line, introduced in 1993, has consistently been a market leader, evolving with new technologies, engine options, and feature sets.
Manufacturing Location:
Polaris vehicles are primarily manufactured in the USA, often in Minnesota.
