Segment:
Mid-size utility ATV, positioned for recreational and light-duty farm/ranch use.
Target Audience:
Off-road enthusiasts, hunters, farmers, and general recreational riders seeking a reliable and capable ATV.
Key Competitors:
Honda Rancher, Yamaha Kodiak, Kawasaki Brute Force, Can-Am Outlander (competitors in similar displacement and capability classes).
Versatility:
Known for its versatile performance across various terrains, including trail riding, mud, and light work applications.
Durability:
Polaris Sportsman line is generally regarded for its robust build and durability, suitable for demanding conditions.
General Coverage:
Comprehensive service and repair for Polaris Sportsman 400 HO and 500 HO ATVs.
Specific Systems Covered:
Engine, Fuel System, Drivetrain, Transmission, Electrical System, Chassis, Suspension, Brakes, Steering, Bodywork, Accessories.
Estimated Pages:
Over 500 pages (typical for a factory service manual of this scope).
Type:
Factory Service Repair Manual / Workshop Manual
Format:
Downloadable Digital File (likely PDF)
Engine And Drivetrain:
Detailed diagrams, specifications, disassembly, assembly, troubleshooting, and repair procedures for the engine, including top-end, bottom-end, cooling system, and oil lubrication.
Fuel And Exhaust:
Carburetor (or EFI if applicable), fuel pump, fuel lines, fuel filter, and exhaust system maintenance and repair.
Transmission And Drive Axles:
Maintenance, inspection, and repair of the automatic transmission, PVT (Polaris Variable Transmission), drive shafts, CV joints, and differentials.
Electrical System:
Wiring diagrams, component testing (starter, alternator/stator, battery, ignition system), lighting, switches, and accessory circuits.
Chassis And Suspension:
Frame inspection, front and rear suspension (A-arms, shocks, springs, bushings), wheel bearings, and hub assemblies.
Brakes And Steering:
Brake system inspection, service (pads, rotors, fluid), bleeding procedures, and steering system components (tie rods, steering column, rack and pinion).
Body And Plastics:
Removal and installation of body panels, fenders, racks, and seat.
Routine Maintenance:
Oil changes, filter replacements, spark plug service, air filter cleaning/replacement, lubrication points, and general inspections.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts.
Component Repair And Rebuild:
Detailed instructions for disassembly, inspection, repair, and reassembly of major components.
Diagnostic Procedures:
Testing of electrical components, fuel system pressures, and ignition timing (if applicable).
Specifications And Tolerances:
Torque values, clearances, fluid capacities, and material specifications for all serviceable parts.
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance to complete engine and transmission overhauls. Designed for professional technicians and advanced DIY mechanics.
Engine Type:
4-stroke, SOHC, 4-valve, Single Cylinder
Displacement 400:
375cc (approximate)
Displacement 500 Ho:
499cc (approximate)
Horsepower 400:
Approx. 25-28 HP (estimated)
Horsepower 500 Ho:
Approx. 30-34 HP (estimated)
Torque 500 Ho:
Approx. 30-32 lb-ft (estimated)
Fuel Delivery 400:
Carburetor (likely Mikuni or Keihin)
Fuel Delivery 500 Ho:
Electronic Fuel Injection (EFI) - High Output
Fuel Type:
Unleaded Gasoline (91 Octane Recommended)
Cooling Method:
Liquid-Cooled
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with Engine Braking
Gear Selection:
High, Low, Neutral, Reverse, Park
Optional Transmissions:
N/A for this model year and configuration.
Drive System:
On-Demand AWD/2WD (Activates automatically when front wheels lose traction)
Final Drive:
Sealed, single-ratio IRS (Independent Rear Suspension) with 2WD/AWD and shaft drive to front and rear wheels.
Length:
Approx. 83 in. (210.8 cm)
Width:
Approx. 46 in. (116.8 cm)
Height:
Approx. 48 in. (121.9 cm) (ground to handlebars)
Wheelbase:
Approx. 50.5 in. (128.3 cm)
Ground Clearance:
Approx. 11.5 in. (29.2 cm)
Front Rack Capacity:
100 lbs (45 kg)
Rear Rack Capacity:
200 lbs (90 kg)
Dry Weight 400:
Approx. 660 lbs (299 kg)
Dry Weight 500 Ho:
Approx. 695 lbs (315 kg)
Towing Capacity:
1500 lbs (680 kg)
Seating Capacity:
1 (with optional 2-up seat kits available)
Atv Safety Standards:
Manufactured to meet applicable ANSI standards.
Braking System:
Hydraulic disc brakes front and rear with sealed parking brake.
Engine Braking:
Integrated engine braking system via the PVT.
Rollover Protection:
N/A (ATVs do not have roll cages by design, always recommend helmet use).
Lighting:
Dual halogen headlights, brake light, and taillight.
Infotainment System:
N/A - Basic utility ATV, no integrated infotainment beyond basic instrumentation.
Driver Assistance Features:
On-Demand AWD system is the primary technological assistance for traction.
Connectivity Options:
N/A
Dashboard Features:
Speedometer, odometer, trip meter, tachometer (on some variants), fuel gauge, 2WD/AWD indicator, high/low gear indicator, battery voltage indicator, engine hour meter.
Oil Change Interval:
Every 100 hours or 6 months (whichever comes first). Check manual for specific usage conditions.
Air Filter Inspection:
Inspect every 25 hours, clean/replace as needed. Replace every 100 hours.
Spark Plug Replacement:
Every 100 hours or annually.
Pvt Belt Inspection:
Inspect every 50 hours for wear and tear, replace as needed or at 100 hours if heavy use.
Engine Oil Type:
SAE 0W-40 Synthetic (Polaris branded or equivalent meeting API CI-4 specifications).
Engine Oil Capacity:
Approx. 1.9 quarts (1.8 L) with filter change.
Coolant Type:
Ethylene Glycol based antifreeze (Polaris recommends specific blend).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Gearcase Oil Type:
SAE 75W-90 Synthetic Gear Oil.
Common Wear Items:
PVT belt, tie rod ends, ball joints, wheel bearings, shock bushings due to off-road use.
Potential Engine Issues:
Carbon buildup in older carbureted models, occasional stator or voltage regulator failures. EFI models generally more reliable.
Electrical Issues:
Corrosion in connectors, battery terminal issues, especially in wet or muddy conditions.
Polariss Heritage:
Polaris Industries Inc. has a long history in powersports, beginning with snowmobiles and expanding into ATVs, motorcycles, and off-road vehicles.
Sportsman Line History:
The Sportsman line has been a cornerstone of Polaris's ATV offerings, known for its comfort, IRS, and AWD capabilities, evolving significantly since its introduction.
Manufacturing Location:
Primarily manufactured in the United States by Polaris Industries.
Model Year Significance:
The 2012 models represent a mature iteration of the Sportsman platform, incorporating refinements based on years of market feedback.
