Positioning:
The Polaris Sportsman 400 HO is positioned as a versatile and capable mid-size ATV, offering a balance of power, comfort, and utility for recreational riders and light-duty farm/ranch work.
Competitors:
Competes with models from Honda (e.g., Rancher), Yamaha (e.g., Kodiak), Can-Am (e.g., Outlander L), and Arctic Cat (e.g., Alterra).
Features:
Independent Rear Suspension (IRS), On-Demand All-Wheel Drive (AWD), Electronic Fuel Injection (EFI) on later models (ensure model specific check), powerful HO engine, comfortable seating, ample rack capacity.
Value:
This comprehensive workshop manual provides DIY mechanics and professional technicians with the essential information to maintain, diagnose, and repair the Polaris Sportsman 400 HO 2012-2013 models, saving time and money.
Engine:
Complete engine overhaul, diagnostics, component testing, specifications
Fuel System:
Fuel pump, injectors, throttle body, fuel lines, fuel tank, carburetor (if applicable to specific sub-models)
Ignition System:
Ignition coil, spark plugs, ECU, wiring diagrams
Transmission:
PVT (Polaris Variable Transmission) operation, clutch maintenance, belt replacement, lubrication
Drivetrain:
AWD system, differentials (front and rear), driveshafts, CV joints, wheel bearings
Brakes:
Hydraulic brake system, calipers, master cylinder, brake lines, pads, rotors, bleeding procedures
Suspension:
Front and rear suspension components, shocks, springs, control arms, bushings, alignment
Steering:
Handlebars, steering stem, tie rods, steering linkage, steering wheel (if applicable), power steering system (if equipped)
Electrical System:
Battery, charging system, starter motor, lighting, switches, fuses, relays, wiring diagrams, ECU diagnostics
Body And Frame:
Body panels, fenders, racks, seat, frame inspection and repair
Cooling System:
Radiator, fan, coolant, thermostat, hoses
Exhaust System:
Muffler, exhaust pipe, heat shields
Maintenance:
Oil changes, filter replacements, lubrication points, tire pressure checks, belt inspection
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, fault code interpretation
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly
Rebuilding:
Comprehensive instructions for engine and transmission rebuilding
Installation:
Instructions for installation of accessories and replacement parts
Depth:
Complete coverage from basic maintenance to advanced diagnostics and complete engine/transmission overhaul
Detail Level:
Includes detailed torque specifications, clearances, and diagnostic parameters
Schematics:
Includes detailed electrical wiring diagrams and hydraulic schematics
Engine Family:
Polaris ProStar (4-stroke SOHC)
Engine Type:
4-stroke, Liquid-Cooled, DOHC, 4-valve, Single Cylinder
Displacement:
Approximately 325cc to 455cc depending on specific engine variant within the HO designation for this period.
Bore X Stroke:
Refer to manual for precise specifications, typically around 85mm x 80mm for similar displacement engines.
Compression Ratio:
Refer to manual, typically around 10.0:1 to 11.0:1.
Cooling Method:
Liquid-Cooled
Horsepower:
Estimated 25-30 HP (varies by year and exact model configuration, consult manual for definitive figures).
Torque:
Refer to manual for specific torque figures.
Fuel Delivery:
Electronic Fuel Injection (EFI) or Carbureted (confirm for specific sub-model and year from manual)
Fuel Type:
Unleaded gasoline, minimum 87 octane
Fuel Tank Capacity:
Approximately 3.25 US gallons (12.3 L)
Oil Type:
SAE 10W-40 Synthetic (confirm specific API rating and JASO standard from manual)
Oil Capacity:
Approximately 2.0 US quarts (1.9 L) with filter change (verify in manual)
Transmission Type:
Polaris Variable Transmission (PVT) with Engine Braking (EB)
Gear Selection:
High, Low, Neutral, Reverse, Park
Clutch System:
Primary and secondary clutch system (belt-driven)
Drive System:
Shaft Drive, On-Demand AWD
Transmission Fluid:
SAE 10W-40 Synthetic (verify specific Polaris specifications in manual)
Final Drive Fluid Type:
Polaris Demand Drive Fluid or equivalent (verify in manual)
Final Drive Fluid Capacity:
Approximately 0.25 L (Front Gearcase), 0.25 L (Rear Gearcase) - verify in manual.
Infotainment Features:
Basic instrumentation: speedometer, odometer, trip meter, fuel gauge, AWD indicator, engine hour meter. No advanced infotainment system.
Driver Assistance:
On-Demand AWD system automatically engages front drive when rear wheels lose traction.
Connectivity:
No factory connectivity features.
Headlights:
Dual Halogen headlights, single brake/taillight.
Ignition Type:
Electric Start with backup recoil starter (confirm availability in manual).
Initial Service:
First service typically around 10 hours or 1 month of use, focusing on fluid levels, belt inspection, and general checks.
Engine Oil Change:
Every 100 hours or 6 months (whichever comes first), use synthetic 10W-40.
Air Filter Cleaning:
Every 50 hours or as needed based on operating conditions (clean and re-oil).
Spark Plug Replacement:
Refer to manual; typically around 100-200 hours.
Pvt Belt Inspection:
Every 100 hours, check for wear, cracks, and proper tension. Replace as needed.
Transmission Fluid Change:
Refer to manual; typically every 200 hours or annually.
Engine Oil Spec:
SAE 10W-40 Synthetic, API CI-4 or newer, JASO MA/MA2 recommended.
Coolant Spec:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water.
Brake Fluid Spec:
DOT 4 Hydraulic Brake Fluid.
Common Issues:
PVT belt wear/failure, occasional electrical gremlins (wiring, grounds), starter solenoid issues, and potential water pump seal leaks. Consult manual for specific troubleshooting.
