Model:
Sportsman 400 HO / 500 HO / Touring 500 HO / Forest Tractor 500 EFI
Chassis Code:
Various (Specific to sub-model, e.g., Sportsman 400 HO likely A12CH40AA, Sportsman 500 HO A12CH50AO, Sportsman Touring 500 HO A12CH50AO, Sportsman Forest Tractor 500 EFI A12CH50EF - refer to specific VIN for absolute confirmation)
Positioning:
This manual serves the robust Polaris Sportsman line, a popular choice for utility and recreational ATV riders. It addresses the needs of owners seeking to maintain, repair, or diagnose issues on their 2012 models.
Competitors:
Competes with service manuals for other utility ATVs of the era, such as Can-Am Outlander, Arctic Cat ATV models, and Yamaha Grizzly.
Features:
Comprehensive coverage for multiple engine displacements and configurations (400 HO, 500 HO, EFI), detailed troubleshooting, and step-by-step repair procedures.
Vehicles Covered:
2012 Polaris Sportsman 400 HO ATV, 2012 Polaris Sportsman 500 HO ATV, 2012 Polaris Sportsman Touring 500 HO ATV, 2012 Polaris Sportsman Forest Tractor 500 EFI ATV
Estimated Page Count:
400-600 pages (typical for comprehensive service manuals of this era and vehicle type)
Type:
Repair Manual / Service Manual / Workshop Manual
Format:
Digital Download (PDF)
Engine System:
Engine removal/installation, lubrication, cooling, fuel system, intake, exhaust, engine specifications, top-end and bottom-end rebuilds
Drivetrain System:
Transmission, drive chain, sprockets, final drive, AWD system (if applicable)
Chassis And Suspension:
Steering system, shocks, suspension components, frame inspection
Electrical System:
Wiring diagrams, battery, charging system, ignition, lighting, starter, ECU, troubleshooting electrical faults
Body And Trim:
Body panels, fenders, racks, seats, storage components
Maintenance:
Routine maintenance schedules, fluid changes (oil, coolant, brake fluid), filter replacements, lubrication points
Repair:
Engine overhauls, transmission repairs, suspension component replacement, electrical diagnostics and repair, brake system servicing
Troubleshooting:
Diagnostic procedures, common problems and solutions, error code interpretation (if applicable)
Depth:
Comprehensive, covering basic to advanced repair and diagnostic procedures. Suitable for DIY mechanics and professional technicians.
Engine Type 400 Ho:
4-stroke, SOHC, 2-valve, Single Cylinder, Liquid-Cooled
Engine Displacement 400 Ho:
375 cc (approx.)
Engine Type 500 Ho:
4-stroke, SOHC, 2-valve, Single Cylinder, Liquid-Cooled
Engine Displacement 500 Ho:
499 cc (approx.)
Engine Type 500 Efi:
4-stroke, SOHC, 2-valve, Single Cylinder, Liquid-Cooled, Electronic Fuel Injection (EFI)
Engine Displacement 500 Efi:
499 cc (approx.)
Horsepower 500 Ho:
Approx. 34 HP (Varies slightly by source, actual output may differ)
Carbureted Models:
Keihin CV Carburetor (specific size depends on model variant, likely 34-36mm for 500 HO)
Efi Models:
Electronic Fuel Injection (EFI), 40mm Throttle Body (typical for 500 EFI)
Cooling Method:
Liquid-cooled with fan assist
Length:
Approx. 83-85 inches (Varies by sub-model; Touring models are longer)
Height:
Approx. 48-50 inches
Dry Weight:
Approx. 650-720 lbs (Varies by sub-model; Touring models are heavier)
Towing Capacity:
1500 lbs (680 kg) (Typical for Sportsman 500 models)
Cargo Capacity Front Rack:
100 lbs (45 kg)
Cargo Capacity Rear Rack:
200 lbs (90 kg)
Atv Safety Standards:
Meets ANSI standards for recreational ATVs.
Braking System:
Hydraulic disc brakes front and rear, often with foot pedal operation for rear and hand lever for front.
Engine Braking:
Standard engine braking provided by the PVT transmission.
Lighting:
Dual headlights, taillight, brake light.
Seat And Ergonomics:
Comfortable seating positions, handgrips, and controls designed for rider control and comfort.
Display Features:
Digital odometer, trip meter, speedometer, high/low gear indicator, fuel gauge (on some models), AWD indicator, clock.
AWD System:
Polaris' On-Demand All-Wheel Drive (AWD) automatically engages front drive when rear wheels lose traction.
Charging System:
12V charging system with AC alternator providing power for ignition, lights, and accessories.
Engine Oil Change Interval:
Every 100 hours or 12 months (whichever comes first) - refer to manual for precise interval and conditions.
Transmission Oil Change Interval:
Every 100 hours or 12 months (whichever comes first) for the transmission/final drive unit.
Air Filter Inspection:
Inspect every 25 hours, clean/replace as needed. More frequent cleaning in dusty conditions.
Spark Plug Replacement Interval:
Typically every 100 hours or as specified in manual, depending on plug type.
Engine Oil Type:
Polaris Synthetic 2W-50 (or equivalent JASO MA certified 4-stroke motorcycle oil with correct viscosity).
Engine Oil Capacity 400 Ho:
Approx. 2.25 quarts (2.1 liters) with filter change.
Engine Oil Capacity 500 Ho:
Approx. 2.25 quarts (2.1 liters) with filter change.
Transmission Gear Lube:
Polaris Demand Drive Fluid (for front differential) and Polaris Angle Drive Fluid (for rear final drive). Specific viscosity grades will be detailed in the manual.
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water) - meeting specific Polaris requirements.
Common Wear Items:
Drive belts (PVT), wheel bearings, tie rod ends, suspension bushings are common wear items on ATVs of this age and usage.
Potential Efi Issues:
On EFI models, issues could include fuel injector clogging, throttle position sensor (TPS) calibration, or idle air control (IAC) valve problems. Fuel quality is critical.
Polariss Heritage:
Polaris Industries Inc. has a long-standing history in powersports, beginning with snowmobiles and expanding into ATVs and other vehicles.
Sportsman Line Evolution:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, capability, and rider-friendly features. The 400 and 500 HO models represent evolutionary steps in Polaris' single-cylinder engine technology and chassis design.
Production Era:
2012 models are part of the Gen 2 (or later) Sportsman platform, refined over many years.
