Polaris Sportsman Touring 500 2012 Service Repair Manual

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Type: Atv

Vendor:

Sku: 60532

Tags: 2012 ATV Polaris Powersports Sportsman Series Sportsman Touring 500

Product variants

Description

The 2012 Sportsman Touring 500 H.O. is a premium utility All-Terrain Vehicle (ATV) designed for recreational riders, hunters, farmers, and anyone requiring comfortable, long-distance capability. Engineered for reliability and performance, this model features a powerful 499cc liquid-cooled engine with Electronic Fuel Injection (EFI) and independent front and rear suspension for superior handling and comfort across varied terrain. Its robust design includes ample cargo capacity and seating for two, making it ideal for extended excursions and demanding tasks. The Sportsman Touring 500 H.O. is a testament to a heritage in producing capable and popular utility ATVs. This comprehensive factory service manual provides detailed information for the repair and maintenance of your 2012 Sportsman Touring 500 H.O. It covers all essential systems, including the engine, fuel system, drivetrain, brakes, suspension, and electrical components. Within its pages, you will find step-by-step repair instructions, routine maintenance procedures, troubleshooting guides, and critical technical specifications such as torque values and fluid capacities. This manual is an invaluable resource for owners and technicians alike, ensuring the longevity and optimal performance of your ATV.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Sportsman Touring 500 H.O.

Year:

Vehicle Type:

All-Terrain Vehicle (ATV)

👋 Introduction

Market Position

Segment:

Premium utility ATV

Target User:

Recreational riders, hunters, farmers, utility users requiring comfortable long-distance riding.

Competitive Analysis

Competitors:

Yamaha Grizzly, Can-Am Outlander, Honda Foreman/Rancher (though Touring variant positions it for longer rides).

Key Features

Touring Capability:

Designed for extended rides with comfortable seating for two and ample cargo capacity.

Engine Performance:

Known for its powerful 499cc liquid-cooled engine providing strong pulling power.

Suspension Design:

Independent front and rear suspension for superior comfort and handling over varied terrain.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service and Repair

Secondary Coverage:

Maintenance and Troubleshooting

Page Count

Estimated Page Count:

Variable, typically 300-500+ pages for a comprehensive service manual.

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

PDF / WinRAR Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, top-end and bottom-end, valve adjustments, piston and cylinder service, lubrication system, cooling system.

Fuel System:

Fuel injection system (EFI) diagnosis and repair, fuel pump, injectors, throttle body, fuel tank, fuel lines.

Body:

Body panels, plastics, seats, handlebars, storage compartments, lighting systems, electrical connectors.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, steering system.

Drivetrain:

All-wheel drive (AWD) system, viscous all-wheel drive (On-Demand AWD), final drive, differentials, drive shafts, CV joints.

Brakes:

Hydraulic brake system, brake calipers, master cylinder, brake lines, brake pads, brake fluid, parking brake.

Electrical System:

Ignition system, starter system, charging system (alternator, battery), lighting, fuses, relays, wiring diagrams, diagnostic codes.

Cooling System:

Radiator, fan, thermostat, coolant hoses, coolant specifications.

Exhaust System:

Exhaust manifold, muffler, catalytic converter (if applicable).

Steering:

Steering mechanism, tie rods, steering wheel, power steering (if applicable).

Procedures Included

Maintenance:

Routine maintenance checks, oil changes, filter replacements, lubrication, tire pressure, battery maintenance.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues, error code interpretation.

Repair:

Step-by-step repair instructions for all major components and systems, including disassembly, reassembly, and adjustments.

Diagnostics:

Electrical system diagnostics, engine performance diagnostics, fuel system diagnostics.

Specifications Data:

Torque specifications for all fasteners, fluid capacities, engine specifications, electrical specifications.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Suitable for professional technicians and experienced DIY mechanics.

📊 Manual Specifications

File Format

Digital Delivery:

Instant Download via Email

Software Compatibility:

Win95/98/ME/XP/vista/7/8/Linux/MAC, iOS, Android devices

Archive Format:

WinRAR

Print Quality

Clarity:

High-resolution images and clear illustrations for easy understanding.

Binding Type

Delivery Method:

Digital download only (no physical copy)

Paper Type

Medium:

Digital PDF

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, SOHC, 4-valve

Engine Displacement:

499 cc (30.4 cu in)

Bore X Stroke:

92 mm x 76 mm (3.62 in x 2.99 in)

Cooling System:

Liquid-cooled

Fuel Delivery:

Electronic Fuel Injection (EFI)

Compression Ratio:

9.5:1

Performance

Horsepower:

Estimated 36-38 HP (actual figures not always published for ATVs, but this is typical for the class).

Torque:

Strong low-end and mid-range torque for hauling and climbing.

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

4.25 US gal (16.1 L)

🔧 Transmission

Standard

Transmission Type:

Automatic (PVT - Polaris Variable Transmission) with engine braking

Drive Modes:

2WD/4WD (On-Demand AWD)

Features

Gear Selection:

High, Low, Reverse, Park

Transmission Fluid Type:

Polaris AGL Synthetic Gearcase Lubricant or equivalent (refer to manual for specific part numbers).

📐 Dimensions

Exterior

Length:

83 in (210.8 cm)

Width:

46 in (116.8 cm)

Height:

47 in (119.4 cm)

Wheelbase:

56.5 in (143.5 cm)

Ground Clearance:

11.25 in (28.6 cm)

Weights

Dry Weight:

620 lbs (281 kg)

Payload Capacity:

200 lbs (91 kg) front rack, 400 lbs (181 kg) rear rack

Towing Capacity:

1500 lbs (680.4 kg)

🛡️ Safety Features

Active Features

Braking System:

Hydraulic disc brakes front and rear, engine braking system (EBS) with ADC (Active Descent Control) often standard or available.

Drivetrain Management:

On-Demand AWD system enhances traction and stability.

Passive Features

Ergonomics:

Designed with rider comfort and control in mind for extended use.

Lighting:

Dual 50W headlights, LED tail/brake light.

💡 Technology Features

Infotainment

Display:

Digital odometer and information display (speed, fuel level, gear indicator, etc.).

Driver Assistance

Descent Control:

Active Descent Control (ADC) on select models aids in controlled descents.

Connectivity

Charging Port:

Often includes a 12V DC outlet for charging accessories.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 12 months, whichever comes first (check manual for specifics).

Air Filter Inspection:

Inspect every 50 hours, clean/replace as needed, more frequently in dusty conditions.

Spark Plug Replacement:

Typically every 2 years or 100 hours (refer to manual for correct gap and type).

Transmission Fluid Change:

Refer to manual, typically every 200-300 hours or 24 months.

Fluid Specifications

Engine Oil Type:

Polaris PS-4 Full Synthetic 0W-40 or equivalent (refer to manual for specific Polaris part numbers and oil specifications).

Coolant Type:

Polaris Premium All-Season Coolant or equivalent ethylene glycol-based coolant (50/50 mix).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for exact specification).

Known Issues

Common Wear Items:

Bushings, tie rod ends, drive belts (PVT), ball joints, wheel bearings are common wear items on all ATVs and should be checked regularly.

Electrical Connections:

Corrosion or loose connections can sometimes cause intermittent electrical issues; manual guides troubleshooting.

Pvt Belt Life:

Proper belt alignment and avoidance of excessive slippage extend PVT belt life.

📚 Vehicle History

Brand Heritage

Manufacturer:

Polaris Industries is a long-standing American manufacturer known for its ATVs, snowmobiles, and powersports vehicles.

Model Evolution

Sportsman Line:

The Sportsman line is Polaris's flagship utility ATV, consistently updated for performance, comfort, and capability.

Touring Variant:

The Touring model is an evolution of the standard Sportsman, specifically adapted for two-up riding and longer excursions.

Production

Manufacturing Location:

Primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

Category Popularity:

Polaris Sportsman models are consistently ranked among the best-selling and most popular utility ATVs in their class.