Polaris Sportsman 400 500 H.O. ATV Complete Workshop Service Repair Manual 2012 2013

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The Sportsman 400 H.O. and Sportsman 500 H.O. are versatile All-Terrain Vehicles (ATVs) produced for the 2012 and 2013 model years. These ATVs are engineered for a blend of utility...

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Taper: Atv

Distributeur:

UGS: 87926

Mots clés: 2012 2013 ATV Misc Polaris Powersports Sportsman 400 Sportsman 500 H.O.

Variantes de produits

Description

The Sportsman 400 H.O. and Sportsman 500 H.O. are versatile All-Terrain Vehicles (ATVs) produced for the 2012 and 2013 model years. These ATVs are engineered for a blend of utility and recreational riding, offering robust performance and signature comfort features, including Independent Rear Suspension (IRS) and the Variable Transmission (PVT). With their substantial towing capacity and cargo rack capabilities, they are well-suited for tasks such as hauling, hunting, and trail exploration. The H.O. designation signifies enhanced power output for their respective classes, making them capable performers in challenging terrains. This comprehensive workshop service repair manual provides detailed guidance for maintaining and repairing your Sportsman 400/500 H.O. ATV. It covers a wide array of systems, including engine overhaul, transmission service, drivetrain maintenance, suspension and brake system repairs, and electrical troubleshooting. Within its pages, you will find step-by-step procedures for routine maintenance tasks, assembly and disassembly instructions, and critical technical specifications such as torque values and fluid capacities. This manual is an essential resource for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman 500 H.O.

Model Variant:

H.O. (High Output)

Vehicle Type:

ATV (All-Terrain Vehicle)

Codes

Product Identifier:

Polaris Sportsman 400 500 H.O. ATV Complete Workshop Service Repair Manual 2012 2013 PDF Download

👋 Introduction

Market Position

Positioning:

The Polaris Sportsman 400/500 H.O. models are positioned as versatile, mid-size ATVs catering to utility and recreational riders, known for their robust performance and Polaris's signature comfort features.

Competitive Analysis

Competitors:

Competes with models from Can-Am (Outlander series), Honda (FourTrax Rancher/Rubicon), Yamaha (Grizzly), and Kawasaki (Brute Force).

Key Features

Features:

Independent Rear Suspension (IRS), Polaris Variable Transmission (PVT), On-Demand AWD, powerful engine options for their class, comfortable seating, and ample carrying capacity.

📋 Manual Details

Coverage Areas

Years Covered:

2012, 2013

Page Count

Estimated Pages:

Likely 300-500+ pages (typical for a complete workshop manual)

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine overhaul, tuning, diagnostics, cooling system, lubrication system, fuel system (carbureted/EFI), ignition system, starting system, exhaust system.

Transmission:

PVT (Polaris Variable Transmission) operation, clutch inspection and adjustment, drive belt service, gearbox maintenance and repair.

Drivetrain:

All-Wheel Drive (AWD) system, front and rear differentials, axle shafts, U-joints, drive shafts, final drive units.

Suspension:

Front and rear suspension components, shocks, struts, control arms, bushings, bearings, alignment procedures.

Brakes:

Hydraulic brake system, master cylinder, calipers, brake pads, brake lines, parking brake, bleeding procedures.

Electrical:

Battery, charging system (stator, regulator/rectifier), starting system (starter motor), lighting, ignition switch, CDI unit, wiring diagrams, troubleshooting electrical faults.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, carburetor (if applicable) or EFI system components (injectors, throttle body).

Steering:

Handlebar assembly, steering shaft, tie rods, ball joints, steering knuckle, troubleshooting steering play or stiffness.

Bodywork:

Body panels, fenders, racks, seat, plastics, trim removal and installation.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, lubrication points, tire pressure checks, battery maintenance, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Diagnostic procedures for common problems, fault finding based on symptoms, error code interpretation (if applicable).

Repair Overhaul:

Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper rebuild, electrical component replacement.

Assembly Disassembly:

Step-by-step instructions for disassembling and reassembling major vehicle components and systems.

Technical Specifications:

Torque specifications for fasteners, clearances, gap settings, fluid capacities, electrical system specifications.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

High-resolution, enabling clear viewing of diagrams and text. Designed for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 2-valve, Single Cylinder (Liquid-Cooled)

Bore X Stroke 400:

Approximately 83mm x 71.6mm (150cc class variant may differ slightly)

Bore X Stroke 500:

Approximately 92.9mm x 71.6mm (499cc class)

Displacement 400:

Typically around 297cc (specific H.O. designation might refer to tuning or slight displacement variation)

Displacement 500:

499cc

Performance

Horsepower 400 Est:

Approx. 25-30 HP

Horsepower 500 Est:

Approx. 34-39 HP

Torque Est:

Varies by model, but designed for strong low-end and mid-range torque for utility and trail riding.

Fuel System

Fuel Delivery:

Carbureted (likely Mikuni) or Electronic Fuel Injection (EFI) depending on specific sub-model/trim. Manual will cover both if applicable.

Fuel Type:

Unleaded Gasoline (87 Octane or higher recommended)

🔧 Transmission

Standard

Type:

Polaris Variable Transmission (PVT) with Engine Braking

Optional

Options:

N/A (PVT is standard)

Features

Gear Selection:

High, Low, Neutral, Reverse, Park

Drive Belt Service:

Crucial maintenance item covered in detail, including inspection, tension, and replacement procedures.

📐 Dimensions

Exterior

Length:

Approx. 83 in. (210.8 cm)

Width:

Approx. 46 in. (116.8 cm)

Height:

Approx. 48 in. (121.9 cm) (Seat height varies)

Cargo

Front Rack Capacity Lbs:

75 lbs (34 kg)

Rear Rack Capacity Lbs:

150 lbs (68 kg)

Weights

Dry Weight Lbs:

Approx. 630-660 lbs (286-299 kg)

Towing Capacity Lbs:

1,500 lbs (680.4 kg)

Ground Clearance In:

Approx. 10.5 in. (26.7 cm)

🛡️ Safety Features

Ratings

Atv Safety Standards:

Adheres to ANSI standards for ATVs. Manual will detail safe operation practices.

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Engine Braking:

PVT system provides engine braking for controlled descents.

Passive Features

Lighting:

Dual headlights, taillight, and brake light for visibility.

Handling:

Independent front and rear suspension contributes to stability and a smoother ride, enhancing control.

💡 Technology Features

Infotainment

Features:

Basic ATV technology focused on functionality. Typically includes odometer, trip meter, fuel gauge (if equipped), and indicator lights. No advanced infotainment systems expected.

Driver Assistance

Features:

None (ATV design prioritizes mechanical systems and rider control).

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Hours:

Every 100 hours or annually (refer to manual for exact specification).

Air Filter Check Hours:

Every 25 hours or more frequently in dusty conditions.

Spark Plug Inspect Hours:

Every 100 hours.

Drive Belt Inspect Hours:

Every 50 hours.

Fluid Specifications

Engine Oil Type:

Polaris Synthetic 0W-40 (or equivalent SAE 0W-40 API CI-4 rated oil)

Engine Oil Capacity Qt:

Approx. 2.0 quarts (1.9 liters) (with filter change)

Gearcase Oil Type:

Polaris Synthetic Gearcase Lubricant (or equivalent SAE 75W-140 GL-5)

Gearcase Oil Capacity Oz:

Approx. 18 oz (532 ml)

Coolant Type:

Ethylene Glycol Antifreeze (50/50 mix with distilled water)

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid

Known Issues

Common Wear Items:

Drive belts, suspension bushings, ball joints, wheel bearings are common wear items on ATVs of this era and usage.

Electrical Connections:

Corrosion in electrical connectors can be an issue if the ATV is frequently exposed to water and mud. The manual will detail inspection and cleaning.

Carburetor Cleaning:

For carbureted models, periodic cleaning and adjustment may be necessary for optimal performance, especially with fuel variations or storage.

📚 Vehicle History

Brand Heritage

Polarisfamily:

Polaris has a long history of manufacturing ATVs, dating back to the early 1980s, with the Sportsman line being a cornerstone of their off-road vehicle offerings.

Model Evolution

Sportsmanline:

The Sportsman model has undergone continuous evolution, with the 400 and 500 H.O. variants representing popular mid-range options offering a balance of power, capability, and value within the Polaris lineup. The 'H.O.' designation signifies enhanced performance over standard models.

Production

Manufacturing:

Polaris ATVs are primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Polaris Sportsman line consistently receives positive reviews and awards for utility, comfort, and performance in the ATV industry. Specific awards for these model years are subject to publication archives.