Applicable Models:
Polaris Sportsman 400 HO (2012), Polaris Sportsman 500 HO (2012), Polaris Sportsman Touring 500 HO (2012), Polaris Sportsman Forest Tractor 500 EFI (2012)
Estimated Page Count:
Varies by specific model variant; typically 500-800+ pages for a comprehensive service manual.
Manual Type:
Service Repair Shop Manual
Format:
Digital PDF Download
Access Method:
Digital download link via email within hours of payment confirmation.
Usage Rights:
Printable and copyable to multiple devices (computers, smartphones, tablets, flash drives, hard drives).
Powertrain:
Engine, Transmission (PVT - Polaris Variable Transmission), Drive Train, Differentials, Axles, Final Drive
Chassis:
Frame, Suspension (Front and Rear), Steering System, Brakes (Hydraulic Disc), Wheels and Tires
Electrical:
Ignition System, Lighting, Starting System, Charging System, Battery, Instrumentation, Wiring Diagrams, EFI System Components
Bodywork:
Body Panels, Fenders, Racks, Seat, Controls, Handlebars
Fuel System:
Fuel Tank, Fuel Pump, Fuel Injectors, EFI Control Module, Fuel Lines
Lubrication Cooling:
Engine Oil System, Cooling System (Radiator, Fan, Coolant)
Steering:
Complete steering system diagnosis, repair, and adjustment procedures, including tie rods, steering shafts, and handle bar assembly.
Shocks:
Information on front and rear shock absorber service, adjustment, and replacement.
Fuel System:
Detailed EFI system components: ECU, sensors (TPS, MAP, IAT, ECT), fuel injectors, fuel pump, and pressure regulator.
Maintenance:
Scheduled Maintenance, Lubrication Points, Fluid Changes (Engine Oil, Transmission Fluid, Brake Fluid), Filter Replacements, Spark Plug Service, Tire Pressure Checks
Repair:
Engine Rebuilds (Top-end and Bottom-end), Transmission Overhaul, Brake System Repair, Suspension Component Replacement, Steering System Service, Electrical Component Diagnosis and Replacement
Diagnostics:
Troubleshooting Guides for Common Issues, EFI System Diagnosis, Electrical System Fault Finding, DTC (Diagnostic Trouble Code) Interpretation
Assembly Disassembly:
Complete Step-by-Step Procedures for Component Removal and Installation, Exploded Diagrams for Part Identification and Reassembly
Engine Removal Installation:
Detailed instructions for removing and reinstalling the engine, including all associated components and connections.
Intake Exhaust:
Procedures for servicing the air intake system, carburetor (if applicable to specific sub-models not detailed in description but common in the era), and exhaust system.
Troubleshooting:
Extensive 'Advanced Troubleshooting' section covering electrical, fuel, and mechanical issues.
Technical Depth:
Comprehensive coverage for professional technicians and knowledgeable DIY enthusiasts, including detailed procedures, OEM specifications, and diagnostic information.
Oem Specifications:
Includes critical OEM specifications such as torque values for fasteners, compression test ranges, piston ring end gap, valve clearances, and electrical connector pinouts.
Diagnostic Charts:
Includes diagnostic flowcharts and troubleshooting trees to systematically identify and resolve issues.
Manual Purpose:
Factory authorized repair, maintenance, and diagnostic procedures for servicing the specified Polaris Sportsman models.
Engine Type 400:
4-Stroke Single Cylinder SOHC, Electronic Fuel Injection (EFI)
Engine Type 500:
4-Stroke Single Cylinder SOHC, Electronic Fuel Injection (EFI)
Bore Stroke 400:
Refer to manual for specific dimensions
Bore Stroke 500:
Refer to manual for specific dimensions
Compression Ratio 400:
Refer to manual for specific ratios
Compression Ratio 500:
Refer to manual for specific ratios
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Fuel Pressure:
Specified in manual (typical EFI range)
Oil Change Interval:
Refer to manual for specific intervals based on operating hours or mileage (typically every 50-100 hours or annually).
Air Filter Cleaning:
Regular inspection and cleaning/replacement recommended, frequency depends on operating conditions.
Spark Plug Replacement:
Refer to manual for recommended replacement intervals.
Engine Oil Type:
Refer to manual for specific viscosity grade (e.g., SAE 5W-50, SAE 10W-40) and API classification.
Transmission Fluid Type:
Refer to manual for specific transmission fluid type (e.g., Polaris synthetic gearcase lubricant, SAE 75W-90).
Coolant Type:
Ethylene Glycol based antifreeze suitable for off-road vehicles.
Common Wear Items:
Drive belt wear, suspension bushings, wheel bearings, and brake pad wear are common maintenance items.
Efi System Maintenance:
Regular cleaning of throttle body and fuel injectors may be beneficial for optimal performance.
