Market Positioning:
The 2012 Polaris Sportsman lineup was positioned as a premium, versatile ATV for recreational riding, utility work, and hunting. The 400 HO and 500 HO models offered a balance of power, comfort, and capability.
Key Competitors:
Can-Am Outlander, Yamaha Grizzly, Arctic Cat 500/550, Honda Foreman/Rancher.
Unique Selling Points 2012:
Polaris's independent suspension, engine braking system (EBS) on select models, Lock & Ride accessory system, powerful ProStar engines (specific to later models, but the HO series was well-regarded), comfortable seating for Touring models.
Manual Coverage:
Comprehensive service and repair for 2012 Polaris Sportsman 400 HO and 500 HO models, including Touring and Forest variants.
Estimated Page Count:
Likely 500-1000+ pages, typical for a dealership-level service manual of this era.
Manual Type:
Dealership Service/Repair Manual
Delivery Method:
Instant download link provided on the checkout page immediately after payment confirmation.
Covered Systems:
General Information, Maintenance, Engine (including EFI), Fuel System, Bodywork, Steering, Suspension, Drivetrain (CVT, Transmission, Final Drive), Brakes, Electrical System, Wiring Diagrams.
Electrical System Details:
Includes detailed wiring diagrams, troubleshooting for lighting, ignition, charging system, sensors, EFI components, and accessories.
Included Procedures:
Routine maintenance, troubleshooting, detailed repair procedures, component disassembly and reassembly, electrical diagnostics, torque specifications, specifications, schematics.
Engine Repair Procedures:
Cylinder head removal/installation, piston replacement, valve adjustment, timing chain inspection, oil pump servicing, complete engine disassembly and reassembly.
Suspension Steering Repair:
Ball joint replacement, tie rod end service, shock absorber inspection and replacement, steering shaft and column repair, wheel bearing replacement.
Brake System Overhaul:
Brake caliper service and replacement, master cylinder repair/replacement, bleeding procedures, brake line inspection and replacement.
Technical Depth:
Dealership-level, covering everything from basic fluid changes and filter replacements to complete engine overhauls, transmission repairs, and electrical system diagnostics.
File Quality:
High-resolution scans for clarity, suitable for printing. Expected to be searchable text for easy navigation.
Compatibility:
Compatible with all versions of Windows and Mac operating systems.
Required Software:
Adobe PDF Reader (free download) and WinZip or compatible unzipping utility.
Print Recommendation:
Printable on standard printers. Recommended for printing key sections as needed.
Binding Type Simulated:
Digital Download (PDF) - No physical binding. Requires PDF reader and unzipping software.
Paper Type Simulated:
N/A (Digital Format)
Engine Type 400:
4-stroke, SOHC, 4-valve
Displacement Cc 400:
375cc (approximate)
Engine Type 500:
4-stroke, SOHC, 4-valve
Displacement Cc 500:
499cc
Horsepower 500 Estimated:
~32 HP (at crankshaft, typical for 500 HO of this era)
Torque 500 Estimated:
~27 lb-ft (at crankshaft, typical for 500 HO of this era)
Fuel Delivery Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (91 Octane Recommended)
Cooling Method:
Liquid-cooled
Ignition System:
Electronic CDI (Capacitor Discharge Ignition)
Transmission Type:
Automatic PVT (Polaris Variable Transmission) with Clutching
Gear Selection:
High (H), Low (L), Neutral (N), Reverse (R), Park (P)
Engine Braking:
Standard on most 500 HO models, often with EBS (Engine Braking System) for downhill control.
Drive Modes:
2WD/4WD selector with ADC (Automatic Descent Control) on some models.
Length In 500:
~81.5 inches (Standard Sportsman 500 HO)
Exterior Dimensions Touring
Length In Touring:
~85 inches (Touring 500 HO)
Dry Weight Lbs 500:
~695 lbs (Standard Sportsman 500 HO)
Dry Weight Lbs Touring:
~715 lbs (Touring 500 HO)
Towing Capacity Lbs:
1500 lbs
Rack Capacity Front Lbs:
200 lbs
Rack Capacity Rear Lbs:
400 lbs
Ground Clearance In:
11.5 inches
Safety Certification:
ATV Safety Institute (ASI) recommended practices apply. Operators must be 16 or older and properly trained.
Active Safety Features:
Locking 4WD, Engine Braking System (EBS), Powerful Hydraulic Disc Brakes, Large Tires for Stability.
Passive Safety Features:
Ergonomic design, integrated lighting, handguards (on some models), handlebar padding.
Infotainment System:
Basic instrumentation cluster (speedometer, odometer, fuel gauge, gear indicator). No advanced infotainment systems typical of automotive vehicles.
Driver Assistance Features:
Engine Braking System (EBS), Automatic 4WD engagement, Active Descent Control (ADC) on select models.
Connectivity Features:
N/A (No integrated connectivity or smart features)
Oil Change Interval:
Every 100 hours or annually, whichever comes first (refer to manual for specific oil type and capacity).
Spark Plug Replacement Interval:
Every 100 hours or annually.
Air Filter Cleaning Interval:
Every 50 hours or annually, more frequently in dusty conditions.
Engine Oil Type:
Polaris Synthetic 0W-40 (or equivalent API SG rated oil with Jaso MA certification).
Coolant Type:
Ethylene Glycol based antifreeze, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid.
Differential Fluid Type:
Polaris AGL Synthetic Gearcase Lubricant or equivalent.
Common Issues 2012 Sportsman:
CVT belt wear (especially under heavy use), starter solenoid issues, occasional fuel injector clogging, potential for radiator fan failure if not maintained, water pump seal leaks.
Maintenance Tip Cvtbelt:
Regular inspection of the CVT belt for fraying or glazing is critical. Replacement is typically recommended every 2-3 years or as indicated by performance degradation.
Polarishistory:
Polaris Industries Inc. is a renowned American manufacturer of powersports vehicles, founded in 1954. They are a leading innovator in the ATV market, having introduced many industry-first features.
Sportsman Evolution:
The Sportsman line has been a flagship for Polaris since its inception. The 2012 models represent a refinement of the successful fifth-generation platform, known for its comfort, independent rear suspension (IRS), and robust performance.
Manufacturing Location:
Primarily manufactured in Spirit Lake, Iowa, USA.
