Polaris Sportsman 400/500 ATV 2012 Repair Manual

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Stichworte: 2012 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500

Produktvarianten

Beschreibung

This manual covers the 2012 Sportsman 400 H.O. and Sportsman 500 H.O. All-Terrain Vehicles (ATVs). The Sportsman line is renowned for its versatility, catering to recreational riders, farm work, and light trail exploration. These ATVs are recognized for their robust engineering, comfortable ride, and capable performance, featuring technologies such as On-Demand All-Wheel Drive and Independent Rear Suspension on the 500 H.O. model. With a strong heritage in powersports, the company consistently delivers reliable and innovative off-road vehicles. This comprehensive factory service manual provides essential information for the maintenance, diagnosis, and repair of your 2012 Sportsman ATV. It details procedures for all major systems, including the engine, fuel, ignition, transmission, chassis, suspension, and electrical components. Within its pages, you will find step-by-step instructions for routine maintenance, troubleshooting common issues, detailed diagnostic techniques, and complete repair and overhaul guidelines. This resource is designed to assist owners, mechanics, and technicians in ensuring the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 400 H.O. / Sportsman 500 H.O.

Year:

Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Segment:

Mid-size utility ATV segment, known for its versatility in recreational riding, farm work, and light trail use.

Competitive Analysis

Competitors:

Competes with models from Honda (FourTrax series), Yamaha (Grizzly series), Can-Am (Outlander series), and Kawasaki (Brute Force series) in the same displacement class.

Key Features

Features Vehicle:

Independent Rear Suspension (IRS) on 500 H.O. model, On-Demand All-Wheel Drive (AWD), powerful Polaris engine, comfortable seating, ample cargo capacity, electronic fuel injection (EFI on 500 H.O. likely).

📋 Manual Details

Coverage Areas

Primary Models Covered:

2012 Polaris Sportsman 400 H.O., 2012 Polaris Sportsman 500 H.O.

Page Count

Estimated Pages:

Refer to actual manual; typically 400-800 pages for comprehensive repair manuals.

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine (400 H.O. / 500 H.O. variants), fuel system, ignition system, exhaust system, transmission (PVT - Polaris Variable Transmission), drive shafts, differentials, axles.

Chassis And Body:

Frame, suspension (front and rear), steering system, braking system (hydraulic disc), wheels, tires, body panels, racks, seats.

Electrical:

Battery, charging system (alternator/stator), starting system, lighting (headlights, taillights, brake lights), instrumentation, wiring diagrams, fuses, relays, ignition switch, kill switch, winch system (if applicable).

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements (oil, air, fuel), spark plug replacement, valve adjustments, lubrication points, brake fluid flush, coolant flush.

Diagnostics And Troubleshooting:

Diagnostic procedures for engine performance issues, electrical faults, fuel delivery problems, starting issues, braking system irregularities. Fault code lookup and interpretation.

Repair And Rebuild:

Complete disassembly and reassembly of engine components, transmission service, suspension component replacement, steering linkage repair, brake system overhaul, electrical component diagnosis and replacement.

Technical Depth

Depth:

Comprehensive, covering routine maintenance, troubleshooting, diagnostics, and full mechanical/electrical repair and overhaul procedures. Includes detailed torque specifications, clearances, and service limits.

📊 Manual Specifications

File Format

Format:

Searchable PDF

Print Quality

Quality:

High-resolution digital scans, suitable for printing individual pages or the entire manual.

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Sportsman 400 H.O.:

375cc, liquid-cooled, 4-stroke, SOHC, single-cylinder. Electronic fuel injection (EFI).

Sportsman 500 H.O.:

499cc, liquid-cooled, 4-stroke, SOHC, single-cylinder. Electronic fuel injection (EFI).

Performance

Horsepower 500 Ho:

Approximately 36-40 HP (estimate, specific figures vary by tuning and conditions).

Torque 500 Ho:

Approximately 28-30 lb-ft (estimate).

Fuel System

Injection Type:

Electronic Fuel Injection (EFI) for both models.

Fuel Type:

Unleaded Gasoline, Octane Rating 87 or higher.

Cooling System

Type:

Liquid-Cooled

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) with engine braking.

Optional

Gearing:

High, Low, Neutral, Reverse, Park.

Features

Drive System:

Shaft Drive; On-Demand All-Wheel Drive (AWD).

Fluid Type

Specification:

Polaris AGL Premium Gearcase Lubricant (or equivalent SAE 10W-50 Synthetic Gear Oil).

📐 Dimensions

Exterior

Length 500 Ho:

Approx. 83 in. (210.8 cm)

Width 500 Ho:

Approx. 48 in. (121.9 cm)

Height 500 Ho:

Approx. 49.5 in. (125.7 cm)

Wheelbase 500 Ho:

Approx. 50.5 in. (128.3 cm)

Weights

Dry Weight 500 Ho:

Approx. 660 lbs (299 kg)

Towing Capacity:

1500 lbs (680 kg)

Rack Capacity Front:

100 lbs (45 kg)

Rack Capacity Rear:

200 lbs (90 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet ANSI standards for recreational off-highway vehicles.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Engine Braking:

Standard feature on Polaris Variable Transmission (PVT) for downhill control.

Passive Features

Lighting:

Dual Halogen Headlights, LED Tail/Brake Light.

Roll Over Protection:

Not equipped with a roll cage; riders must adhere to safe operating practices and wear appropriate safety gear.

💡 Technology Features

Infotainment

Display Features:

Digital odometer, trip meter, high beam indicator, neutral indicator, reverse indicator, oil/coolant/battery indicators.

Driver Assistance

Driving Modes:

On-Demand AWD system automatically engages front wheels when rear wheels slip.

Connectivity

Charging Ports:

Often equipped with a 12V power outlet for accessory charging.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 12 months (refer to manual for exact interval based on usage).

Air Filter Cleaning:

Check every 25 hours, clean/replace as needed. More frequently in dusty conditions.

Spark Plug Replacement:

Refer to manual; typically every 200-300 hours or as needed based on inspection.

Fluid Specifications

Engine Oil Type Capacity:

Polaris Synthetic 0W-40 or SAE 10W-40 (refer to manual for exact spec and capacity - approx. 2 quarts).

Coolant Type:

Polaris Premium 2-Stroke Pre-Mix (or equivalent ethylene glycol-based coolant with corrosion inhibitors) - typically 50/50 mix.

Known Issues

Common Wear Items:

Drive belts (PVT), brake pads, suspension bushings, tie rod ends, wheel bearings. Regular inspection and replacement are key.

Potential Electrical Concerns:

While generally reliable, earlier models sometimes experienced voltage regulator or stator issues. Diagnosis is crucial.

Filter Part Numbers

Oil Filter Example 500 Ho:

Polaris part number 3082999 or equivalent aftermarket.

📚 Vehicle History

Brand Heritage

Heritage:

Polaris Industries Inc. is a major American manufacturer of off-road vehicles, including ATVs, snowmobiles, and side-by-sides. Known for innovation in the powersports industry.

Model Evolution

Sportsman Line:

The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, evolving with technological advancements like IRS, EFI, and improved suspension geometry to enhance comfort and performance.

Production

Manufacturing Location:

Primarily manufactured in the United States (e.g., Roseau, Minnesota).

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Polaris Sportsman models consistently receive positive reviews for their comfort, capability, and value within the ATV market.