2012-2013 Polaris Sportsman 400 HO Service & Repair Manual

1 GENERAL 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEMS 5 BODY / SUSPENSION

6 CLUTCH 7 FINAL DRIVE 8 TRANSMISSION 9 BRAKES 10 ELECTRICAL

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN)1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2012 SPORTSMAN 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2012 SPORTSMAN 500 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2012 SPORTSMAN TOURING 500 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2012 SPORTSMAN FOREST TRACTOR 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16

1.2 GENERAL INFORMATION 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. MODEL NUMBER INFORMATION Model Number The machine model number must be used with any correspondence regarding warranty or service. Vehicle Identification Number (VIN) Engine Designation Numbers EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start EH46PLE - Single Cylinder, Liquid Cooled,4 Stroke, Electric Start Vehicle and Engine Serial Numbers The machine model number and serial number are important for vehicle identification. Be sure to refer to the engine model number and serial number (A) whenever corresponding about an engine. This information can be found on the sticker applied to the top side of the crankcase (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. The vehicle serial number is located: 400 / 500 Non Touring Vehicles (B) 500 Touring Vehicles (C) A 12 MN 50 AX } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine Vehicle Descriptor Vehicle Identifier  Check Digit Model Year Body Style Plant No Individual Serial Number * This could be either a number or a letter Powertrain Emissions 4 X A M N 5 0 A * 0 P 0 0 0 0 0 0 A B C

1.3 GENERAL INFORMATION 1 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. Transmission I.D. Location Publication Part Numbers Year Model Model No. Owner's Manual PN Parts Manual PN 2012 Sportsman Touring 500 H.O. A12DH50AX, AZ 9923410 9923411 2012 Sportsman Touring 500 H.O. International A12DH50FX 9923438 9923413 2012 Sportsman 400 H.O. A12MH46AX, AZ 9923420 9923421 2012 Sportsman 500 H.O. A12MH50AD, AQ, AX, AZ, 9923420 9923422 2012 Sportsman Forest 500 International A12MH50FF 9923423 9923424 2012 Sportsman Forest Tractor 500 EFI International A12MN50ET 9923430 9923431 The Transmission I.D. number is located on the RH side transmission case; viewable from the RH side of the vehicle.

1.4 GENERAL INFORMATION 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. VEHICLE SPECIFICATIONS 2012 Sportsman 400 H.O. MODEL NUMBER: A12MH46AX, AZ, AF ENGINE MODEL: EH460PLE050 Category Dimension Length 83 in. / 210.8 cm Width 48 in. / 121.9 cm Height 48 in. / 121.9 cm Wheel Base 50.75 in. / 128.9 cm Ground Clearance 11.25 in. / 28.6 cm Dry Weight 688 lbs. / 312 kg Front Rack Capacity 90 lbs. / 41 kg Rear Rack Capacity 180 lbs. / 81.6 kg Towing Capacity 1225 lbs. / 555.7 kg Max. Weight Capacity 485 lbs. / 220 kg Hitch Tongue Weight 120 lbs. / 34 kg Unbraked Trailer Towing Capacity (EU) Data based on EU Directive: 76/432/EEC 1786 lbs. / 810 kg Engine Platform Fuji 4-cycle, L/C, Single Cyl. Engine Model Number EH460PLE050 Engine Displacement 455cc Number of Cylinders 1 Bore & Stroke (mm) 87.9 x 75 mm Compression Ratio 10.1:1 Compression Pressure 50-90 psi Engine Idle Speed 1200+/- 200 RPM Engine Max Speed 7000 RPM Cooling System / Cap. Liquid / 2.7 qt. (2.5 L) Overheat Warning HOT on Instrument Cluster Lubrication Dry Sump Oil Requirements PS-4 Plus / 2 qt. (1.9 L) Exhaust System Single Pipe - USFS Approved Carburetion Carburetor model Mikuni BST 34mm Main Jet 160 Pilot Jet / Pilot Air Jet 42.5 / 160 Jet Needle 4IB33-3 Needle Jet P-6M Pilot / Air Screw 2.75 Turns Out (Initial setting) Float Height 13mm from carburetor body Fuel Delivery Fuel Pump (Impulse) Fuel Capacity / 4.25 gal. (16 L) Fuel Requirement (Octane) 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 260 watt @ 3000 RPM Voltage Regulator 3-Phase PDM Pod Lighting 1x 12V / 50 Watts Grill Lighting 2x 12v / 50 Watts Brake Light 12V / 26.9 watts Tail Light 12V / 8.26 watts Ignition System DC / CDI Ignition Timing 30° ± 2° BTDC @ 5000 RPM Spark plug / Gap NGK BKR6E / .035 in. (.9 mm) Battery Maintenance-Free / 12 Amp Hr. Circuit Breakers 10A - Accessory / 10A - Fan / 15A - Main Harness Starting Electric Instrument Cluster Digital Gauge LCD, Analog Speedometer

1.5 GENERAL INFORMATION 1 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. JETTING CHART Drivetrain Transmission Type In-Line H/L/N/R/P Transmission Fluid Type / Fluid Capacity AGL Plus 33.8 oz. (1000 ml) Front Gearcase Fluid Type / Fluid Capacity Polaris Demand Drive Hub Fluid / 8.97 oz / 265 ml Gear Ratio : Low (Front/Rear) Rev (Front/Rear) High (Front/Rear) 7.70:1/23.91:1 7.00:1/21.74:1 3.41:1/10.57:1 Clutch Type CVT Belt 3211077 Steering / Suspension Front Suspension / Shock MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock IRS / Progressive Rate Rear Travel 9.5. / 24.1 cm Turning Radius 65 in. / 165.1 cm (unloaded) Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Toe Out 0-1/16 in. (0-.159 mm) Wheels / Brakes Front Wheel Size Front Tire Model / Size 12x5 NHS 489 / 25 x 8-12 Rear Wheel Size Rear Tire Model / Size 12x8 NHS 489 / 25 x 10-12 Tire Air Pressure - F / R 5 psi (34.5 kPa) Brakes - Front & Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 4 Brake Fluid ALTITUDE AMBIENT TEMPERATURE Below 40° F Below 5° C Above +40° F Above +5° C Meters (Feet) 0-1800 (0-6000) 167.5 160 1800-3700 (6000- 12000) 155 150 Table 1-1: Clutching (NON EBS) Altitude Shift Weight Drive Clutch Spring Meters (Feet) 0-1800 (0-6000) 10WHF 5632283 Blue / Grey 7042202 1800-3700 (6000- 12000) 20-40 or 10RH 5631356 (20-40) 5630709 (10RH)

1.6 GENERAL INFORMATION 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. 2012 Sportsman 500 H.O. MODEL NUMBER: A12MH50AX, AZ, AD, AQ, FF, FY, FX ENGINE MODEL: EH500PLE13B Category Dimension / Capacity Length 83 in./210.8 cm Width 48 in./121.9 cm Height 48 in./121.9 cm Wheel Base 50.75 in./128.9 cm Ground Clearance 11.25 in./28.6 cm Dry Weight 696 lbs./313 kg (Wet weight model FF, FY, FX) 776 lbs / 352 kg) Front Rack/Box Capacity 90 lbs./40.8 kg Rear Rack Capacity 180 lbs./81.6 kg Max. Weight Capacity 485 lbs. / 220 kg Towing Capacity 1225 lbs ./ 555.7 kg Unbraked Trailer Towing Capacity (EU)* NOTE: *Data based on EU Directive: 76/432/EEC 1786 lbs. / 810 kg Hitch Tongue Capacity 120 lbs./54.4 kg Rear rack capacity and tongue weight not to exceed 180 lbs./82 kg ENGINE Platform Fuji Single Cylinder Engine Model Number EH500PLE13B Engine Displacement 498cc Number of Cylinders 1 Bore & Stroke (mm) 92 x 75 mm Compression Ratio 10.2:1 Compression Pressure 70-90 psi W/Compression Release Engine Idle Speed 1200+/- 200 RPM Engine Max Operating Rpm 7000 Rpm ± 200 Rpm Cooling System / Capacity Liquid - 2.7 qt / 2.5 litre Overheat Warning HOT on Instrument Cluster Lubrication Pressurized Dry Sump Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 litre Exhaust System Single Pipe USFS Approved Fuel System Carburetor Mikuni BST 40mm Main Jet 150 Pilot Jet 40 Jet Needle / Clip Position 6MGH1-94-3 Needle Jet X-6M Pilot Screw 1 Turn Out (initial) Pilot Air Jet 40 Float Height 14.7mm ± 1 (.58 ± 0.40") Fuel Delivery Fuel Pump Fuel Capacity / Requirement 4.25 gal US / 15.5 liters 87 Octane (minimum) or 89 Oxygenated Electrical Alternator Output 260 w @ 3000 RPM Voltage Regulator 3-phase PDM Lights : Pod 50 watts Grill 2 x 50 watts Brake 26.9 watts Tail 8.26 watts Ignition System DC/CDI Ignition Ignition Timing 30°± 2° BTDC @ 5000 RPM Spark plug / Gap BKR6E / .035 in. / 0.9 mm Battery Maintenance-Free / 12 Amp Hr. Circuit Protection 5 / 15 / 20 Amp Fuses 10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD

1.7 GENERAL INFORMATION 1 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc. Table 1-2: Sportsman 500 H.O. Drivetrain Transmission Type Drumshift - H/L/N/R/P Transmission Capacity AGL Plus 33.8 oz. (1000 ml) Front Gearcase Capacity 8.97 oz. / 265 ml Gear Ratio : Low (Front/Rear) Rev (Front/Rear) High (Front/Rear) 7.70:1/23.91:1 7.00:1/21.74:1 3.41:1/10.57:1 Clutch Type PVT Non-EBS Belt 3211077 Steering / Suspension Front Suspension / Shock A-arm / MacPherson Strut Front Travel 8.2 in. / 20.8 cm Rear Suspension / Shock Progressive Rate Indepen- dent - w/ 2" Coil-over shock Rear Travel 9.5 in. / 24.13 cm Ground Clearance 11.25 in. / 28.6 cm Shock Preload Adjustment Front / Rear Front -Non Adjustable. Rear - Ratchet Style- Std. Turning Radius 65 in./165.10 cm unloaded Toe Out 0-1/16 in / .0 - .159 mm Wheels / Brakes Front Wheel Size Front Tire Model / Size 12x5 NHS 489 / 25 x 8-12 Rear Wheel Size Rear Tire Model / Size 12x8 NHS 489 / 25 x 10-12 Tire Air Pressure - F / R 5 psi (34.5 kPa) Brakes - Front & Rear Single Control Hydraulic Disc Brake Fluid Polaris DOT 4 Brake Fluid Table 1-3: Sportsman 500 H.O. Jetting Altitude AMBIENT TEMPERATURE Below 40 ° F Below 5 ° C +40 to +80 ° F +5 to +28 ° C Meters (Feet) 0-1800 (0-6000) 155 150 1800-3700 (6000- 12000) 147.5 142.5 Table 1-4: Clutching (EBS and NON EBS) Altitude Shift Weight Drive Clutch Spring Meter s (Feet) 0-1800 (0-6000) 10 WHF (5632283) Green / Blue (7041157) 1800- 3700 (6000- 12000) 10 RH (5630709) Green / Blue (7041157)

2012-2013 Polaris Sportsman 400 HO Service & Repair Manual

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