Positioning:
The 2012 Polaris Sportsman lineup represented Polaris's strong presence in the utility ATV market, offering versatile options for work, recreation, and specialized tasks.
Competitors:
Key competitors in this segment included Can-Am Outlander, Yamaha Grizzly, and Kawasaki Brute Force ATVs.
Durability:
Polaris Sportsman models are known for their robust construction and capability in demanding off-road conditions.
Versatility:
The range of models (400 HO, 500 HO, Touring, Forest Tractor) highlights the versatility of the platform, catering to different user needs from trail riding to heavy-duty work.
Engine Options:
Offered with different engine displacements and configurations (HO - High Output, EFI - Electronic Fuel Injection) to suit performance and efficiency requirements.
Covered Models:
2012 Polaris Sportsman 400 HO, 2012 Polaris Sportsman 500 HO, 2012 Polaris Sportsman Touring 500 HO, 2012 Polaris Sportsman Forest Tractor 500 EFI
Specific Variants Covered:
All configurations and options for the specified models.
Estimated Pages:
Likely extensive, typical of factory service manuals (estimated 500+ pages, actual count not specified in product info).
Type:
Factory Service Repair Manual
Engine:
Detailed repair and maintenance procedures for the engine, including disassembly, assembly, tuning, and troubleshooting.
Fuel Systems:
Coverage of fuel delivery systems, including carburetors (for non-EFI models) and EFI components, fuel pumps, injectors, and filters.
Body Suspension:
Comprehensive information on body panels, frame, suspension components (shocks, A-arms, bushings), steering system, and bodywork repairs.
Clutch:
Detailed procedures for clutch inspection, service, and replacement, including primary and secondary clutch components.
Final Drive:
Information on drive shafts, CV joints, differentials, and axle maintenance and repair.
Transmission:
Repair and maintenance for the transmission, including gear selection, shifting mechanisms, and internal components.
Brakes:
Detailed guidance on brake system maintenance, including hydraulic lines, calipers, master cylinders, rotors, and bleeding procedures.
Electrical:
Extensive coverage of the electrical system, including battery, charging system, ignition system, lighting, starter, wiring diagrams, and component testing.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, and general upkeep.
Repair:
Step-by-step instructions for component repair, troubleshooting, and replacement for all major vehicle systems.
Diagnostics:
Troubleshooting guides and diagnostic procedures to identify and resolve common and complex issues.
Depth:
Comprehensive, covering everything from basic routine maintenance to complex engine and transmission overhauls, suitable for professional mechanics and experienced DIY enthusiasts.
400 Ho Engine:
Likely a Polaris 325cc or 375cc, liquid-cooled, 4-stroke engine (specific displacement not provided, typical for 400 class).
500 Ho Engine:
Typically a Polaris 499cc liquid-cooled, SOHC, 4-stroke engine. HO denotes higher output for improved performance.
Touring 500 Ho Engine:
Utilizes the same 499cc engine as the standard 500 HO, optimized for comfort and extended riding with two-up capability.
Forest Tractor 500 Efi Engine:
A 499cc liquid-cooled, SOHC, 4-stroke engine with Electronic Fuel Injection for precise fuel delivery and throttle response, often tuned for torque for work applications.
Horsepower Torque:
Horsepower and torque figures vary by engine size but are generally robust for utility ATV applications. Specific figures require consulting the manual.
Efi:
Electronic Fuel Injection is featured on the Forest Tractor model, providing better cold starting, fuel efficiency, and throttle response compared to carbureted systems.
Carburetor:
Non-EFI models (400 HO, 500 HO, Touring 500 HO) likely use a Keihin or similar carburetor, requiring specific tuning and maintenance.
Type:
Automatic PVT (Polaris Variable Transmission) with High, Low, Neutral, and Reverse gears.
Options:
N/A (PVT is standard across the lineup).
Engine Braking:
The PVT system typically incorporates engine braking for controlled descents.
Transmission Fluid Type:
Requires specific Polaris branded PVT fluid or an equivalent meeting Polaris specifications. Consult manual for exact type and viscosity.
Length:
Varies by model, typically around 80-83 inches for standard models and longer for touring versions. Specific figures in manual.
Width:
Varies by model, typically around 46-48 inches. Specific figures in manual.
Height:
Varies by model, typically around 48-50 inches. Specific figures in manual.
Dry Weight:
Varies by model, typically in the range of 650-750 lbs. Specific figures in manual.
Towing Capacity:
Generally rated for 1500 lbs towing capacity across the lineup. Specific figures in manual.
Rack Capacity:
Front and rear racks with significant weight carrying capacity, often around 100 lbs front and 200 lbs rear. Specific figures in manual.
Crash Tests:
ATVs are not subject to the same standardized crash testing as passenger vehicles. Safety is primarily determined by design and operator responsibility.
Braking System:
Hydraulic disc brakes on all wheels for effective stopping power.
Suspension:
Independent Front and Rear Suspension (often MacPherson Strut front, Dual A-Arm rear with Independent Rear Suspension on some) for stable handling and control.
Operator Safety:
Emphasis on proper rider training, protective gear, and adherence to safe operating practices as detailed in the owner's manual and this service manual.
Display:
Features a digital LCD display providing essential information such as speed, RPM, fuel level, gear indicator, and trip meters.
Efi:
Electronic Fuel Injection on the Forest Tractor model enhances drivability and efficiency.
Charging System:
Standard 12V DC electrical system with alternator for charging the battery and powering accessories.
Headlights Taillights:
Equipped with dual headlights and a taillight/brake light for visibility and safety.
Oil Change:
Typically recommended every 100 hours or 6 months, whichever comes first. Specifics will be detailed in the manual.
Air Filter:
Inspection and cleaning/replacement recommended at frequent intervals, especially in dusty conditions. Schedule in manual.
Spark Plug:
Replacement interval typically around 100-200 hours, or based on inspection. Manual will specify type and gap.
Belt Inspection:
PVT belt inspection and adjustment/replacement are critical maintenance items. Intervals specified in manual, often yearly or based on hours/condition.
Engine Oil:
Likely SAE 0W-40 or 10W-40 synthetic ATV specific oil. Manual will list exact grade and capacity.
Coolant:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Manual will specify type and capacity.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid. Manual will specify exact type and reservoir capacity.
Pvp Belt Wear:
Variable transmission belts can wear over time and require periodic inspection and replacement to prevent loss of power or clutch damage.
Suspension Bushings:
Like many ATVs, suspension bushings can wear, leading to play and decreased handling performance. Regular inspection and lubrication are key.
Electrical Connections:
Corrosion or loose electrical connections can lead to intermittent issues with lights, ignition, or accessories. Manual covers troubleshooting.
Polaris Atv History:
Polaris has been a pioneer in the ATV industry since the 1980s, known for innovation and building rugged, capable machines.
Sportsman Lineage:
The Sportsman has been a cornerstone of Polaris's ATV offerings, evolving significantly over the years to incorporate advanced technology, improved ergonomics, and enhanced performance.
Manufacturing Location:
Polaris ATVs are primarily manufactured in the United States, with key facilities in Minnesota and Iowa.
