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Polaris

POLARIS SPORTSMAN 400 HO 400 HO TOURING 500 HO FOREST Tractor 500 EFI Service Repair Manual 2012-2013

POLARIS SPORTSMAN 400 HO 400 HO TOURING 500 HO FOREST Tractor 500 EFI Service Repair Manual 2012-2013

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Vehicle data plateRef 51452
Brand
Polaris
Vehicle
ATV
Models covered
400 HO TOURING, 500 HO FOREST Tractor, Misc, SPORTSMAN 400 HO
Years
2012, 2013
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman 400 HO, Sportsman 400 HO Touring, Sportsman 500 HO, Sportsman 500 HO Forest Tractor, Sportsman 500 EFI
Model Variants:
400 HO, 400 HO Touring, 500 HO, 500 HO Forest Tractor, 500 EFI
Year:
2012, 2013
Codes
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Positioning:
The Polaris Sportsman line is a dominant force in the utility ATV market, known for its ruggedness, versatility, and rider comfort. This manual targets owners and technicians who require in-depth knowledge to maintain and repair these popular machines.
Competitive Analysis
Competitors:
This manual covers models that compete with offerings from brands like Can-Am (Outlander), Yamaha (Grizzly), Kawasaki (Brute Force), and Suzuki (KingQuad) in the mid-to-large displacement utility ATV segment.
Key Features
Manual Benefits:
Provides factory-level repair information, essential for accurate diagnostics, efficient repairs, and proper maintenance, ultimately saving time and money compared to guesswork or incomplete online resources.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair and maintenance for all listed Polaris Sportsman models and variants.
Page Count
Estimated Page Count:
Likely over 800 pages (based on typical comprehensive factory service manuals for ATVs).
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, transmission, driveline, final drive.
Chassis:
Frame, suspension (front and rear), steering system, wheels, tires, brakes (hydraulic, parking), body panels, racks.
Electrical:
Battery, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting system, instrumentation, wiring diagrams, electronic control modules (ECMs/ECUs), sensors.
Accessories & Other:
Winch operation (if applicable), accessories installation, fluid capacities and specifications, lubrication points.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning/replacement, lubrication, valve clearance checks.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, common problem diagnosis and solutions.
Repair & Overhaul:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major systems.
Component Specific Procedures:
Engine rebuild procedures, transmission overhaul, carburetor/fuel injection adjustment and cleaning, brake caliper servicing, suspension component replacement.
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY technicians. Covers everything from basic fluid checks to complete engine and transmission rebuilds.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans, clear diagrams, searchable text (typical for quality digital manuals).
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
400 Ho Engine:
Typically a 375cc, liquid-cooled, 4-stroke engine. Exact horsepower and torque figures vary slightly by year but generally around 25-30 HP.
500 Ho Engine:
Typically a 499cc, liquid-cooled, 4-stroke, SOHC, 2-valve engine. Horsepower typically in the range of 30-36 HP, with torque figures around 27-30 lb-ft.
500 Efi Engine:
Typically a 499cc, liquid-cooled, 4-stroke, SOHC, 2-valve engine with Electronic Fuel Injection (EFI). Similar performance to the carbureted 500 HO but with improved throttle response and fuel efficiency.
Performance
Bore Stroke 400:
Approx. 82mm x 71.5mm (varies)
Bore Stroke 500:
Approx. 83mm x 92mm (varies)
Fuel System
Fuel Delivery 400:
Carbureted (likely Mikuni BSR series, e.g., BSR34/36)
Fuel Delivery 500 Efi:
Electronic Fuel Injection (EFI) with throttle body and fuel pump
Ignition System
Ignition Type:
Electronic CDI (Capacitor Discharge Ignition)
Cooling System
Cooling Method:
Liquid-cooled with fan assist
Oil Specifications
Engine Oil Type:
Typically SAE 5W-50 Synthetic or a high-quality ATV specific oil meeting Polaris standards (e.g., PS-4).
🔧 Transmission
Standard
Transmission Type:
Automatic (CVT - Continuously Variable Transmission) with High/Low range and Reverse.
Optional
Optional Transmissions:
N/A (CVT is standard for all listed models)
Features
Clutch System:
Primary and secondary clutch system for automatic gear changes.
Fluid Specs
Transmission Fluid Type:
Typically Polaris AGL Synthetic Gearcase Oil or equivalent. Check manual for specific part numbers and capacities.
📐 Dimensions
Exterior
Length:
Approximately 83 inches for standard models, longer for Touring variants (e.g., 85-90 inches).
Width:
Approximately 46 inches.
Height:
Approximately 45 inches.
Weights
Dry Weight:
Ranging from approximately 600 lbs (400 HO) to 700+ lbs (500 HO Touring).
Ground Clearance:
Typically around 10.25 inches.
Cargo
Front Rack Capacity:
Typically 100 lbs.
Rear Rack Capacity:
Typically 200 lbs.
Towing
Towing Capacity:
Typically 1500 lbs (receiver hitch rated).
Payload Capacity:
Typically 250-300 lbs.
🛡️ Safety Features
Ratings
Atv Safety Considerations:
ATVs are not street legal. Operators must wear helmets and protective gear. Operate responsibly and be aware of terrain.
Active Features
Braking System:
Hydraulically actuated disc brakes on all wheels. Single-lever front braking, foot-actuated rear braking. Parking brake on rear caliper.
Traction Control:
Standard AWD (All-Wheel Drive) system with Automatic Decoupling (ADC - Automatic Drive Control), which engages front drive when rear wheels slip.
Passive Features
Lighting:
Dual 50W headlights, dual taillight/brake lights.
Operator Safety:
Anti-kickback steering mechanism, handlebar grips, throttle limiter (adjustable).
💡 Technology Features
Infotainment
Infotainment Systems:
Minimal. Primarily focused on functionality and utility. May include basic LCD instrumentation displaying speed, RPM, fuel level, odometer, trip meter, AWD indicator, and gear position.
Driver Assistance
Assistance Features:
Automatic AWD engagement, engine braking via CVT deceleration.
Connectivity
Connectivity Options:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 100 hours or 12 months, whichever comes first. Check manual for specific recommendations.
Air Filter Cleaning:
Every 25 hours or more frequently in dusty conditions.
Spark Plug Inspection:
Every 100 hours or 12 months.
Valve Clearance Check:
Typically every 100 hours or 24 months.
Transmission Fluid Change:
Typically every 100 hours or 12 months.
Fluid Specifications
Engine Oil Capacity 400:
Approx. 2.0 L (with filter change).
Engine Oil Capacity 500:
Approx. 2.2 L (with filter change).
Gearcase Oil Capacity:
Approx. 0.5 L (check manual for specific fill level).
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors. Typically 50/50 mix with distilled water.
Known Issues
Common Problems:
CVT belt wear/slipping, occasional charging system issues (rectifier failure), throttle cable adjustment, suspension wear on high-mileage units. EFI models may require occasional injector cleaning.
📚 Vehicle History
Brand Heritage
Polaris Atv History:
Polaris is a pioneering manufacturer in the ATV industry, credited with developing many key features and popularizing the sport-utility ATV segment. They have a long history of innovation and building durable off-road vehicles.
Model Evolution
Sportsman Line Evolution:
The Sportsman line has been a cornerstone of Polaris' ATV offerings for decades. The 400 and 500 models represent mid-range workhorses known for their reliability and capability, evolving with engine updates, suspension improvements, and the introduction of EFI.
Production
Production Period:
These specific models (400 HO, 500 HO, 500 EFI) were prominent in Polaris' lineup during the late 2000s and early 2010s, with continuous updates and variations.
🏆 Awards & Recognition
Recognitions
Atv Industry Awards:
While specific awards for these exact 2012-2013 models are not readily published, the Polaris Sportsman line has consistently been recognized for its overall utility, durability, and rider comfort by various ATV publications and consumer satisfaction surveys over many years.

Delivery & file format

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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