Polaris Sportsman 400-500 (2012) - Repair, Service Manual and Electrical Wiring Diagrams

CLICK HERE FOR SAMPLE MANUAL

POLARIS SPORTSMAN 400-500 (2012) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, to ATV Polaris Sportsman 400 500 (2012).

 
CONTENTS:

MODEL NUMBER INFORMATION
- Model Number
- Vehicle Identification Number (VIN)
- Engine Designation Numbers
- Vehicle and Engine Serial Numbers
- Transmission I.D. Location
- Publication Part Numbers
VEHICLE SPECIFICATIONS
- 2012 Sportsman 400-500 H.O.
- 2012 Sportsman 500 H.O.
- 2012 Sportsman Touring 500 HO
- 2012 Sportsman Forest Tractor 500 EFI Specifications MODEL NUMBER: A12MN50ET, EX
MISC. NUMBERS/CHARTS
- Conversion Table
- Standard Bolt Torque Specification
- Metric Bolt Torque Specification
- SAE Tap Drill Sizes
- Metric Tap Drill Sizes
- Decimal Equivalents
- Paint Codes
- Replacement Keys
- Glossary Of Terms
SPECIAL TOOLS
MAINTENANCE
- Periodic Maintenance Chart
- Maintenance Chart Key
- Periodic Maintenance Chart
LUBRICANTS / SERVICE PRODUCTS
- Polaris Lubricants, Maintenance and Service Products
LUBRICATION / FLUIDS
- Pre-Ride / Daily Inspection
- Lubrication Components
- Front Gearcase Lubrication
- Transmission Lubrication
ADC SYSTEM (IF EQUIPPED)
- ADC System Fluid Reservoir Location
- ADC Differential Hydraulic Circuit Fluid Change
VEHICLE INSPECTION
- Shift Link Rod Inspection
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment
- Fuel System
- Fuel Lines
- Vent Lines
- Choke (Enricher) Adjustment - (500 Carb)
- Compression Test
- Engine Mounts
- Spark Plug
- Battery Maintenance
- Liquid Cooling System Overview
- Coolant Strength / Type
- Cooling System Hoses
- Radiator/Grill Screen
- Cooling System Pressure Test
- Coolant Level Inspection
- Radiator Coolant Level
- Air Filter/Pre-Filter Service
- Air Box Sediment Tube
- Breather Filter Inspection
- Breather Hose
- Recoil Housing
- Engine Oil Level
- Oil and Filter Change
- Oil Pump Priming Procedure
- Valve Clearance
- Intake Valve Clearance Adjustment
- Exhaust Valve Clearance Adjustment
- Steering
- Tie Rod End/Steering Inspection
- Camber and Caster
- Wheel Alignment
- Toe Alignment Adjustment
- Exhaust Pipe
- Brake System Inspection
- Brake Pad Inspection
- Hose/Fitting Inspection
- Auxiliary Brake Testing
- Auxiliary Brake Adjustment (Hydraulic)
- Suspension Spring Preload Adjustment
- Front Suspension
- CV Shaft Boot Inspection
- Controls
- Wheels
- Wheel, Hub, And Spindle Torque Table
- Wheel Removal Front or Rear
- Wheel Installation
- Tire Pressure
- Tire Inspection
- Frame, Nuts, Bolts, Fasteners
CARBURETOR MAINTENANCE
- Choke (Enricher) Adjustment (Non EFI)
- Pilot Screw
- Pilot Screw Adjustment
- Idle Speed Adjustment (Non EFI)
- Fuel Filter (Non EFI)
- Carburetor Draining
- Maintenance Schedule
SPECIFICATIONS
- Torque Specifications
- Engine Fastener Torque Patterns
- Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted)
- Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted)
- Sportsman 400-500 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
- Sportsman 400-500 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
SPECIAL TOOLS
GENERAL ENGINE SERVICE
- Cooling System Specifications
- Cooling System
- Accessible Components
- Engine Removal
- Engine Installation Notes
- Cylinder Hone Selection/ Honing Procedure
- Honing To Oversize
- Cleaning the Cylinder After Honing
- Crankshaft Straightening
- Engine Lubrication
- Oil Pressure Test
- Oil Flow
- Oil Flow Diagram
- Engine Exploded Views
ENGINE DISASSEMBLY
- Cam Chain Tensioner / Rocker Arm / Camshaft Removal
- Cam Chain Tensioner Inspection
- Rocker Arm / Shaft Inspection
- Camshaft Removal
- Automatic Compression Release Removal / Inspection
- Automatic Compression Release Installation
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder Head Exploded View
- Cylinder Head Inspection
- Cylinder Head Warpage
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Assembly
- Valve Sealing Test
- Valve Clearance Adjustment
- Cylinder / Piston Removal and Inspection
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection / Honing Procedure
- Honing to Oversize
- Cleaning the Cylinder After Honing
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Identification
- Piston Ring Installed Gap
- Crankcase Disassembly
- Starter Drive Removal / Inspection
- Flywheel and Stator Removal / Inspection
- Cam Chain / Tensioner Blade
- One Way Valve
- Crankcase Separation
- Oil Pump Removal / Inspection
- Oil Pump Assembly
- Counter Balancer Shaft Removal / Inspection
- Crankshaft Removal / Inspection
- Crankcase Bearing Inspection
- Oil Seal / Mechanical Seal Removal (Engine Disassembled)
- Crankcase Inspection
- Bearing Installation
- End Play Inspection / Adjustment
- Crankshaft End Play Adjustment
- Counter Balancer Shaft End Play Adjustment
- Oil Pump Shaft End Play Adjustment
ENGINE REASSEMBLY
- Pump Shaft Oil Seal Installation
- Crankshaft / Counter Balance / Oil Pump Installation
- Crankcase Assembly
- Water Pump Mechanical Seal Installation
- Water Pump Mechanical Seal Removal (Engine Installed)
- One Way Valve Installation
- Cam Chain Drive Sprocket Installation
- Tensioner Blade Installation
- Piston Ring Installation
- Piston Installation
- Cylinder Installation
- Cylinder Head Installation
- Cam Chain / Camshaft Installation
- Camshaft Timing
- Camshaft Timing Illustration
- Cam Chain Tensioner Installation
- Stator, Flywheel and Starter Drive Installation
- Rocker Shaft / Rocker Arm Assembly Installation
- Thermostat Installation
- Oil Pipes
- Oil Pump Priming Procedure
RECOIL (ACCESSORY)
- Recoil Disassembly/Inspection
- Recoil Assembly
TROUBLESHOOTING
- Spark Plug Fouling
- Engine
- Cooling System
GENERAL INFORMATION AND SPECIFICATIONS
- Carburetor Jetting
- Mikuni Jet Part Numbers
- Special Tools
CARBURETION
- BST 40 Carburetor Exploded View 1 of 2
- BST 40 Carburetor Exploded View 2 of 2
- CV Carburetor System Function
- Mikuni CV Carb Operation
- Carburetor Venting
- Starter System (Choke or Enrichment)
- Pilot (Idle and Slow) System
- Main System
- Float System
- Pilot Screw
- Air/Fuel Mixture Ratio
- Jet Needle
- Needle Jet
- Throttle Opening vs. Fuel Flow
- Carburetor Disassembly – Mikuni CV
- Carburetor Cleaning
- Carburetor Inspection
- Carburetor Assembly
- Float Height Adjustment
- Needle and Seat Leakage Test
- Fuel Level Test
CARBUTATED FUEL TANK / FUEL DELIVERY SYSTEM
- Fuel System Exploded View
FUEL PUMP (CARBURATED)
- Fuel Filter Replacement (Carbureted)
FUEL GAUGE SENDING UNIT TEST
- Fuel Sending Unit Test
FUEL PICK-UP / SENDING UNIT REPLACEMENT (CARB.)
- Fuel Pick-up / Sending Unit Replacement
FUEL TANK VENT ROUTING (NON INTL)
- Fuel Tank Vent Hose Routing
500 H.O. INTERNATIONAL EMISSIONS SYSTEM
- Overview
TROUBLESHOOTING
- Fuel Starvation/Lean Mixture
SPECIAL TOOLS
- Part Numbers / Descriptions
500 EFI TRACTOR SPEED CONTROL
- System Operation Overview
- Air Control Body Removal and Disassembly
- Air Control Body Assembly and Installation
- Air Solenoid Valve Test / Replacement
- Exhaust System
EFI SERVICE NOTES
- General Service Information
EFI SYSTEM EXPLODED VIEW
EFI SYSTEM
- Component Locations/Identification
FUEL SYSTEM AND FUEL TANK
- Fuel System and Fuel Tank Exploded View
ELECTRONIC FUEL INJECTION
- General Information
- EFI Operation Overview
- Initial Priming / Starting Procedure
FUEL LINES
- Quick Connect Removal/Installation
ELECTRONIC CONTROL UNIT (ECU)
- Operation Overview
- ECU Replacement
- ECU Service
FUEL PUMP ASSEMBLY
- Operation / Testing
- FUEL PUMP TEST
- Fuel Tank Replacement
- Fuel Sending Unit Test
- Fuel Pump Replacement
FUEL PRESSURE REGULATOR
- General Information
FUEL FILTER
- General Information
FUEL INJECTOR
- General Information
CRANKSHAFT POSITION SENSOR (CPS)
- General Information
MANIFOLD AIR PRESSURE SENSOR (MAP)
- Operation Overview
- Map Sensor Test
- Map Sensor Replacement
INTAKE AIR TEMPERATURE SENSOR (IAT)
- Operation Overview
- Intake Air Temperature Sensor Test
- Intake Air Temperature Sensor Replacement
I DLE AIR CONTROL (IAC)
- General Information
THROTTLE POSITION SENSOR (TPS)
- Operation Overview
- Throttle Position Sensor Test
- Throttle Position Sensor Replacement
- Throttle Position Sensor Initialization
ENGINE TEMPERATURE SENSOR
- General Information
- Engine Temperature Sensor Test
- Engine Temperature Sensor Replacement
FUEL SYSTEM TROUBLESHOOTING
- FUEL STARVATION / LEAN MIXTURE
EFI DIAGNOSTICS USING ‘BLINK CODES’
- Blink Codes - Operation
DIGITAL WRENCH™ OPERATION
- Digital Wrench™ Diagnostic Software Overview
- Special Tools (also refer to page 3.2)
- Diagnostic Software Version
- ECU Replacement
- Guided Diagnostic Available
- Digital Wrench™ Communication Errors
- Digital Wrench™ - Diagnostic Connector
- Digital Wrench™ Version and Update ID
- Digital Wrench™ Updates
- Digital Wrench™ Serial Number Location
- Digital Wrench™ Feature Map
- Engine Controller Reprogramming (Reflash)
TROUBLESHOOTING DIAGRAMS
- EFI CIRCUIT - Power On
- EFI CIRCUIT - Crank Position Sensor
- EFI CIRCUIT - Fuel Pump
- EFI CIRCUIT - Ignition Coil
- EFI CIRCUIT - Idle Air Control
- EFI CIRCUIT - Throttle Position Sensor
- EFI CIRCUIT - Manifold Absolute Pressure Sensor
- EFI CIRCUIT - Engine Coolant Temperature
- EFI CIRCUIT - Air Temperature Sensor
- EFI CIRCUIT - Malfunction Indicator Light
GENERAL INFORMATION
- Torque Specifications
- Special Tools
- Decal Replacement
- Plastic Insert Removal / Installation
BODY
- Side Panel Removal
- Front Storage Box Lid / Front Rack and Access Panel Removal / Installation
- Foot Well Removal / Installation
- Front Bumper Removal / Installation
- Mud Guard Removal / Installation
- Front Fender Removal/Installation
- Front Rack / Storage Box Lid Assembly
- Front Cab Assembly
- Front Bumper Assembly
- Rear Rack Assembly
- Rear Cab And Seat Assembly
- Rear Storage Box Assembly
- Winch and Front Bumper Mounting
- Headlight Pod Exploded View
500 EFI TRACTOR SEAT ASSEMBLY
- Overview
- Seat Dampener Repair
- Seat Pivot Repair
- 500 EFI Tractor Seat Assembly Exploded View
500 EFI TRACTOR STEERING POST AND LOCK
- Steering Assembly Exploded View
STEERING
- Handlebar Block Installation Procedure
- Steering / A-arm Exploded View
- A-Arm Replacement
- Ball Joint Replacement
- Steering Post Removal
- Steering Post Assembly
SUSPENSION
- Front Strut Cartridge Replacement
- Strut Assembly
- Sportsman Rear Suspension Assembly
- Torsion Bar Exploded View
SPECIAL TOOL AND SUPPLIES
TORQUE SPECIFICATIONS
- PVT System Fastener Torques
PVT SYSTEM OVERVIEW
- General Operation
- Drive Clutch Operation
- Driven Clutch Operation
- PVT Break-In (Drive Belt / Clutches)
- Maintenance / Inspection
- Clutching Chart
- Overheating / Diagnosis
PVT EXPLODED VIEWS
- PVT Sealing And Ducting Components
- Drive Clutch Exploded Views (EBS vs. Non-EBS)
PVT SYSTEM SERVICE
- Disassembly
- Assembly
DRIVE BELT
- Belt Removal
- Belt Inspection
- Belt Installation
- PVT Break-In (Drive Belt / Clutches)
CLUTCH ALIGNMENT
- Clutch Alignment Tool Use
- Belt Deflection (Tension)
CLUTCH CENTER DISTANCE
- Setting Center-To-Center Distance
DRIVE CLUTCH SERVICE (NON EBS)
- Exploded View (NON EBS)
- Clutch Disassembly
- Drive Clutch Spring Inspection
- Shift Weight Inspection
- Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- Bearing Inspection
- Clutch Inspection
- Moveable Sheave Bushing Inspection
- Clutch Assembly
EBS DRIVE CLUTCH SERVICE
- EBS Drive Clutch Exploded View
- Drive Clutch Disassembly
- Spider Removal
- Button To Tower Clearance Inspection
- Shift Weight Inspection
- Drive Clutch Inspection
- Moveable Sheave Bushing Inspection
- One-Way Clutch Inspection (EBS Drive Clutch)
- Drive Clutch Reassembly
DRIVE CLUTCH BUSHING SERVICE (NON EBS AND EBS)
- Bushing Service
DRIVEN CLUTCH SERVICE (NON EBS)
- Exploded View (NON EBS)
- Clutch Disassembly / Inspection
- Clutch Assembly
DRIVEN CLUTCH SERVICE (EBS)
- Driven Clutch Exploded Views (EBS)
- Clutch Disassembly
- Clutch Assembly
DRIVEN CLUTCH BUSHING SERVICE
- Driven Clutch Bushing Service (NON EBS and EBS)
TROUBLESHOOTING
SPECIFICATIONS
- Torque Table
- Special Tools
- Gearcase Fluid / Capacity
FRONT HUB
- Disassembly
- Assembly
FRONT GEARCASE REMOVAL AND INSTALLIATION (ADC AND NON ADC)
- Gearcase Removal
- Gearcase Installation
FRONT GEARCASE - CENTRALIZED HILLIARD NON ADC (4X4)
- Operation NON ADC
- Disassembly / Inspection NON ADC
- Reassembly / Inspection NON ADC
- Front Gearcase Diagnosis
- Setting Ring Gear Backlash NON ADC
FRONT GEARCASE - CENTRALIZED HILLIARD ADC
- Operation
- ADC Gearcase Exploded View
- ADC Operation
- Front Gearcase Diagnosis
- Coil Testing
- ADC Differential Hydraulic Circuit Bleeding
- Disassembly / Inspection
- ADC Gearcase Piston Replacement Procedure
- Assembly
- Setting Ring Gear Backlash
FRONT DRIVE (CV) SHAFT
- Inspection
- Removal
- Installation
REAR HUB
- Removal
- Disassembly
- Assembly
- Installation
REAR DRIVE (CV) SHAFT
- Inspection
- Removal
- Installation
CV DRIVE SHAFT SERVICE
- Drive Shafts and Propshafts Components
- Drive Shaft and CV Joint Handling Tips
- Outer CV Joint / Boot Replacement
- Inner Plunging Joint / Boot Replacement
- Drive Shaft Exploded Views
PROP SHAFT - FRONT OR REAR
- Removal and Installation
U-JOINT SERVICE
- Disassembly
- Assembly
TRANSMISSION - GENERAL
- Torque Specifications
- Special Tools
- Lubrication
- Transmission Frame Mounts
- Transmission Upper Frame Mount
- Transmission Rear Stabilizer Mounts
- Transmission Control Arm Bracket Mounts
- Shift Linkage Inspection
- Gear Selector Removal
- Transmission Removal
- Transmission Installation
- Troubleshooting Checklist
2012 SPORTSMAN TRANSMISSION EXPLODED VIEW
- 2012 Sportsman Transmission Exploded View
TRANSMISSION DISASSEMBLY / ASSEMBLY
- Transmission Disassembly
- Snorkel / Output Gear Backlash Procedure
- Transmission Assembly
SPECIFICATIONS
- Torque Table
- Component Service Limits
SPECIAL TOOLS
- Special Tools
HYDRAULIC BRAKE SYSTEM
- Operation Overview
- Overview: Sportsman Forest 500 (INTL A12MH50FF)
- Brake Noise Troubleshooting
- Brake Bleeding / Fluid Change
BRAKE SYSTEM EXPLODED VIEWS
- Sportsman Touring 500 HO Component Exploded View
- Sportsman 400-500 HO, 500 HO and International Forest Component Exploded View
- Sportsman Forest Tractor 500 (INTL A12MH50FF) Component Exploded View
BRAKE CALIPER EXPLODED VIEWS
- Sportsman 400-500 HO, 500 HO, Touring and Forest 500 (INTL.) Front Caliper Assembly
- Sportsman 500 HO Touring Rear Caliper Assembly (non INTL.)
- 400-500, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.) Rear Caliper Assembly
- Sportsman Forest 500 (INTL.) Front Caliper Assembly
FRONT MASTER CYLINDER ALL MODELS
- Removal
- Installation
FRONT BRAKES
- Pad Removal
- Assembly
- Brake Burnishing Procedure
FRONT BRAKE DISC
- Inspection
- Removal / Replacement
FRONT CALIPER
- Removal
- Inspection
- Reassembly
- Installation
REAR BRAKE PAD
- Touring Pad Removal
- Touring Pad Installation
- Sportsman Rear Pad Removal
- Sportsman Rear Pad Installation
- Brake Burnishing Procedure
TOURING REAR CALIPER
- Removal
- Inspection
- Reassembly
SPORTSMAN REAR CALIPER
- Removal and Inspection
- Assembly
REAR BRAKE DISC
- Inspection
REAR MASTER CYLINDER
- Sportsman 500 HO Touring Exploded View (Non Intl)
- Sportsman 400-500 HO, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.)
- Overview
- Touring Rear Master Cylinder Removal and Installation
- Sportsman Rear Master Cylinder Removal / Installation
- Pedal Removal and Installation
TROUBLESHOOTING
- Brakes Squeal
- Poor Brake Performance
- Lever Vibration
- Caliper Overheats (Brakes Drag)
- Brakes Lock
GENERAL INFORMATION
- Special Tools
- Ignition System / Basic Electrical Components
- Electrical Service Notes
- Troubleshooting
INSTRUMENT CLUSTER
- Overview
- Instrument Cluster Diagnostic Mode
- Setting A New Service Interval
- EFI Diagnostic Mode
- Speedometer Removal
- Speedometer Installation
ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING
- TEST 1 - No All Wheel Drive
- TEST 2 - No Speedometer Display
- TEST 3 - No Reverse Speed Limit
- TEST 4 - No AWD Hub Safety Limit
- TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor
- TEST 6 - Vehicle Speed Sensor
- Speed Sensor Location
- Speed Sensor Testing
- TEST 7 - Fuel Gauge Display Not Working
- TEST 8 - Shift Indicator Not Working
ALL WHEEL DRIVE (AWD) COIL
- Operation Overview
- Diagnosing System Failures
COOLING SYSTEM COMPONENTS
- Fan Control Circuit Operation
- Fan Control Bypass Test - EFI
- Fan Control Bypass Test - H.O.
- Fan Motor Current Draw Test
- Coolant Temperature Sensor - EFI
- Coolant Temperature Fan Switch - H.O.
GEAR POSITION INDICATOR SWITCH
- Test Diagram
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH
- Operation Overview
- ETC Test
IGNITION SYSTEM
- Overview
- Components of Alternator and DC / CDI Ignition System
- EFI Ignition System Testing Flow Chart
- Crankshaft Position Sensor Gap
- Ignition Troubleshooting
- Ignition Output Test Using Gap Tester
CHARGING SYSTEM
- Current Draw - Key Off
- Break Even Test
- Alternator Output Test
- Charging System Testing Diagrams
RELAYS
- Operation
FUSES/CIRCUIT BREAKER
- Operation
LIGHTING
- High Beam Headlight Bulb Replacement
- Headlight Housing Replacement
- High Beam Headlight Adjustment
- Lower Headlamp Removal / Installation
- Low Beam Headlight Adjustment (Non Intl)
- Lower Headlight Adjustment (Forest Tractor)
- Headlamp Switch Test
- Brake Light Replacement
- Brake Light Switch
SPEED SENSOR
- Testing
- Replacement
FUEL SENDER
- Testing
- ACCESSORY POWER
- Wire Connections
STARTER SYSTEM
- Troubleshooting
- VOLTAGE DROP TEST
- Starter Lockout Troubleshooting- EFI
- Starter Lockout Troubleshooting- H.O.
- Starter Lockout Diagram- EFI
- Starter Lockout Diagram- Carb
- Starter Motor Removal / Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter Solenoid Bench Test
- Starter Exploded View
STARTER DRIVE
- Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement
STARTER SYSTEM TESTING FLOW CHART
- Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. This flow chart assumes that the starter lockout sys...
BATTERY
- Battery Identification
- Battery Conductance Analyzer
- Battery Activation (Conventional)
- Battery Terminals/Bolts
- Conventional Battery Inspection / Removal
- Conventional Battery Installation
- Conventional Battery Testing
- Conventional Battery OCV - Open Circuit Voltage Test
- Conventional Battery Specific Gravity Test
- Battery Load Test
- Off Season Storage
- Charging Procedure
- Low Maintenance Battery
- Low Maintenance Battery Charging
- Low Maintenance Battery Inspection / Removal
- Low Maintenance Battery Installation
- Low Maintenance Battery - OCV- Open Circuit Voltage Test
- Low Maintenance Battery Load Test
- Low Maintenance Battery Charging Procedure
- Low Maintenance Battery Off-season Storage
TROUBLESHOOTING DIAGRAMS
- All Wheel Drive - EFI
- Fuel Pump - EFI
- Fan Control - EFI
SPORTSMAN 500 EFI FOREST TRACTOR ELECTRICAL
- Head Lamps / Tail Lamps - Exploded View
- Hazard / Flasher Module
- Rear Tail Lamp / Turn Signal Lamp Replacement
- Front Turn Signal Lamp Replacement
- Pod Indicator Lamp / Switch Replacement
- Trailer Connector and Fuses
- Speed Control Diagram