Polaris Sportsman 500 HO Touring 2012 2013 Service Manual

Normaler Preis: $16.99
Verkaufspreis: $16.99
Normaler Preis
Grundpreis: pro

25 people are viewing this right now

Typ: Atv

Anbieter:

Art.-Nr: 71138

Stichworte: 2012 2013 ATV Misc Polaris Powersports Sportsman 500 HO Touring

Produktvarianten

Beschreibung

The Polaris Sportsman 500 HO Touring, produced for the 2012 and 2013 model years, represents a premium all-terrain vehicle engineered for both capable trail riding and comfortable two-up excursions. Featuring an extended wheelbase for enhanced stability and passenger comfort, this model is powered by a robust 500cc High Output engine, delivering ample power for hauling, towing, and tackling diverse terrain. Its independent front and rear suspension systems ensure a smooth ride and superior control, characteristic of advanced ATV engineering. This Workshop Service Manual provides comprehensive guidance for the maintenance, diagnosis, and repair of your Polaris Sportsman 500 HO Touring. It covers all essential systems, including the engine, fuel, ignition, cooling, transmission, drivetrain, suspension, brakes, steering, and electrical systems. Detailed procedures for routine maintenance, troubleshooting, component overhaul, and adjustments are included, along with specifications and special tool requirements. This manual is an indispensable resource for professional technicians and owners aiming to maintain the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 HO Touring

Model Variant:

Touring

Model Trim:

HO (High Output)

Production Years Covered:

2012, 2013

Codes

Chassis Code:

AWD/2WD configurations, standard for this model

Engine Code:

Likely A90 (refer to VIN for precise engine type)

👋 Introduction

Market Position

Vehicle Segment:

Premium all-terrain, multi-purpose ATV, designed for rider and passenger comfort and capability.

Competitive Analysis

Competitors 2012 2013:

Can-Am Outlander MAX, Yamaha Grizzly 550/700, Arctic Cat TRV.

Key Features Vehicle

Touring Capability:

Extended wheelbase for enhanced rider and passenger comfort, integrated passenger seat and backrest.

Engine Power:

500cc HO engine providing robust power for hauling, towing, and trail riding.

Suspension System:

Independent front and rear suspension for superior ride quality and control over varied terrain.

Manual Utility

Target Audience:

Professional mechanical technicians, experienced DIY enthusiasts, and owners seeking in-depth maintenance and repair knowledge.

Value Proposition:

Enables owners to perform maintenance and repairs effectively, reducing reliance on external service centers and extending vehicle lifespan.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual

Language:

English

Format:

PDF Download

Page Count

Estimated Page Count:

Varies by specific edition, typically 500-700 pages for this type of detailed manual.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, and reassembly of the engine; cylinder head, piston, crankshaft, valve train, timing systems.

Fuel System:

Carburetor (likely Mikuni BST40 for this model) tuning, cleaning, and rebuilding; fuel pump operation; fuel tank and lines.

Ignition System:

CDI unit, ignition coil, spark plug diagnosis, stator and rotor inspection.

Cooling System:

Radiator, fan, thermostat, coolant flow, water pump.

Transmission And Drivetrain:

PVT (Polaris Variable Transmission) system, drive clutch, driven clutch, belt inspection and replacement, final drive gears, differential, driveshafts, CV joints.

Suspension:

Front and rear suspension components, shock absorbers, A-arms, bushings, ball joints, wheel bearings.

Brakes:

Hydraulic brake system, master cylinders, brake calipers, brake pads, brake lines, bleeding procedures, parking brake.

Steering:

Handlebar assembly, steering post, tie rods, steering rack/mechanism.

Electrical System:

Wiring diagrams, battery, charging system (alternator/stator), starter motor, lighting (headlights, taillights, brake lights), instrumentation, switches, fuses, relays.

Chassis And Body:

Frame inspection, body panels, fenders, seat, rack systems, removal and installation procedures.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug maintenance, air filter cleaning/replacement, lubrication points.

Troubleshooting Guides:

Diagnostic charts and procedures for common and uncommon problems across all systems.

Repair Procedures:

Step-by-step instructions for component removal, repair, and installation.

Overhaul Procedures:

Detailed guidance for complete engine or transmission rebuilds.

Adjustment Procedures:

Carburetor tuning, valve lash adjustments, brake adjustments, clutch adjustments.

Special Tool Requirements:

Identification of and instructions for using specific tools required for certain repairs.

Technical Depth

Depth Of Coverage:

Comprehensive, ranging from basic owner maintenance to advanced mechanical and electrical diagnostics and repairs.

Diagnostic Capabilities:

Detailed diagnostic flowcharts and troubleshooting for ignition, fuel, electrical, and mechanical issues.

Rebuild Specifications:

Includes all necessary torque specifications, tolerances, and clearances for major component rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, allowing for quick information retrieval.

Print Quality

Image Resolution:

Typically high-resolution for clear diagrams and photographs.

Binding Type

Physical Format Analogy:

Not applicable (digital download), but professionally laid out for print if desired.

Paper Type

Digital Equivalent:

High-resolution digital pages, suitable for on-screen viewing or printing.

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, SOHC, liquid-cooled

Displacement:

499cc (30.4 cu. in.)

Bore X Stroke:

92.0 mm x 75.0 mm (3.62 in. x 2.95 in.)

Compression Ratio:

Typically 9.0:1 or similar for this era 500cc engine.

Performance

Horsepower Rated:

Approx. 38-40 HP (specific rating can vary slightly by test conditions and model year, manual will confirm exact figures).

Torque Rated:

Not explicitly stated in product description, but ample for its class.

Fuel System

Carburetor Model:

Likely Mikuni BST40, 40mm

Fuel Type:

Unleaded gasoline, minimum 87 octane

Fuel Tank Capacity:

Typically 3.25 gallons (12.3 L)

🔧 Transmission

Standard

Transmission Type:

Automatic PVT (Polaris Variable Transmission) with Engine Braking

Optional

Gearing:

High and Low range, Neutral, Reverse

Features

Drive System:

On-Demand True All-Wheel Drive (AWD) / 2WD

Final Drive:

Shaft Drive

📐 Dimensions

Exterior

Wheelbase:

57 inches (144.8 cm)

Length:

83 inches (210.8 cm)

Width:

46 inches (116.8 cm)

Height:

50 inches (127 cm)

Cargo

Front Rack Capacity:

100 lbs (45.4 kg)

Rear Rack Capacity:

200 lbs (90.7 kg)

Weights

Dry Weight:

Approx. 661 lbs (299.8 kg)

Towing Capacity:

1,500 lbs (680.4 kg)

ગ운 Capacity:

300 lbs (136 kg)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Designed to meet ANSI standards for recreational ATVs.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Engine Braking:

Integrated into the PVT system for downhill control.

Passive Features

Lighting:

Dual headlights, taillight/brake light.

Passenger Safety:

Integrated passenger seat with handholds and backrest.

💡 Technology Features

Infotainment

Instrumentation:

Digital instrumentation cluster typically includes speedometer, odometer, trip meter, tachometer, fuel gauge, and indicator lights.

Driver Assistance

AWD System:

Polaris's On-Demand True All-Wheel Drive system automatically engages the front wheels when slippage is detected.

Connectivity

Charging System:

12V DC output from stator, allowing for charging of battery and powering accessories.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 100 hours or annually, whichever comes first. Manual will specify exact interval.

Air Filter Maintenance:

Check every 20-40 hours, clean/replace as needed. Crucial for engine longevity.

Spark Plug Replacement:

Check/gap every 50-100 hours, replace as recommended.

Transmission Belt Inspection:

Inspect every 50 hours for wear and damage. Replace based on condition or at recommended mileage/hour intervals.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 4-stroke engine oil (or equivalent SAE 5W-50 full synthetic motorcycle oil, refer to manual for exact specification).

Engine Oil Capacity:

Approximately 1.7 US quarts (1.6 L) with filter change. Manual will provide precise capacity.

Coolant Type:

Ethylene glycol based antifreeze (e.g., Polaris Premium Antifreeze or equivalent 50/50 mix).

Transmission Gearcase Oil:

Likely a specific Polaris gearcase lubricant or SAE 80W-90 hypoid gear oil. Manual is essential for confirmation.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. Manual will specify.

Known Issues

Typical Wear Items:

Brake pads, wheel bearings, tie rod ends, ball joints, suspension bushings, PVT belt, and starter brushes are common wear items.

Common Concerns Engine:

Carburetor gumming from ethanol fuels if not properly stored, stator failures (less common on this model but possible), and heat management in heavy use.

Common Concerns Drivetrain:

PVT belt wear, especially under aggressive riding or heavy loads. AWD system engagement can sometimes be sensitive to maintenance.

📚 Vehicle History

Brand Heritage

Polaris History:

Polaris Industries Inc. is a long-standing American manufacturer known for pioneering snowmobiles and expanding into ATVs, UTVs, and motorcycles.

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris's ATV offerings, evolving with features like independent suspension and the VersaTrac AWD system. The Touring models represent an expansion to cater to two-up riding comfort.

Production

Manufacturing Location:

Primarily manufactured in the USA.

🏆 Awards & Recognition

Recognitions

Atv Segment Awards:

The Polaris Sportsman line consistently receives positive reviews for its comfort, capability, and value within the utility and touring ATV segments. Specific awards for the 2012/2013 500 HO Touring model would be detailed in industry publications of the time.

Ratings

Consumer Satisfaction:

Generally high for Polaris ATVs, particularly regarding ride comfort and utility features.