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Polaris

2012 Polaris Sportsman 400 500 HO Service Repair Factory Manual

2012 Polaris Sportsman 400 500 HO Service Repair Factory Manual

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$17.99
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Vehicle data plateRef 47893
Brand
Polaris
Vehicle
ATV
Models covered
Misc, Sportsman 400, Sportsman 500 HO
Years
2012
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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  • The same link is emailed to you — re-download any time
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  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Polaris
Model:
Sportsman
Model Variant:
400 / 500 HO
Year:
2012
Codes
Product Code Reference:
SP012
👋 Introduction
Market Position
Category:
Utility All-Terrain Vehicle (ATV)
Target Audience:
Recreational riders, hunters, farmers, utility users
Competitive Analysis
Competitors:
Can-Am Outlander, Yamaha Grizzly, Honda Foreman, Arctic Cat Prowler
Key Features
Versatility:
Suitable for various terrains and tasks, from trail riding to hauling
Durability:
Renowned for robust construction and reliability in demanding conditions
Performance:
Balanced power delivery and capable off-road handling
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
500+
Manual Type
Manual Scope:
Factory Authorized Service Manual
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, and overhaul of 400cc and 500 HO engines
Transmission:
Service and repair of the Automatic Transmission (PVT) and final drive
Drivetrain:
Front and Rear Drive System, Driveshafts, CV Joints, Differential
Suspension:
Front and Rear Suspension components, Shock Absorbers, Bushings, Ball Joints
Brakes:
Hydraulic Brake System, Calipers, Rotors, Master Cylinder, Bleeding Procedures
Electrical System:
Ignition, Starting System, Charging System, Lighting, ECU, Wiring Diagrams
Fuel System:
Fuel Injection System (EFI), Fuel Pump, Injectors, Fuel Filter
Cooling System:
Radiator, Fan, Water Pump, Thermostat, Coolant Specifications
Exhaust System:
Muffler, Exhaust Pipes, Catalytic Converter (if applicable)
Frame And Bodywork:
Frame inspection, Body panel removal/installation, Fenders, Racks
Steering:
Handlebar assembly, Steering shaft, Tie Rods, Rack and Pinion (if applicable)
Wheels And Tires:
Tire specifications, Wheel torque, Bearing maintenance
Procedures Included
Maintenance:
Scheduled maintenance, Oil changes, Filter replacements, Lubrication
Troubleshooting:
Diagnostic flowcharts for common problems and symptoms
Repair:
Step-by-step instructions for component removal, repair, and reinstallation
Rebuilds:
Complete engine and transmission overhaul procedures
Technical Specifications:
Torque values, Clearances, Gap settings, Fluid capacities
Wiring Diagrams:
Detailed electrical schematics for all systems
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine rebuilds and advanced diagnostics
📊 Manual Specifications
File Format
Format:
Digital PDF
Searchability:
Searchable text for quick information retrieval
Print Quality:
High-resolution scans, suitable for printing
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type 400:
4-stroke, SOHC, 2-valve, Single Cylinder
Displacement 400:
360 cc
Engine Type 500:
4-stroke, SOHC, 4-valve, Single Cylinder, High Output (HO)
Displacement 500:
499 cc
Performance
Horsepower 400:
Approx. 30 HP
Horsepower 500 Ho:
Approx. 39 HP
Cooling System:
Liquid-Cooled
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane)
Ignition
Ignition Type:
Electronic Ignition
🔧 Transmission
Standard
Transmission Type:
Polaris Variable Transmission (PVT) Automatic
Gear Selection:
High, Low, Neutral, Reverse, Park
Features
Drive Modes:
On-Demand All-Wheel Drive (AWD) / 2WD
Engine Braking:
Integrated Engine Braking
📐 Dimensions
Exterior
Length:
81 in (205.7 cm)
Width:
46 in (116.8 cm)
Height:
47 in (119.4 cm)
Wheelbase:
50.5 in (128.3 cm)
Ground Clearance:
11.5 in (29.2 cm)
Weights
Dry Weight:
660 lbs (299.4 kg)
Towing Capacity:
1500 lbs (680.4 kg)
Rack Capacity Front:
50 lbs (22.7 kg)
Rack Capacity Rear:
100 lbs (45.4 kg)
Cargo
Cargo Bed Type:
Rear Cargo Rack
🛡️ Safety Features
Ratings
Safety Standard:
Meets ANSI/ROHVA standards for recreational off-highway vehicles
Active Features
Braking System:
Hydraulic Disc Brakes (Front and Rear)
Drive System:
On-Demand AWD for enhanced traction
Passive Features
Lighting:
Dual Halogen Headlights, Single LED Taillight
Ergonomics:
Comfortable seating and handlebar position for extended use
💡 Technology Features
Infotainment
Instrument Cluster:
Digital instrument cluster with speedometer, tachometer, odometer, trip meter, fuel gauge, high beam indicator, neutral indicator, reverse indicator, AWD indicator.
Driver Assistance
AWD System:
On-Demand All-Wheel Drive (AWD) engages front wheels automatically when rear wheels lose traction.
Connectivity
Charging Port:
12V DC outlet for charging accessories.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 100 hours or 6 months (refer to manual for specific guidance)
Air Filter Cleaning:
Inspect every 25 hours, clean/replace as needed
Spark Plug Replacement:
Refer to manual, typically ~1000 hours or as needed
Fluid Specifications
Engine Oil Type:
SAE 5W-50 Synthetic (API CI-4 rated or equivalent)
Engine Oil Capacity:
Refer to manual for specific capacity (approx. 2.0 - 2.5 quarts)
Coolant Type:
Ethylene Glycol based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 Hydraulic Brake Fluid
Transmission Fluid Type:
Polaris AGL Premium Synthetic Gearcase Oil (or equivalent)
Known Issues
Common Wear Items:
CV boots, tie rod ends, wheel bearings, drive belts
Electrical Gremlins:
Occasional issues with charging system components or connectors, often preventable with proper maintenance.
Drive Belt Wear:
Regular inspection and replacement of the drive belt is crucial to prevent drivetrain damage.
📚 Vehicle History
Brand Heritage
Brand Origin:
Polaris Industries Inc., founded in 1954
Model Evolution
Sportsman Lineage:
The Sportsman line has been a cornerstone of Polaris' ATV offerings, known for its utility and comfort.
2012 Updates:
While specific year-over-year changes can be minor, 2012 models typically refine existing platforms with minor component upgrades or cosmetic adjustments.
Production
Manufacturing Location:
Primarily USA
🏆 Awards & Recognition
Recognitions
Atv Industry Awards:
Polaris Sportsman line consistently recognized for utility and off-road capability by industry publications.
Ratings
Consumer Satisfaction:
Generally high consumer satisfaction for durability and performance in its class.
Certifications
Emissions Certification:
Meets relevant emissions standards for its model year.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

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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