Segment:
Mid-size utility ATV
Target Audience:
Recreational riders, farmers, hunters, and utility users
Key Competitors:
Can-Am Outlander 400, Honda Foreman 400/500, Suzuki KingQuad 400/500, Yamaha Grizzly 450/550
Vehicle Usp:
Reputation for ruggedness, versatility, and reliable performance in varied terrain
Manual Value Proposition:
Provides essential knowledge for owners to maintain, troubleshoot, and repair their ATVs, maximizing lifespan and performance.
Applicable Models:
Polaris Sportsman 400 (2012-2013), Polaris Sportsman 500 (2012-2013)
Market Segments:
All-Terrain Vehicle (ATV)
Estimated Pages:
Comprehensive (Exact count not specified, but implied extensive for FSM)
Type:
Factory Service Manual (FSM)
Subtype:
Service and Repair Manual
Powertrain:
Engine, Fuel System, Lubrication System, Cooling System, Transmission, Drivetrain
Chassis:
Suspension, Steering, Brakes, Wheels and Tires
Electrical:
Ignition System, Lighting System, Charging System, Battery, Wiring Diagrams, Instruments and Gauges
Body And Frame:
Frame, Body Panels, Seat, Handlebars, Racks
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Lubrication Points
Diagnostics:
Troubleshooting Guides, Diagnostic Codes, Symptom Analysis
Repair:
Component Removal and Installation, Assembly and Disassembly, Specific Repair Procedures
Overhaul:
Engine Rebuilding, Transmission Overhauling, Suspension Component Rebuilding
Adjustment:
Carburetor Adjustment, Valve Clearance Adjustment, Brake Adjustment
Depth:
Comprehensive (from basic checks to complete engine rebuilds)
Diagnostics Level:
Advanced diagnostic procedures, including electrical circuit testing
Special Tools:
Identification of required special tools for specific procedures
Engine Type:
4-Stroke, Liquid-Cooled, SOHC
Sportsman 400 Displacement:
455cc
Sportsman 500 Displacement:
499cc
Bore X Stroke 400:
92mm x 82mm (approximate, specific to 455cc)
Bore X Stroke 500:
92mm x 92mm (approximate, specific to 499cc)
Compression Ratio:
Approx. 9.5:1 (Typical for these displacements)
Horsepower 400:
Approx. 30-33 HP (Varies slightly by year/tuning)
Horsepower 500:
Approx. 34-37 HP (Varies slightly by year/tuning)
Torque Peak 500:
Approx. 28-30 lb-ft @ 5000 RPM (estimated)
Fuel Delivery:
Carburetor (Likely Keihin CVK)
Carburetor Size:
Approx. 34mm (Typical for this class)
Fuel Type:
Unleaded Gasoline, 87 Octane Minimum
Coolant Type:
Antifreeze/Coolant Mixture (e.g., 50/50 Ethylene Glycol)
Oil Type:
SAE 10W-40, API SG or higher (Check manual for specific Polaris recommendation)
Oil Capacity:
Approx. 2.2 US quarts (2.1 liters) with filter change (Verify in manual)
Oil Filter Part Number:
Polaris Part # 3083722 or equivalent aftermarket (Verify in manual)
Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
Shaft Drive, On-Demand AWD (All-Wheel Drive)
Gearing:
High, Low, Neutral, Reverse, Park
Cvts Belt Inspection:
Manual details critical inspection and replacement intervals for the drive belt.
Final Drive Fluid Type:
Polaris Demand Drive Fluid or equivalent (Verify in manual)
Final Drive Fluid Capacity:
Front Gearcase: Approx. 5.8 oz (170 ml), Rear Gearcase: Approx. 7.7 oz (227 ml) (Verify in manual)
Length:
Approx. 83 inches (210.8 cm)
Width:
Approx. 46 inches (116.8 cm)
Height:
Approx. 48 inches (121.9 cm) to handlebars
Dry Weight:
Approx. 650-680 lbs (295-309 kg)
Ground Clearance:
Approx. 10.5 inches (26.7 cm)
Towing Capacity:
1500 lbs (680 kg)
Rack Capacity Front:
100 lbs (45 kg)
Rack Capacity Rear:
200 lbs (90 kg)
Atv Safety Standards:
Compliance with ANSI/SVIA standards recommended for ATVs.
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Parking Brake:
Hand-operated brake lever or thumb lever engaging rear brake
Lighting:
Dual Halogen Headlights, Taillight/Brake Light
Rollover Protection:
N/A for ATVs (Emphasis on rider training and safe operating practices)
Operator Safety:
Manual includes vital safety warnings, protective gear recommendations, and riding techniques.
Infotainment System:
N/A (ATV platform focused on utility and performance, not entertainment)
Active Safety Tech:
On-Demand AWD system is a primary active safety/performance feature.
Connectivity Features:
N/A
Gauge Cluster:
Digital/Analog mix, including speedometer, odometer, trip meter, fuel gauge, gear indicator, 4WD indicator, high-temp warning.
Initial Service:
First service typically around 10-20 hours or 100 miles (Check manual for specific break-in procedure)
Engine Oil Change:
Every 100 hours or 12 months (whichever comes first)
Air Filter Cleaning:
Every 25 hours or 6 months, depending on operating conditions
Spark Plug Inspection:
Every 100 hours or 12 months
Cvts Belt Inspection:
Every 50 hours or 6 months (Critical for drivetrain health)
Engine Oil Viscosity:
SAE 10W-40
Coolant Type:
Ethylene Glycol based (50/50 mix with distilled water)
Brake Fluid:
DOT 3 or DOT 4 Hydraulic Brake Fluid (Check manual for specific recommendation)
Common Wear Items:
CVT belt wear, suspension bushings, wheel bearings, brake pads
Potential Electrical Issues:
While generally reliable, issues with rectifier/regulator or stator can occur over time; manual provides diagnostic steps.
Carburetor Tuning:
Can require periodic cleaning and adjustment, especially if fuel quality varies or the ATV sits for extended periods.
Manufacturer:
Polaris Inc. (Established 1954)
Atv Pioneering:
Polaris is a significant player in the ATV market, known for innovation and market share.
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, evolving with updated engines, chassis, and features.
2012-2013 Updates:
These model years represent a mature iteration of the Sportsman platform, incorporating refinements from earlier generations.
Manufacturing Location:
Primarily manufactured in the USA (e.g., Roseau, Minnesota)