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

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

Variantes de produits

Description

The Polaris Sportsman Touring 500 H.O. is a premium utility All-Terrain Vehicle (ATV) designed for recreational riders, hunters, farmers, and outdoor enthusiasts. Produced for the 2012 and 2013 model years, this ATV is engineered for capability and comfort, featuring ergonomic seating for both rider and passenger, substantial cargo capacity, and a comfortable suspension system. Its robust 499cc liquid-cooled engine delivers ample power for various terrains and towing needs, complemented by an On-Demand True All-Wheel Drive (AWD) system for superior traction. The Sportsman line, a cornerstone of offerings, is recognized for its balance of performance, comfort, and utility, making the Sportsman Touring 500 H.O. a reliable choice for demanding outdoor activities. This comprehensive workshop service repair manual provides detailed guidance for the complete service, repair, and maintenance of the Polaris Sportsman Touring 500 H.O. Covering over 500 pages, it encompasses all essential systems, including engine mechanicals, fuel, cooling, ignition, and exhaust systems, as well as transmission, drivetrain, suspension, steering, braking, and electrical systems. The manual includes step-by-step troubleshooting procedures, diagnostic information, scheduled maintenance tasks, and critical technical specifications, such as torque values and fluid requirements. This resource is an invaluable tool for owners, mechanics, and technicians to ensure the proper upkeep, efficient operation, and longevity of their ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Touring 500 H.O.

Vehicle Type:

All-Terrain Vehicle (ATV)

Model Years Covered:

2012, 2013

Codes

Vin Prefix:

👋 Introduction

Market Position

Market Segment:

Premium Utility ATV

Target User:

Recreational riders, hunters, farmers, and outdoor enthusiasts requiring a capable and comfortable touring ATV

Competitive Analysis

Key Competitors:

Yamaha Grizzly, Can-Am Outlander, Arctic Cat TRV

Key Features

Touring Capability:

Ergonomic seating for rider and passenger, ample cargo capacity, comfortable suspension

Engine Power:

Strong 499cc liquid-cooled engine providing ample power for various terrains and towing

4Wd System:

On-Demand True All-Wheel Drive (AWD) for superior traction

📋 Manual Details

Coverage Areas

Primary Coverage:

Complete Service, Repair, and Workshop Procedures

Secondary Coverage:

Troubleshooting, Diagnostics, Maintenance, Parts Identification, Specifications

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, piston, crankshaft, camshaft, valve train, timing

Engine Fuel System:

Fuel pump, injectors, throttle body, fuel filter, fuel tank, fuel pressure regulator

Engine Cooling System:

Radiator, fan, water pump, thermostat, coolant hoses, coolant specifications

Engine Ignition System:

Spark plugs, ignition coils, CDI unit, timing specifications

Engine Exhaust System:

Exhaust pipes, muffler, catalytic converter (if applicable)

Transmission Drivetrain:

PVT (Polaris Variable Transmission) belt, clutches, gearcase, differential, driveshafts, CV joints

Suspension Steering:

Front and rear suspension components, shocks, springs, bushings, steering column, tie rods, ball joints

Braking System:

Hydraulic disc brakes (front and rear), brake calipers, master cylinder, brake lines, brake fluid specifications

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting, wiring diagrams, fuses, relays

Body Chassis:

Frame, body panels, racks, seat, fenders, plastics, fasteners

Cooling Fan Operation:

Cooling fan switch and relay operation

Instrumentation Controls:

Speedometer, odometer, fuel gauge, warning lights, handlebar controls

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, spark plug checks, belt inspections, lubrication points

Troubleshooting Diagnostics:

Step-by-step diagnostic procedures for common and uncommon issues

Engine Rebuild:

Complete engine disassembly, inspection, repair, and reassembly procedures

Transmission Repair:

PVT belt replacement, clutch service, gearcase maintenance

Brake Service:

Brake pad replacement, caliper service, bleeding procedure

Electrical Diagnostics:

Wiring harness checks, component testing, charging system diagnosis

Suspension Alignment:

Steering alignment, suspension component replacement

Bodywork Repair:

Panel removal and installation, plastic repair

Wiring Diagrams:

Detailed electrical schematics for all systems

Torque Specifications:

All critical fastener torque values

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine/transmission overhaul)

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchable Text:

Printable:

Print Quality

Image Resolution:

High (suitable for viewing detailed diagrams)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-Stroke, Liquid-Cooled, SOHC, Single Cylinder

Displacement:

499 cc (30.4 cu. in.)

Bore X Stroke:

92.0 mm x 76.0 mm (3.62 in x 2.99 in)

Compression Ratio:

10.2:1

Fuel Delivery:

Electronic Fuel Injection (EFI)

Performance

Horsepower:

Approximately 30-32 HP (estimated, specific rating may vary)

Torque:

Approximately 32-34 lb-ft (estimated, specific rating may vary)

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

4.0 gal (15.1 L)

🔧 Transmission

Standard

Transmission Type:

Polaris Variable Transmission (PVT) with Engine Braking

Gear Selection:

H, L, N, R, P (High, Low, Neutral, Reverse, Park)

Drive System:

Shaft Drive

Drivetrain Engagement:

On-Demand True All-Wheel Drive (AWD)

Features

Engine Braking:

Standard feature for controlled descents

📐 Dimensions

Exterior

Length:

83 in (210.8 cm)

Width:

46 in (116.8 cm)

Height:

47.2 in (119.9 cm)

Wheelbase:

56 in (142.2 cm)

Cargo

Front Rack Capacity:

100 lbs (45 kg)

Rear Rack Capacity:

200 lbs (90 kg)

Weights

Dry Weight:

693 lbs (314 kg)

Towing Capacity:

1,500 lbs (680 kg)

ગOund Clearance:

11.5 in (29.2 cm)

🛡️ Safety Features

Ratings

Safety Certifications:

All Polaris ATVs are designed and manufactured to meet ANSI standards for recreational ATVs.

Active Features

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power.

Engine Braking:

Provides assistance when descending inclines.

On Demand AWD:

Automatically engages all four wheels when traction is needed.

Passive Features

Roll Over Protection:

Integrated ROPS elements within the chassis design and handlebars.

Lighting:

Dual halogen headlights and a single taillight/brake light for visibility.

Handlebar Design:

Ergonomically designed handlebars for control and grip.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital gauge with speedometer, odometer, trip meter, tachometer, fuel level, AWD indicator, clock, and service indicator.

Driver Assistance

Engine Braking:

Built-in feature for enhanced control on descents.

Connectivity

Accessory Power:

Accessory outlet for charging devices or powering accessories.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 12 months, whichever comes first.

Pvt Belt Inspection:

Inspect every 100 hours; replace as needed.

Air Filter Cleaning:

Clean every 25 hours or annually; replace as needed.

Spark Plug Check:

Inspect every 100 hours or 12 months.

Brake Fluid Flush:

Recommended every 24 months.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 Full Synthetic 5W-50 (or equivalent API SG rated oil)

Engine Oil Capacity:

2.0 US qt (1.9 L) with filter change

Coolant Type:

Polaris brand ethylene glycol coolant (50/50 mix with distilled water)

Brake Fluid Type:

DOT 3 or DOT 4 Hydraulic Brake Fluid

Gearcase Oil Type:

Polaris AGL Heavy Duty Gearcase Lubricant (or equivalent SAE 80W-90 GL-5)

Gearcase Oil Capacity:

240 ml (8.1 oz)

Known Issues

Common Maintenance Items:

PVT belt wear, suspension bushing wear, cooling fan operation checks.

Electrical Connector Corrosion:

Ensuring electrical connectors are clean and protected from moisture is crucial.

📚 Vehicle History

Brand Heritage

Brand Origin:

Polaris Industries Inc. is an American manufacturer of off-road vehicles, including ATVs, UTVs, snowmobiles, and motorcycles.

Founding Year:

Model Evolution

Sportsman Lineage:

The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its comfort, utility, and off-road capability. The 'Touring' designation signifies models optimized for two-up riding.

Engine Development:

The 500 H.O. (High Output) engine has been a popular and reliable powerplant for Polaris ATVs for many years, offering a balance of power and efficiency.

Production

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Atv Industry Awards:

While specific awards for the 2012-2013 Sportsman Touring 500 H.O. are not individually cataloged, the Polaris Sportsman line has consistently received accolades and positive reviews within the ATV industry for its performance, comfort, and utility.