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Polaris
2012 Polaris Sportsman 400 500 HO Touring 500 HO Forest Tractor 500 EFI Service Repair Manual
2012 Polaris Sportsman 400 500 HO Touring 500 HO Forest Tractor 500 EFI Service Repair Manual
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Vehicle data plateRef 51156
- Brand
- Polaris
- Vehicle
- ATV
- Models covered
- Sportsman 400, Sportsman 500 EFI, Sportsman 500 HO Forest Tractor, Sportsman 500 HO Touring, Sportsman Series
- Years
- 2012
- Format
- PDF, searchable, print-ready
- Delivery
- Instant download after checkout
- Language
- English
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- Download link opens on the order page immediately
- The same link is emailed to you — re-download any time
- Open on phone, tablet or PC; print only the pages you need
- Not sure it covers your model year? Ask us before you buy
| Basic Information | |
| Identification | |
| Make: | Polaris |
| Model: | Sportsman 400/500 HO/500 HO Touring/500 HO Forest/500 EFI Forest Tractor |
| Year: | 2012 |
| Generation | |
| Model Generation: | This manual covers models from the 2012 model year, representing an iteration within the Polaris Sportsman line, known for its utility and off-road capabilities. |
| Introduction | |
| Market Position | |
| Positioning: | The Polaris Sportsman series is positioned as a versatile and robust line of All-Terrain Vehicles (ATVs) for utility, recreation, and work, with the 400 and 500 models representing popular mid-range options. |
| Competitive Analysis | |
| Competitors: | Competes directly with other major ATV manufacturers' mid-size utility and recreational models, such as Can-Am Outlander, Arctic Cat, and Yamaha Kodiak/Grizzly. |
| Key Features | |
| Distinctive Features: | Known for Polaris's Pro-Ride™ suspension, on-demand All-Wheel Drive (AWD) systems, and ergonomic design for rider comfort and control. |
| Manual Value | |
| Value Proposition: | This manual provides essential technical documentation for owners and technicians, enabling efficient maintenance, accurate diagnostics, and effective repairs, thereby maximizing the lifespan and performance of the ATV. |
| Manual Details | |
| Coverage Areas | |
| Manual Scope: | Comprehensive service and repair for 2012 Polaris Sportsman 400 HO, 500 HO, 500 HO Touring, 500 HO Forest, and 500 EFI Forest Tractor ATVs. |
| Page Count | |
| Estimated Page Count: | Information not explicitly stated, but service repair manuals of this nature typically range from 400 to over 1000 pages due to the depth of technical information and diagrams. |
| Manual Type | |
| Type: | Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF Download |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Detailed diagnostics, repair, and overhaul procedures for the engine, including cooling systems, lubrication, and exhaust. |
| Fuel System: | In-depth coverage of fuel delivery systems, including carburetor/EFI components, fuel pump, fuel filter, and tank. |
| Body Suspension: | Covers frame, body panels, plastics, front and rear suspension systems, steering components, and wheel alignment. |
| Clutching: | Detailed information on primary and secondary clutch inspection, maintenance, and replacement, including spring and weight adjustments. |
| Final Drive: | Procedures for servicing and repairing front and rear differentials, drive axles, and universal joints. |
| Transmission: | Service and repair of the transmission (gearbox) and drive system, including gear selection and lubrication. |
| Brakes: | Complete brake system service, including hydraulic components, brake pads, rotors, and bleeding procedures. |
| Electrical: | Extensive coverage of the electrical system, including battery, charging system, ignition, lighting, and accessories. |
| Wiring Diagrams: | Includes comprehensive, color-coded wiring diagrams essential for electrical diagnostics and troubleshooting. |
| Procedures Included | |
| Maintenance: | Regular scheduled maintenance procedures, including fluid changes, filter replacements, and lubrication points. |
| Disassembly Assembly: | Step-by-step instructions for the disassembly and reassembly of all major components and systems. |
| Troubleshooting: | Diagnostic charts and procedures to identify and resolve common and complex operating issues. |
| Special Tools: | Identification and usage of specialized tools required for specific repair and maintenance tasks. |
| Technical Depth | |
| Depth: | Covers everything from basic tune-ups and fluid services to complete engine rebuilds, transmission overhauls, and electrical system diagnostics. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Compatibility: | Compatible with all versions of Windows and Mac operating systems. |
| Requirements: | Requires Adobe PDF Reader or compatible software for viewing. |
| Print Quality | |
| Printability: | All pages are printable, allowing for physical use in a workshop environment. |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Liquid-cooled, 4-stroke, SOHC (Single Overhead Cam) gasoline engine. |
| Displacement 400: | Approximately 325cc (specifics may vary slightly by sub-model). |
| Displacement 500: | Approximately 499cc. |
| Engine Orientation: | Typically a single-cylinder engine mounted longitudinally. |
| Performance | |
| Horsepower 500: | Estimated to be in the range of 30-35 HP (Horsepower), though official figures are not always published by Polaris for ATVs. |
| Torque 500: | Torque figures are application-specific but designed for strong low-end power for pulling and climbing. |
| Fuel System | |
| Fuel Delivery 500 Efi: | Electronic Fuel Injection (EFI) system for optimal fuel/air mixture, cold starts, and altitude compensation. |
| Fuel Delivery 400 500 Ho: | Often utilizes a carburetor (e.g., Mikuni BSR series) for non-EFI models. |
| Fuel Type: | Unleaded gasoline, octane rating as specified by Polaris (typically 87). |
| Cooling System | |
| Cooling Method: | Liquid-cooled with a radiator and fan. |
| Lubrication | |
| Oil Type: | Polaris recommends specific synthetic or semi-synthetic ATV engine oils meeting certain API classifications (e.g., SJ or higher). Specific viscosity grades like 0W-40 or 10W-40 are common. The manual will detail exact specifications. |
| Oil Capacity: | Approximately 2.0-2.5 quarts (1.9-2.4 liters) for the 500 HO, including filter. The manual will provide precise capacities. |
| Ignition | |
| Ignition System: | Electronic ignition system, likely CDi based. |
| Transmission | |
| Standard | |
| Transmission Type: | Automatic PVT (Polaris Variable Transmission) with High, Low, Neutral, and Reverse gears. |
| Optional | |
| Gear Reduction: | Integrated gear reduction systems for enhanced torque and durability. |
| Features | |
| Drive System: | On-demand All-Wheel Drive (AWD) with 2WD/4WD activation. Some models may have specific locking differentials or AWD systems. |
| Final Drive Type: | Shaft drive to front and rear differentials. |
| Maintenance | |
| Transmission Fluid Type: | Specific synthetic gear oil or transmission fluid recommended by Polaris. The manual will specify the exact product and grade. |
| Dimensions | |
| Exterior | |
| Length: | Varies by model, typically around 83-85 inches (211-216 cm) for standard Sportsman models and longer for Touring variants. |
| Width: | Generally around 46 inches (117 cm). |
| Height: | Approximately 48 inches (122 cm). |
| Weights | |
| Dry Weight: | Varies significantly by model and configuration, but typically in the range of 600-750 lbs (272-340 kg). |
| Towing Capacity: | Typically rated for 1,500 lbs (680 kg). |
| Rack Capacity Front: | Typically 200 lbs (91 kg). |
| Rack Capacity Rear: | Typically 400 lbs (181 kg). |
| Tires | |
| Front Tire Size: | Commonly 25x8-12 or 26x8-12. |
| Rear Tire Size: | Commonly 25x10-12 or 26x10-12. |
| Wheel Bolt Pattern: | Typically 4x110 mm for front and rear wheels. |
| Safety Features | |
| Ratings | |
| Atv Safety Standards: | Designed to meet industry safety standards for ATVs, emphasizing stability and rider control. Specific crash ratings are not applicable in the same way as automotive vehicles. |
| Active Features | |
| AWD System: | The On-Demand AWD system enhances traction and control in challenging terrain. |
| Braking System: | Hydraulic disc brakes front and rear provide reliable stopping power. |
| Passive Features | |
| Handlebars: | Ergonomic handlebars with comfortable grip and control placement. |
| Lighting: | Dual headlights, taillight, and brake light for visibility. |
| Technology Features | |
| Infotainment | |
| Instrument Cluster: | Digital instrument cluster providing speed, RPM, fuel level, gear indicator, odometer, trip meter, and diagnostic indicators. |
| Driver Assistance | |
| AWD Engagement: | Electronic engagement of All-Wheel Drive for seamless transitions between 2WD and 4WD. |
| Connectivity | |
| Diagnostic Ports: | Diagnostic port for connecting service tools and accessing error codes, crucial for troubleshooting EFI models. |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Typically every 100 hours of operation or annually, whichever comes first. The manual will provide detailed intervals. |
| Air Filter: | Inspection and cleaning/replacement recommended every 50 hours or as needed based on operating conditions. The manual will specify part numbers and procedures. |
| Spark Plug: | Recommended replacement every 100 hours or annually. Specific plug type (e.g., NGK) and gap will be in the manual. |
| Valve Clearance: | Inspection and adjustment typically recommended every 100-200 hours or annually. The manual will provide specific procedures and tolerances. |
| Fluid Specifications | |
| Coolant: | Ethylene glycol-based antifreeze mixed with distilled water (typically 50/50 ratio). The manual will specify the exact type and capacity. |
| Brake Fluid: | DOT 3 or DOT 4 hydraulic brake fluid, depending on the specific system requirements detailed in the manual. |
| Known Issues | |
| Common Wear Items: | Common wear items include brake pads, bearings (wheel, steering), drive belts (for PVT), and suspension bushings. The manual will provide part numbers and replacement procedures. |
| Efi Maintenance: | For EFI models, regular cleaning of the throttle body and injectors may be beneficial, as detailed in the manual's advanced troubleshooting sections. |
| Vehicle History | |
| Brand Heritage | |
| Polaris History: | Polaris Industries is a long-standing American manufacturer, founded in 1954, with a strong reputation for powersports vehicles, including ATVs, snowmobiles, and motorcycles. |
| Model Evolution | |
| Sportsman Line: | The Sportsman line has been a cornerstone of Polaris's ATV offerings for decades, continuously evolving with technological advancements and market demands, known for its comfort and utility. |
| Production | |
| Manufacturing Location: | Polaris ATVs are primarily manufactured in the United States, with key facilities in Minnesota and South Dakota. |
| Awards & Recognition | |
| Recognitions | |
| Industry Awards: | Polaris Sportsman models have historically received praise in Powersports publications for their comfort, handling, and utility features, often winning 'best in class' awards within their respective categories. |
| Certifications | |
| Industry Certifications: | Manufactured to meet applicable regulatory and safety standards for ATVs in its target markets. |
Delivery & file format
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
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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2012 Polaris Sportsman 400 500 HO Touring 500 HO Forest Tractor 500 EFI Service Repair Manual
Polaris / Atv · PDF · Instant download
$16.99
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