Vehicle Segment:
Utility ATV (All-Terrain Vehicle)
Target User:
Recreational riders, hunters, farmers, and general utility users.
Competitors:
Honda FourTrax, Yamaha Grizzly, Can-Am Outlander, Kawasaki Brute Force.
Key Selling Points:
Polaris's reputation for power, comfort, and a wide range of accessories for customization.
Manual Benefit:
Empowers owners to perform maintenance and repairs, saving on labor costs and ensuring proper upkeep.
Manual Benefit Detail:
Provides clarity on complex procedures, reducing guesswork and potential for damage.
Primary Coverage:
Complete repair and service information for the 2012 Polaris Sportsman 400 H.O.
Secondary Coverage:
Maintenance schedules, diagnostic procedures, troubleshooting guides, component specifications.
Estimated Page Count:
Estimated 500-800 pages, typical for comprehensive factory service manuals. Exact count not specified.
Manual Type:
Factory Service Repair Manual
Intended Audience:
Professional Mechanics and DIY Enthusiasts
Engine:
Detailed information on engine disassembly, assembly, tuning, and component overhaul.
Drivetrain:
Coverage of AWD/2WD system, clutches, driveshafts, and differential units.
Suspension:
Front and rear suspension systems, including shock absorbers, control arms, and bushings.
Brakes:
Hydraulic brake system components, including master cylinder, calipers, rotors, and bleeding procedures.
Electrical System:
Wiring diagrams, ignition system, charging system, lighting, starter, battery, and accessories.
Fuel System:
Fuel tank, fuel pump, fuel filter, carburetor (if applicable) or fuel injection system.
Cooling System:
Radiator, fan, thermostat, coolant flow, and water pump.
Exhaust System:
Exhaust manifold, muffler, and heat shields.
Body And Frame:
Body panels, fenders, racks, seat, handlebars, and frame integrity checks.
Steering:
Steering column, tie rods, and steering linkage.
Wheels And Tires:
Wheel specifications, tire pressures, and mounting procedures.
Maintenance:
Routine maintenance tasks, lubrication points, filter changes, tune-ups.
Troubleshooting:
Diagnostic trees, symptom-based troubleshooting for various systems.
Repair:
Detailed step-by-step instructions for component removal, installation, and repair.
Disassembly Assembly:
Comprehensive instructions for complete or partial teardown and reassembly of all major components.
Adjustments:
Calibration and adjustment procedures for various systems (e.g., carburetor, throttle, brakes).
Depth:
Factory-level depth, covering everything from basic checks to complete engine and transmission rebuilds.
Diagnostic Tools:
Information on required special tools and diagnostic procedures.
Engine Type:
4-Stroke DOHC Twin Cylinder
Displacement:
398cc (approximate, check specific VIN for exact)
Bore X Stroke:
Not specified, but detailed in manual.
Cooling System:
Liquid-Cooled
Fuel Induction:
Carburetor (likely Mikuni or Keihin, specific model in manual)
Horsepower:
Approx. 30 HP (Estimate, exact spec in manual)
Torque:
Not specified, but detailed in manual.
Fuel Type:
Unleaded Gasoline
Fuel Capacity:
3.7 US Gallons (14 L)
Transmission Type:
Automatic (CVT - Continuously Variable Transmission)
Drive System:
On-Demand AWD/2WD
Gear Selection:
High, Low, Neutral, Reverse
Clutch:
Primary and Secondary Clutch System (PVT - Polaris Variable Transmission)
Transmission Fluid Spec:
Polaris AGL Synthetic Gearcase Lubricant or equivalent (detailed in manual)
Atv Safety Standards:
Meets ANSI and SFI standards (typical for Polaris ATVs).
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Parking Brake:
Integrated into transmission or separate caliper.
Lighting:
Dual 50W Halogen Facet Headlights, Single 30W Halogen Brake-Tail Light.
Seat Belt Recommendation:
Not equipped with seat belts; helmet and protective gear mandatory.
Initial Break In:
First 10 hours or 200 miles, with specific oil change and inspection points detailed in the manual.
Regular Oil Change:
Every 100 hours or 1,000 miles (check manual for specific recommendations).
Air Filter Maintenance:
Inspect and clean every 25 hours; replace as needed.
Spark Plug Replacement:
Recommended every 1,500 miles or annually.
Engine Oil Type:
Polaris PS-4 5W-50 or SAE 0W-40 Synthetic (refer to manual for exact type and capacity).
Coolant Type:
Polaris Genuine Polaris Coolant or equivalent (e.g., 50/50 ethylene glycol/distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Common Wear Items:
Drive belts (CVT), ball joints, tie rod ends, wheel bearings, brake pads.
Potential Issues:
Carburetor tuning can be sensitive to altitude and temperature; CVT belt longevity is crucial for performance.
Manual Benefit Maintenance:
Provides correct torque values, fluid capacities, and diagnostic steps for common issues.
Brand Origin:
Polaris Inc. is an American manufacturer founded in 1954, known for powersports vehicles.
Sportsman Lineage:
The Sportsman line is Polaris's flagship utility and recreational ATV series, established in the early 1990s.
Sportsman 400 History:
The 400cc class has been a staple in the Polaris lineup, offering a balance of power and affordability.
Manufacturing Location:
Typically manufactured in Roseau, Minnesota, USA or other Polaris facilities.
Atv Awards:
While specific awards for the 2012 Sportsman 400 H.O. are not readily cited, the Polaris Sportsman line consistently receives positive reviews for performance, reliability, and utility from outdoor and powersports publications.
Consumer Ratings:
Generally positive consumer feedback for its utility and value proposition in the mid-size ATV market.
Manual Certification:
Produced by Polaris, implying it meets internal factory standards for accuracy and completeness.
