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   Summary of Contents for Polaris A12MH46AX

  • Page 1

    GENERAL MAINTENANCE ENGINE FUEL SYSTEMS BODY / SUSPENSION...

  • Page 2

    CLUTCH FINAL DRIVE TRANSMISSION BRAKES ELECTRICAL...

  • Page 3

    NOTES...

  • Page 4: General

    2012 SPORTSMAN TOURING 500 HO ........

  • Page 5: General Information, Model Number Information, Model Number

    (A). An additional number is stamped on the side of the crankcase beneath the cylinder coolant elbow. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 6: Transmission I.d. Location, Publication Part Numbers

    A12MH50AD, AQ, AX, AZ, 9923420 9923422 Sportsman Forest 500 2012 A12MH50FF 9923423 9923424 International Sportsman Forest Tractor 2012 A12MN50ET 9923430 9923431 500 EFI International 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 7: Maintenance, Vehicle Specifications

    Maintenance-Free / 12 Amp Hr. 10A - Accessory / 10A - Fan / Circuit Breakers 15A - Main Harness Starting Electric Digital Gauge LCD, Analog Instrument Cluster Speedometer 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 8

    Tire Air Pressure - F / R 5 psi (34.5 kPa) Single Control Brakes - Front & Rear Hydraulic Disc Brake Fluid Polaris DOT 4 Brake Fluid 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 9

    180 lbs./82 kg Circuit Protection 5 / 15 / 20 Amp Fuses 10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 10: Clutch

    Below 40 ° F +40 to +80 ° F Below 5 ° C +5 to +28 ° C Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000- 147.5 142.5 12000) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 11: Sportsman Touring 500 Ho

    180 lbs./82 kg Circuit Breakers 5 / 15 / 20 Amp Fuses 10 Amp Circuit Breaker - Fan Starting Electric Instrument Cluster Analog Speedo w/ LCD 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 12

    Below 40 ° F +40 to +80 ° F Below 5 ° C +5 to +28 ° C Meters 0-1800 (Feet) (0-6000) 1800-3700 (6000- 147.5 142.5 12000) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 13

    Low Beam 37 watts Brake 26.9 watts Tail 8.26 watts Parking Lights 5 watts x 2 Turn 10 watts Ignition System DC/CDI Ignition 1.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 14

    Weight Spring 0-1800 10 WHF Green / Blue (0-6000) (5632283) (7041157) Meters 1800-3700 (Feet) 10 RH Green / Blue (6000- (5630709 (7041157) 12000) 1.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 15: Misc. Numbers/charts, Conversion Table

    5 - 40 = °F  ¸ °C to °F: 9 (°C + 40) ¸ °F to °C: 5 (°F + 40) 9 - 40 = °C 1.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 16: Standard Bolt Torque Specification, Metric Bolt Torque Specification

    151 (205) 177 (240) 59 (80) 85 (115) 159 (215) 232 (315) 273 (370) 81 (110) 118 (160) 225 (305) 321 (435) 376 (510) 1.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 17

    63/64 ....9844 11x1.50 0.375 1 ..12x1.50 13/32 0.406 13/32 12x1.75 13/32 0.406 13/32 1.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 18: Paint Codes, Replacement Keys

    Should both keys become lost, ignition switch replacement is required. Series # Part Number 4010278 Key Cover PN 5433534 4010278 4010321 4010321 4010321 4010321 4110141 4110148 4010278 4010278 1.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 19: Glossary Of Terms

    Mile/miles. mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040,. Nm: Newton meters. OD: Outside diameter. 1.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 20: Table Of Contents

    HOSE/FITTING INSPECTION ..........2.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual...

  • Page 21: Table Of Contents

    MAINTENANCE SCHEDULE ..........2.36 SPECIAL TOOLS SPX Corporation - 1-800-328-6657 or http://polaris.spx.com 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 22: Maintenance Chart Key

    Improperly performing the procedures marked with  could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 23

    *Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 24: Periodic Maintenance Chart

    Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 25

    Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California)  Have an authorized Polaris dealer perform these services. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 26: Lubricants / Service Products, Polaris Lubricants, Maintenance And Service Products, Lubrication / Fluids

    • Engine coolant - check for proper level at the 2871329 Dielectric Grease (Nyogel™) recovery bottle Coolant 2871323 60/40 Coolant (Gallon) (6 Count) 2871534 60/40 Coolant (Quart) (12 Count) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 27: Lubrication Components

    AWD operation). Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M, or Mobilgrease Special. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 28: Front Gearcase Lubrication

    Hub Fluid the fill plug hole threads. Refer to procedures. 5. Install / torque fill plug and check for leaks. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 29

    Capacity: 33.8 oz. (1000 ml) 5. Check for leaks. 6. Install fill plug. Torque to specification. Transmission Check/Fill Plug Torque: 14 ft.lbs. (19 Nm) 2.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 30: Adc System (if Equipped), Adc System Fluid Reservoir Location, Adc Differential Hydraulic Circuit Fluid Change

    Close bleeder valve before oil level falls below minimum fill line. Refilling empty reservoir will result in air pockets becoming trapped. 2.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 31: Vehicle Inspection, Throttle Inspection, Shift Link Rod Inspection

    3. Repeat procedure at the other five locations as shown. NOTE: Do not attempt to remove cover until all latch points are released. 2.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 32

    • Never drain the system when the engine is hot. Severe burns may result. 2.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 33: Compression Test, Vent Lines, Choke (enricher) Adjustment - (500 Carb), Engine Mounts

    = In. / mm. Choke Cable Freeplay: 1/16 - 3/16" (1.6 - 4.76mm) 2.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 34: Spark Plug, Battery Maintenance

    Do not use the alternator to charge a new bat- tery. Recommended Spark Plug: BKR6E Spark Plug Torque: 14 Ft. Lbs. (19 Nm) 2.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 35: Liquid Cooling System Overview, Cooling System Hoses, Coolant Strength / Type

    (PN 2871323) or radiator fitting may distort, causing a restriction to coolant flow. Radiator hose clamp torque is 36 in. lbs. (4 Nm). 2.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 36: Radiator/grill Screen, Coolant Level Inspection, Cooling System Pressure Test

    Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. 2.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 37: Radiator Coolant Level

    Using a funnel, add coolant until the fluid level is to the top of the filler neck. 6. Reinstall the pressure cap and install the front access cover. 2.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 38: Air Filter/pre-filter Service

    7. Inspect element for tears or damage. 8. Inspect main filter and replace if necessary. If the filter has been soaked with fuel or oil it must be replaced. 2.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 39: Air Box Sediment Tube, Breather Hose, Recoil Housing, Breather Filter Inspection

    Some engine oil will be lost if crankcase drain is opened. • If recoil handle (B) seal has been damaged, the handle should be replaced. 2.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 40: Engine Oil Level, Oil And Filter Change

    If the oil level is over the full mark, change the oil. Reference mark 6. Allow oil to drain completely. 2.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 41

    22. Place gear selector in Park and set parking brake. NOTE: Clamp or pinch off the vent line 2” from the oil tank as shown in the Oil Pump Priming Procedure. 2.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 42: Valve Clearance

    The camshaft lobes should be pointing downward. 2.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 43: Intake Valve Clearance Adjustment, Exhaust Valve Clearance Adjustment

    Use only genuine Polaris replacement parts. Feeler gauge for both valves NOTE: The exhaust valves share a common rocker arm, and must be adjusted using two feeler gauges. 2.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 44: Final Drive, Tie Rod End/steering Inspection, Camber And Caster, Wheel Alignment

    • Refer to the Body/Steering Chapter 5 or Final (A) - (B) = 0 to 1/16" (0 to 1.6mm) Drive Chapter 7 for service procedures. 2.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 45: Transmission, Toe Alignment Adjustment, Exhaust Pipe

    • After alignment is complete, torque jam nuts to specification. Tie Rod Jam Nut Torque: 12-14 ft. lbs. (16-19 Nm) 2.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 46: Brake System Inspection

    • Check brake for excessive travel or spongy feel. • Check brake system for fluid leaks. • Check friction pads wear, damage looseness. • Check surface condition of the disc. 2.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 47: Brake Pad Inspection, Auxiliary Brake Testing, Hose/fitting Inspection

    Check brake system hoses and fittings for cracks, Full deterioration, abrasion, and leaks.Tighten any loose Full Height Engagement fittings and replace any worn or damaged parts. Floor Board Surface 2.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 48: Suspension Spring, Auxiliary Brake Adjustment (hydraulic), Preload Adjustment, Front Suspension, Cv Shaft Boot Inspection

    Refer to Chapter 7 for CV boot replacement. Bleed the hydraulic auxiliary brake system in a conventional manner, following the procedure outlined in Brake Chapter 9. Inspect Boots 2.29 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 49

    Front Hub Retaining Nut 60 ft.lbs. (81 Nm) Rear Hub Retaining Nut 80 Ft. Lbs. (109 Nm) Align throttle control assembly clamp with knurl on handlebar. 2.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 50: Wheel Removal Front Or Rear, Wheel Installation, Tire Pressure

    Maintain proper tire pressure. Refer to the warning tire pressure decal applied to the vehicle. Tire Pressure (Cold) Front Rear 5 (34.5 Kpa) 5 (34.5Kpa) 2.31 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 51: Tire Inspection, Carburetor Maintenance, Choke (enricher) Adjustment (non Efi), Frame, Nuts, Bolts, Fasteners

    Periodically inspect the torque of all fasteners in accordance with the maintenance schedule. Check that all cotter pins are in place. Refer to specific fastener torques listed in each chapter. 2.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 52: Pilot Screw Adjustment

    3. Connect an accurate tachometer that will read in increments of + or - 50 RPM such as the PET 2100DX (PN 8712100DX) or the PET 2500 (PN 8712500). 2.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 53: Fuel Filter (non Efi), Idle Speed Adjustment (non Efi)

    6. Install clamps on fuel line. 7. Turn fuel valve “ON”. Idle speed: 8. Start engine and inspect for leaks. 1100 +/- 200 RPM 2.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 54: Carburetor Draining

    NOTE: All tubes attached to the carburetor must be check for pinching or blockage, as this will effect engine performance Drain tube attached here Drain Screw Fuel Valve 2.35 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 55: Maintenance Schedule

    MAINTENANCE Maintenance Schedule Service Date Hours / Miles Service Performed Serviced By:  2.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 56: Table Of Contents

    SPORTSMAN 500 H.O. ENGINE SERVICE DATA ......3.4 SPORTSMAN 500 H.O. ENGINE SERVICE DATA ......3.5 SPORTSMAN 400 H.O.

  • Page 57: Table Of Contents

    TROUBLESHOOTING........... 3.58 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual...

  • Page 58: Engine Fastener Torque Patterns

    5-6.5 (7-9 Nm) Rocker Cover 7-8 (9-11 Nm) Rocker Support 8-10 (11-13 Nm) Rocker Adjuster Screw 6-7 (8-10 Nm) Water Pump Impeller 5-6.5 (7-9 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 59

    ENGINE Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted) Cylinder Head / Valve EH50PLE (498cc) Rocker arm ID .8669-.8678”(22.020-22.041 mm) Rocker shaft OD .8656-.8661 (21.987-22.0 mm) Rocker Arm .0008-.0021” (.020-.054 mm) Rocker shaft Oil Clearance Limit .0039”...

  • Page 60

    ENGINE Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted) Cylinder / Piston / Connecting Rod EH50PLE (498cc) Surface warpage limit (mating with cylinder head) .0020” (0.05 mm) Cylinder bore 3.6221-3.6228" (92.00-92.02 mm) Taper limit .0020” (0.050 mm)

  • Page 61

    .075” (1.9 mm) 5.512-5.520” (140-140.2 mm) Drum I.D. Limit 5.528” (140.4 mm) Starting Clutch (Centrifugal Clutch) .059” (1.50 mm) Friction Material Thickness Limit .020” (0.50 mm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 62

    Crankshaft runout limit .0024" (.06 mm) KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off Side. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 63: General Engine Service, Cooling System Specifications

    Polaris Premium 60/40 Antifreeze/ Coolant is recommended for use in all cooling systems, and comes pre-mixed, ready to use. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 64: Cooling System

    RECOMMENDED COOLANT Use only high quality antifreeze/coolant mixed with distilled water in a 50/50 or 60/40 ratio, depending on freeze protection required in your area. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 65: Accessible Components, Engine Removal

    8. Disconnect the engine wiring harness connections near the flywheel cover (Stator). 9. Disconnect the engine coolant temperature sensor harness at the cylinder head. 3.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 66

    NOTE: Use caution when lifting the engine out of crankcase. frame. Use an engine lift or other means if the engine appears too heavy to be lifted manually. 3.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 67: Engine Installation Notes, Cylinder Hone Selection/ Honing Procedure

    Allow air to purge and top off as necessary. Reinstall radiator cap and bring engine to operating temp. Check level in reservoir tank after engine is cool and add coolant if necessary. 3.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 68: Electrical, Honing To Oversize, Cleaning The Cylinder After Honing

    1/2” (1.3 cm) above and below the bore at the end of each stroke. 3.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 69: Crankshaft Straightening, Engine Lubrication, Oil Pressure Test

    2. To correct a situation like the one shown in the illustration, squeeze the crankshaft at points A. (Use tool from alignment kit). HIGH .002 (.05 mm) HIGH .005 (.13 mm) 3.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 70: Oil Flow

    One way valve Bottom fitting is oil Oil Tank exhaust or return Top fitting is oil to tank feed or intake from bottom of tank 3.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 71: Oil Flow Diagram

    Bearing Cam Shaft Metal Journal Crank Pin Oil Filter Bypass Through Cylinder Stud Front Left Crankshaft Delivery Pipe Crankcase Delivery Pipe Oil Gallery 3.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 72: Engine Exploded Views

    ENGINE Engine Exploded Views Cylinder/ Crankcase Cylinder Head Crankshaft Valvetrain and Piston 3.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 73: Engine Disassembly, Cam Chain Tensioner Inspection

    3. Release ratchet pawl and push inward on plunger. It should remain locked in position and not move inward. 3.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 74: Rocker Arm / Shaft Inspection

    NOTE: Always inspect camshaft lobe if rocker arms are worn or damaged. Rocker Arm & Support I.D.: .8669-.8678” (22.020-22.041 mm) 3.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 75: Camshaft Removal

    4. Remove camshaft end cap and O-ring. 9. Inspect cam sprocket teeth for wear or damage. Replace if necessary. Sprocket teeth Inspect for Areas of Tooth Wear or Damage 3.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 76

    4. Inspect lobe on end of release lever shaft and actuator ball for wear and replace if necessary. 3.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 77: Camshaft Inspection, Cylinder Head Removal

    4. Measure camshaft journal outside diameter (O.D.) 5. Measure ID of camshaft journal bore. Camshaft Journal I.D.: Mag & PTO End: 1.4963-1.4970” (38.005-38.025 mm) 3.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 78: Cylinder Head Exploded View

    ENGINE Cylinder Head Exploded View 3.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 79: Cylinder Head Inspection, Cylinder Head Disassembly, Cylinder Head Warpage

    (D). 3. Push valve out, keeping it in order for reassembly in the same guide. 3.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 80: Valve Inspection

    NOTE: Be sure to measure each guide and valve combination individually. 8. Replace valve and/or guide if clearance is excessive. Compare to specifications. 3.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 81: Combustion Chamber, Valve Seat Reconditioning

    6. Place cylinder head on cylinder head table. NOTE: Be sure cylinder head is still at 212° F (100° C) before installing new guides. 3.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 82

    11. Apply cutting oil to valve seat and cutter. 15. Insert valve into guide and tap valve lightly into place a few times. 3.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 83

    Seat - 45 or 46 23. Spray electrical contact cleaner into oil passage and dry using compressed air. Top - 30 or 31 3.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 84: Cylinder Head Assembly, Valve Sealing Test, Valve Clearance Adjustment

    VALVE CLEARANCE .006” (.15 mm) 3. When clearance is correct, hold adjuster screw and tighten locknut securely. 3.29 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 85: Cylinder / Piston Removal And Inspection

    7. Rock cylinder forward and backward and lift it from the crankcase, supporting piston and connecting rod. Support piston with Piston Support Block (PN 2870390). 8. Remove dowel pins from crankcase. 3.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 86

    *By hand: Placing both thumbs as shown, spread the ring open and push up on the opposite side. Do not scratch the ring lands. 3.31 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 87: Cylinder Inspection, Cylinder Hone Selection / Honing Procedure

    (1/2" down from top, in the middle, and 1/2" up from bottom). 3.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 88

    (or cylinder centered on arbor) and to bring the stone approximately 1/2" (1.3 cm) beyond the bore at the end of each stroke. 3.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 89: Piston-to-cylinder Clearance, Piston / Rod Inspection

    .9053 - .9055” (22.994 - 23.0 mm) EH500PLE (498cc) 3. Measure connecting rod small end ID. Std: 3.6204-3.6215” (91.970-91.985 mm) EH46PLE (455cc) Std: 3.4594-3.4600” (87.870-87.885 mm) 3.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 90: Piston Ring Installed Gap, Piston Identification

    *Pistons and rings marked 50 equal .50mm (.020”) completely. Wipe cylinder bore with an oiled rag oversized immediately to remove residue and prevent rust. 3.35 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 91: Crankcase Disassembly, Starter Drive Removal / Inspection

    6. Remove oil passage O-Ring (C). Std. Bushing ID: .4735”-.4740” (11.11-12.04 mm) Std. Shaft OD: .470”-.472” (11.93-11.99 mm) 3.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 92: Cam Chain / Tensioner Blade

    7. Inspect woodruff key for wear. 8. Replace any worn or damaged parts. 2. Remove blade and inspect for cracks, wear, or damage. 3.37 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 93: One Way Valve, Oil Pump Removal / Inspection, Crankcase Separation

    4. Remove three oil pump retaining bolts and pump. 2. Separate crankcase by tapping with a soft faced hammer in reinforced areas. 3.38 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 94

    11. Remove inner and outer feed rotor and pump chamber body. 12. Repeat measurements for scavenge rotor. 13. Remove inner and outer scavenge rotor and inspect pump shaft for wear. 3.39 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 95: Oil Pump Assembly, Counter Balancer Shaft Removal / Inspection

    The inner race should be firm with minimal side to side movement and no detectable up and down movement. 3.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 96: Crankshaft Removal / Inspection

    4. Place the crankshaft in a truing stand or V-blocks and measure the runout on both ends with a dial indicator. Max Runout: .0024” (.06 mm) 3.41 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 97: Crankcase Bearing Inspection, Oil Seal / Mechanical Seal Removal, Engine Disassembled, Crankcase Inspection

    2. Check the oil pump and oil passage mating surfaces to be sure they are clean and not damaged. 3.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 98: Bearing Installation, Crankshaft End Play Adjustment, End Play Inspection / Adjustment

    3. Subtract the thickness of the straightedge from the measurement obtained in Step 2 and record. PTO Case Depth______________________ 3.43 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 99: Counter Balancer Shaft End Play Adjustment

    Subtract the thickness of seats with a micrometer or dial caliper and record. the straightedge and record. Crankshaft Width______________________ 3.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 100: Engine Reassembly, Pump Shaft Oil Seal Installation, Oil Pump Shaft End Play Adjustment

    Loosen the nut and remove the threaded rod from the crankshaft. If removal is difficult, install two nuts on the end of the threaded rod and tighten against each other. 3.45 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 101: Water Pump Mechanical Seal Installation, Crankcase Assembly

    Continually check alignment of the cases during installation, closing the gap equally until the surfaces are tightly seated. 3. Remove the tool. 3.46 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 102

    Continue rotating until outer portion of mechanical seal is separated from the metal seal body. T-Handle Main Puller Body 3.47 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 103

    1. Install the tensioner blade and tighten the mounting bolt to specified torque. Tensioner Blade Mounting Bolt Torque: 6 ft. lbs. (8 Nm) 3.48 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 104

    Verify all ring end gaps are correctly located. upon installation to prevent loss of radial tension. Severe engine damage may result if circlips are re-used or deformed during installation. 3.49 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 105

    10. Install the two 6 mm bolts. Cylinder Bolt Torque: 10mm - 46 ft. lbs. (62 Nm) 6mm - 6 ft. lbs. (8 Nm) 3.50 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 106: Cam Chain / Camshaft Installation, Camshaft Timing

    Lubricate automatic compression release mechanism with clean engine oil. 2. Install the camshaft with the lobes facing downward 3.51 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 107

    6. Install the sprocket on the camshaft. Apply Loctite™ 242 (PN 2871949) to the cam sprocket bolts and torque to specifications. Cam Sprocket Bolt Torque: 6 ft. lbs. (8 Nm) 3.52 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 108: Camshaft Timing Illustration

    Camshaft Timing Illustration Crankshaft to Camshaft Centerline Dots Sprocket Alignment Pin Single TDC Mark Aligned TDC mark Rotation Do Not Use Advance Marks 3.53 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 109: Cam Chain Tensioner Installation, Stator, Flywheel And Starter Drive Installation

    2. Install a new O-Ring in the oil passage recess in the crankcase. 3. Apply Crankcase Sealant (PN 2871557) or an equivalent sealer to the stator plate outer surface and install a new O-Ring. 3.54 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 110: Thermostat Installation, Rocker Shaft / Rocker Arm Assembly Installation, Oil Pipes

    7. Adjust valves according to the valve adjustment procedure found in Chapter 2, Maintenance. 8. Apply clean engine oil liberally to the valve springs, cam chain, rocker arms, and camshaft. 3.55 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 111: Recoil (accessory)

    7. Hold reel firmly in housing. Pull rope handle until 12- housing to prevent water from entering. 18" (30-46cm) of rope is exposed, and hold reel in place. 3.56 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 112

    13. See “Specifications” in the beginning of this chapter. 1. Place spring in housing with the end positioned so the spring spirals inward in a counterclockwise direction. See photo at right. 3.57 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 113: Troubleshooting

    • Tank vent plugged • Carb starter circuit • Engine flooded • Low compression (high cylinder leakage) • No spark (Spark plug fouled) 3.58 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 114

    Leak at Water Pump Weep Hole • Exhaust system air leaks • Faulty water pump mechanical seal (coolant leak) • Faulty pump shaft oil seal (oil leak) 3.59 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 115

    ENGINE NOTES 3.60...

  • Page 116: Fuel System

    FUEL SYSTEM CHAPTER 4 FUEL SYSTEM   CARBURETION SYSTEM..............4.3   ELECTRONIC FUEL INJECTION SYSTEM (EFI).......4.25...

  • Page 117

    FUEL SYSTEM...

  • Page 118: Table Of Contents

    TROUBLESHOOTING........... 4.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual...

  • Page 119: General Information And Specifications

    ATV carburetors, and ensures constant If you spill gasoline on your skin or clothing, performance, reliability and easier starting. immediately wash with soap and water and change clothing. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 120: Bst 40 Carburetor Exploded View 1 Of

    Throttle Control Cover Plate Diaphragm Assembly Carburetor Body Needle Jet Enrichment Plunger Jet Block Assembly Enrichment Spring Washer Cable guide Main jet Pilot Air Jet Cover Spring 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 121: Bst 40 Carburetor Exploded View 2 Of

    Needle Valve Assembly Float Bowl Drain Screw Throttle Plate Throttle Shaft Idle RPM Speed Adjustment Screw Throttle Shaft Return Spring Spring Needle Valve Retaining Plate Floats 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 122: Cv Carburetor System Function, Mikuni Cv Carb Operation

    Atmospheric pressure in the chamber below the diaphragm forces the diaphragm upward, raising the slide against spring pressure. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 123: Carburetor Venting, Starter System (choke Or Enrichment)

    (6) in the main Note: Diagrams are for explanation of theory only, and are not true bore. representations of Mikini BST carburetor. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 124: Pilot (idle And Slow) System, Main System

    (5); the clearance through which the emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 125: Float System

    Pilot Screw Location Inlet Pipe Brass Plug Installed Brass Plug Removed 4.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 126: Air/fuel Mixture Ratio, Jet Needle, Needle Jet

    This air initiates the mixing and atomizing process inside the needle jet. Needle Jet Main Jet 4.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 127: Throttle Opening Vs. Fuel Flow, Carburetor Disassembly – Mikuni Cv

    O–Ring. If an anti–tamper plug is installed over the pilot screw cavity, it must be removed for access. O-Ring Washer Spring Pilot Screw 4.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 128: Carburetor Inspection, Carburetor Cleaning

    CAUTION: Do not use wire or welding tip cleaners as the orifice size may be altered. 5. Use low pressure air to dry carburetor body and all components. 4.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 129: Carburetor Assembly, Float Height Adjustment

    Clip. Refer to parts manual for more information. 2. Be sure the tab (E) on outer edge of diaphragm is positioned properly in the carburetor body. FRONT (Engine) Pilot Screw 4.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 130: Needle And Seat Leakage Test, Fuel Level Test

    NOTE: If a line was removed to perform this procedure, it must be replaced. 4.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 131: Carbutated Fuel Tank / Fuel Delivery System

    Domestic (USA) Fuel Cap Align Fuel Pickup/Sender as Shown PFA Nut Carburetor Mounting 70 ft. lbs (95 Nm) Fuel Pick-up / Sender PFA Gasket 4.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 132: Fuel Pump (carburated), Fuel Gauge Sending Unit Test

    3. Install new filter onto fuel lines and install clamps. 4. Dispose of fuel / shop towels properly. 5. Check for leaks and repair if necessary. 4.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 133: Fuel Pick-up / Sending Unit Replacement (carb)

    Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so could result in serious injury or complications. 4.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 134

    12. Use cleaning wipes provided to clean fuel tank surface and threads. Remove all debris, grease and oil. Allow surfaces to dry completely. 4.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 135

    22. Re-install the body components that were previously removed. 23. Check for leaks and repair if necessary. 70 ± 5 ft. lbs. (95 ± 7 Nm) PU-50326 4.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 136: Fuel Tank Vent Routing (non Intl)

    Be sure the fuel tank vent hose is routed correctly and not kinked. Installed In Locating Feature of CVT Outlet Duct Under Foam 4.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 137: H.o. International Emissions System

    (E), which contains a catalyst. This catalyst also reduces emissions by interacting with the exhaust as it passes through the silencer. NOTE: No maintenance or service of the catalyst is required. Air Flow 4.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 138

    • Poor fuel quality (old fuel) • Loose jets • Worn jet needle/needle jet or other carburetor parts • Dirty carburetor (air bleed passages or jets) 4.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 139

    CARBURATION AND FUEL SYSTEM NOTES 4.24...

  • Page 140: Table Of Contents

    THROTTLE POSITION SENSOR INITIALIZATION ......4.53 4.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 141: Table Of Contents

    EFI CIRCUIT - MALFUNCTION INDICATOR LIGHT ......4.69 4.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 142: Special Tools

      Always stop the engine and refuel outdoors or in a well ventilated area. 4.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 143

    This tester allows the use of a digital multi-meter to test TPS function as well perform initialization procedures. Polaris Dealers can order special tools from SPX. 4.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 144: Efi Tractor Speed Control, System Operation Overview

    500 EFI FUEL SYSTEM 500 EFI TRACTOR SPEED CONTROL System Operation Overview Sportsman 500 EFI Tractor models are equipped with a speed control system from the factory. This system is designed to meet various international safety standards. The speed control system consists of: •...

  • Page 145

    6. Install a new valve onto the bracket. Tighten the Jet Block screws sufficiently. 7. Follow the routing learned from removal to reconnect the harness and air valve tubes. Body 4.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 146: Exhaust System

    500 EFI FUEL SYSTEM Exhaust System The exhaust system is typical of Sportsman ATVs, with an extra shield installed per regulations. Maintain the exhaust canister according to the maintenance procedures outlined in Chapter 2 of the Service Manual. 500 EFI Tractor 4.31...

  • Page 147: Efi Service Notes

    • Never use a quick-start battery charger to start the engine. • Always unplug ECU from the wire harness before performing any welding on the ATV. 4.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 148: Efi System Exploded View

    9. Fuel Tank Assy. 10. Engine Coolant Temperature Sensor (ECT)  11. Throttle Position Sensor (TPS) LH side of Throttle body 12. Throttle Body 4.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 149: Efi System, Component Locations/identification

    - Located inside the mag / recoil cover on the RH side intake track. of the engine 4 & 7 9 & 10 4.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 150

    - Located in the fuel tank. 4 & 9 & 10 13. Engine Coolant Temperature Sensor (ECT) - Located on the LH side of the cylinder head. 4.35 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 151: Fuel System And Fuel Tank, Fuel System And Fuel Tank Exploded View

    * Fuel Filter * Fuel Pump / (30 micron) Pressure Regulator Unit Fuel Supply Rail Injectors * component located in fuel tank and is non-serviceable 4.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 152: Electronic Fuel Injection, Initial Priming / Starting Procedure, Efi Operation Overview

    When the intake valve opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned. 4.37 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 153: Electronic Control Unit (ecu), Quick Connect Removal/installation

    4.38 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 154: Ecu Service

    Install the upper-left retaining screw spacer and screws. Tighten screws to 10 in. lbs. (1.1 Nm). 4.39 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 155: Fuel Pump Assembly, Fuel Pump Test, Operation / Testing

    NOTE: FUEL GAUGE SENDER TEST - To test fuel the fuel pump assembly. gauge sender function, refer to Chapter 10 in this service manual. 4.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 156: Fuel Tank Replacement

    5. Relieve the fuel pressure. 6. Loosen the fuel tank hose and pull the fuel line from the tank. 4.41 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 157

    8. Carefully pull the fuel tank out of the frame. Keep the fuel tank horizontal during removal, this will keep the fuel in the tank from spilling out the top inlet. 4.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 158: Fuel Pump Replacement

    Excessive debris in fuel tank may cause premature wear of fuel pump and/or clogging of internal fuel filters. 4.43 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 159

    PFA nut, ensuring threads are properly aligned. Verify orientation marks are still aligned between fuel pump and fuel tank. 4.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 160

    23. Test the fuel pump by turning on the key and listening for the pump to activate. Cycle the key several times Clean Threads to prime the system. 4.45 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 161: Fuel Filter, Fuel Pressure Regulator, Fuel Injector

    The in-tank filter is non-serviceable. Tank flushing to the speed and load requirements of the engine. remove sediments may temporarily restore fuel flow, but is not a recommended service procedure. 4.46 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 162

    Fuel Rail Mounting Screws: 5~7 ft. lbs. (6-9 Nm) Doubler Plate Screws 8~9.5 ft. lbs. (11-13 Nm) 4.47 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 163

    The CPS must be properly connected at all times. If the sensor fails or becomes disconnected for any reason, the engine will quit operating. 4.48 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 164: Map Sensor Test, Map Sensor Replacement

    29 in. lbs. (3.3 Nm) pressure reading, indicating that the engine is on the intake stroke. Once this has been ‘learned’, the ECU will 4.49 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 165: Idle Air Control (iac), Intake Air Temperature Sensor Test, Intake Air Temperature Sensor Replacement

    3. Lightly coat the grommet with soapy water and install a new sensor, using a twisting motion to properly seat the sensor in the grommet. Re-connect the harness. 4.50 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 166: Throttle Position Sensor (tps), Throttle Position Sensor Test

     2 to GND -----  1 - 2 Closed (reference)  1 - 2 Open (reference)   ----- 1 - 3 4.51 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 167

    The voltage should increase smoothly with no “jumps” or decreases when the throttle is applied. • If the TPS does not function correctly, replace it. 4.52 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 168: Throttle Position Sensor Replacement, Throttle Position Sensor Initialization

    • Open and close throttle plate a couple of times to ensure full throttle closing. Do not snap closed, as this could cause unnecessary throttle plate to throttle body interference and/or damage. 4.53 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 169: Engine Temperature Sensor, Engine Temperature Sensor Test, Engine Temperature Sensor Replacement

    If for any reason the engine temperature sensor 18.5 ft. lbs. (25 Nm) circuit is interrupted, the fan will default to “ON”. 4.54 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 170: Fuel System Troubleshooting, Fuel Starvation / Lean Mixture

    • Failed Sensor or disconnected wiring • TPS setting incorrect • Injector failure • Failed Sensor or disconnected wiring • Throttle stop screw tampering - replace throttle body 4.55 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 171: Efi Diagnostics Using 'blink Codes, Blink Codes - Operation

    Diagnostic Lamp: Short Circuit To Battery Fuel Pump: Open Load / Short Circuit to Ground Fuel Pump: Short Circuit to Battery END SEQUENCE 4.56 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 172: Digital Wrench™ Operation, Digital Wrench™ Diagnostic Software Overview, Special Tools (also Refer To Page)

    ECU is transferred to the replacement ECU. Refer to procedure and carefully follow all instructions provided in Digital Wrench™. 4.57 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 173: Digital Wrench™ Communication Errors, Digital Wrench™ - Diagnostic Connector

    ‘Connected’ in the lower left corner of the screen. 5. Once connected, proceed with using Digital Wrench™. 4.58 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 174: Digital Wrench™ Version And Update Id, Digital Wrench™ Updates

    IMPORTANT: You must already have the current version installed before adding an update. Updates will not install if you are using an older version loaded on your PC. 4.59 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 175: Digital Wrench™ Serial Number Location

    Digital Wrench™ start-up screen should match the update you just downloaded. Digital Wrench Update Version NOTE: Versions and updates are subject to change. 4.60 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 176: Digital Wrench™ Feature Map

    500 EFI FUEL SYSTEM Digital Wrench™ Feature Map 4.61 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 177: Engine Controller Reprogramming (reflash)

    Connector” on page 4.58. Reprogramming updates are provided periodically and contain the most recent calibrations (see 3. Open the Digital Wrench™ program. “Digital Wrench™ Updates”). 4.62 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 178

    Authorization Key 6. Select “Engine Controller Reprogramming”. NOTE: Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen. 4.63 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 179

    “Authorize” button 15. Once reprogramming procedure complete, click the ‘Finish’ button on the screen. Verify the reflash was a success by starting the vehicle. 4.64 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 180: Troubleshooting Diagrams

    500 EFI FUEL SYSTEM TROUBLESHOOTING DIAGRAMS EFI CIRCUIT - Power On EFI CIRCUIT - Crank Position Sensor 4.65 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 181: Efi Circuit - Fuel Pump, Efi Circuit - Ignition Coil

    500 EFI FUEL SYSTEM EFI CIRCUIT - Fuel Pump EFI CIRCUIT - Ignition Coil 4.66 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 182

    500 EFI FUEL SYSTEM EFI CIRCUIT - Idle Air Control EFI CIRCUIT - Throttle Position Sensor 4.67 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 183

    500 EFI FUEL SYSTEM EFI CIRCUIT - Manifold Absolute Pressure Sensor EFI CIRCUIT - Engine Coolant Temperature 4.68 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 184

    500 EFI FUEL SYSTEM EFI CIRCUIT - Air Temperature Sensor EFI CIRCUIT - Malfunction Indicator Light 4.69 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 185

    500 EFI FUEL SYSTEM NOTES 4.70...

  • Page 186: Table Of Contents

    STRUT ASSEMBLY ........... . 5.24 SPORTSMAN REAR SUSPENSION ASSEMBLY ......5.25 TORSION BAR EXPLODED VIEW .

  • Page 187

    Do not hold the torch too close to the surface. Keep the torch moving to prevent damage. 2. Apply the decal. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 188: Plastic Insert Removal / Installation

    The inside insert (A) will still be installed in the outside insert (B). NOTE: The inside insert (A) will still be installed in the outside insert (B). 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 189: Side Panel Removal

    Step 2 3. Move the seal out of the sealing channel and pull up on the front of the access cover. Remove the access cover. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 190: Foot Well Removal / Installation

    3. Reverse the removal procedures to install the foot well. Be sure to properly align the fender ends into the foot wells upon reassembly. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 191: Front Bumper Removal / Installation, Mud Guard Removal / Installation

    7. Remove the front bumper by gently the pulling the lower portion of the bumper away from the vehicle frame and sliding it down. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 192: Front Fender Removal/installation

    9. Reverse the removal steps for installation. Torque (6) front fender-to-frame screws to specification. Fender to Frame Screws 24 in.lbs. (2.7 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 193: Front Rack / Storage Box Lid Assembly

    BODY / STEERING / SUSPENSION Front Rack / Storage Box Lid Assembly Front Rack / Storage Box Lid Latch Asm. Seal Cable Hinge 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 194: Front Cab Assembly

    BODY / STEERING / SUSPENSION Front Cab Assembly Front Cover / Access Panel Side Cover Front Cab Side Cover Splash Guards 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 195: Front Bumper Assembly

    LH RADIATOR SHIELD UPPER RADIATOR BRACKET 1/4-20X5/8 (X6) BUMPER FRAME RH RADIATOR SHIELD BUMPER ASM. #8X1.00 (X4) 5/16-18X3/4 (X2) FRONT FANG COVER WINCH ACCESS PANEL 5.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 196: Rear Rack Assembly

    BODY / STEERING / SUSPENSION Rear Rack Assembly #14X1-3/4 (X2) 5/16-18X3-1/4 (X2) 1/4-20X1-1/2 (X4) REAR RACK 5/16-18X2-1/2 (X2) REAR RACK SUPPORT SPACER SPACER 5/16-18X1-3/4 (X4) MAIN FRAME 5.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 197: Rear Cab And Seat Assembly

    SEAT LATCH RETAINER PLASTIC RIVETS (X12) BUMPERS SEAT ASM. LATCH SPRING RETAINER BRACKETS RIVETS RUBBER MOUNTS REAR CAB LH FOOTWELL 1/4-20X1.00 (X8) RH FOOTWELL 5.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 198: Rear Storage Box Assembly

    BODY / STEERING / SUSPENSION Rear Storage Box Assembly PANEL FOAM PLASTIC RIVETS (X2) STORAGE BOX GASKET DRAIN PLUG DOOR LATCH 5.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 199: Winch And Front Bumper Mounting

    BODY / STEERING / SUSPENSION Winch and Front Bumper Mounting 5.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 200: Headlight Pod Exploded View

    • Install two side Phillips screws • Install one rear Phillips screw • To adjust headlight, refer to procedure outlined in Chapter 2 5.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 201: Efi Tractor Seat Assembly, Seat Dampener Repair, Seat Pivot Repair

    Torque standard specifications as listed in Chapter 1 of the Sportsman Service Manual. 6. Reinstall seat and adjust spring pre-load to desired setting. 5.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 202

    BODY / STEERING / SUSPENSION 500 EFI Tractor Seat Assembly Exploded View 5.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 203: Efi Tractor Steering Post And Lock

    Chapter 1 whenever servicing the steering lock components. Lock System / Description A. Lock Collar B. Lock Set C. Bolt, Lock Set D. Bolt(s), Lock Collar E. Nut(s), Lock Collar 5.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 204: Handlebar Block Installation Procedure

    5. Install the rear bolts and tighten evenly. Evenly torque the 2 rear bolts to specification. NOTE: There will be a slight gap on the backside of the blocks after the procedure is performed. 5.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 205: Steering / A-arm Exploded View

    The steering post arm bolt (B) points up; the rod end bolts (A) point down. Verify inner rod ends are placed between the steering post arms. 5.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 206: A-arm Replacement

    Ball Joint Nut Torque: 30 ft. lbs. (41 Nm) WARNING Upon A-arm installation completion, test vehicle at low speeds before putting into regular service. 5.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 207: Ball Joint Replacement

    20. Install A-arm on ball joint and torque castle nut to specification. Castle Nut Torque: 30 ft. lbs. (41 Nm) 21. Reinstall cotter pin with open ends toward rear of machine. 5.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 208: Steering Post Removal, Front Strut Cartridge Replacement, Steering Post Assembly

    7. Check the steering, the handle bars must move freely and easily from full left to full right without binding. 8. Install front cab. 5.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 209: Strut Assembly

    BODY / STEERING / SUSPENSION Strut Assembly 15 ft. lbs. (21 Nm) 17 ft. lbs (23 Nm) 5.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 210: Sportsman Rear Suspension Assembly

    (69 Nm) Rear Compression Spring Preload Adjustment Cam Lower Control Arm Wheel Bearing Carrier 37 ft. lbs. (50 Nm) 37 ft. lbs. (50 Nm) 5.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 211: Torsion Bar Exploded View

    (50 Nm) Stabilizer Bar 30 ft. lbs. (40 Nm) 37 ft. lbs. (50 Nm) Note Orientation of Bushings 30 ft. lbs. (40 Nm) 5.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 212

    NOTES...

  • Page 213: Table Of Contents

    TROUBLESHOOTING........... 6.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual...

  • Page 214: Torque Specifications, Special Tool And Supplies, Pvt System Overview, General Operation

    PVT Outer Cover Bolts 45-50 in. lbs (5-5.6 Nm) Drive Clutch Spider 200 ft. lbs. (271 Nm) Drive Clutch Cover Plate 90 in. lbs. (10 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 215: Drive Clutch Operation, Driven Clutch Operation

    Rather than vary throttle position, as a conventional governor does, the PVT system changes engine load requirements by either upshifting or backshifting. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 216: Clutching Chart, Maintenance / Inspection, Sportsman Forest Tractor 500 Efi

    PVT system and also to prevent water and other contaminants from entering the PVT area. This is especially critical on units subjected to frequent water forging. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 217: Overheating / Diagnosis

    High: High ground speeds, speeds above 7 MPH. IMPORTANT: Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of drive belt burning. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 218: Pvt Exploded Views

    Boot Duct Clutch Cover Seal Inner Seal Cover Seal Retainer Bracket Clutch Cover Drive Clutch Exploded Views (EBS vs. Non-EBS) One Way Clutch NON-EBS 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 219: Pvt System Service

    Drive Clutch Holder (PN 9314177) 11. Remove inner cover retaining bolts at rear of cover. 12. Remove cover along with foam seal on back of cover or shaft. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 220

    15. Reinstall PVT outer clutch cover and secure with screws. Torque to specification. Seal outer edge to cover with RTV silicone sealant 6. Torque rear inner cover bolts (B) to specification. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 221: Drive Belt, Belt Removal

    Drive Clutch Retaining Bolt Torque: over the driven clutch outer sheave. 47 ft. lbs. (64 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 222: Belt Inspection, Clutch Alignment, Belt Installation

    3. The belt then should be able to be pushed down into and between the sheaves. Be sure to position belt so part number is easily read. 6.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 223

    You may need to add more than one alignment washer. Alignment Washers (.060”) PN: 7556120 6.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 224

    6.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 225: Drive Clutch Service (non Ebs), Exploded View (non Ebs)

    Lock Washer Spring Cover Bearing Spider Bolt Bearing Flat Non-Braking Washer Spacer Bearing Cover Button Screws Roller Washers Button Bolt Shift Washers Weight 6.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 226

    Cover Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 227: Drive Clutch Spring Inspection

    2.55” (64.77 mm) Drive Clutch Spring Specifications 2012 Sportsman 500 HO, Touring, Forest, Tractor 500 EFI Color Green / Blue Free Length 2.53” (64.262 mm) 6.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 228

    4. Rubber-backed buttons can and should be used in all ATV clutches if the hollow roller pin is changed to a solid roller pin. 6.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 229

    See “Roller, Pin and Thrust Washer Inspection”. 2. Inspect sheave surfaces. Replace the entire clutch if worn, damaged or cracked. 6.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 230: Bearing Inspection, Clutch Inspection

    3. Remove the moveable clutch sheave. 4. Lift bearing (3) and thrust washer (4) off shaft. Replace as an assembly if worn, damaged, or if problems were noted. 6.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 231

    Measure the thickness and compare to specification. Replace if worn or damaged. = In. / mm. PTFE Washer Thickness Standard: .030” (.76mm) Service Limit: .025” (.64mm) 6.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 232

    “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier, in moveable sheave. 6.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 233: Ebs Drive Clutch Service, Ebs Drive Clutch Exploded View, Drive Clutch Disassembly

    4. Inspect area on shaft where bushing rides for wear, galling, nicks, or scratches. Replace clutch assembly if worn or damaged. 6.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 234

    Clutch Holding Fixture: (PN 2871358-A) brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 235

    It is recommended to weight bolts and weights. switch all buttons to the rubber version during service (if needed). 6.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 236: Drive Clutch Inspection

    = In. / mm. Shaft Diameter: Standard: 1.3745 - 1.375 ( Service Limit: 1.3730” Thrust Washer Thickness Standard: .030, (.76mm) Service Limit: .025, (.64mm) 6.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 237: One-way Clutch Inspection (ebs Drive Clutch)

    Moveable Sheave Bushing Inspection: Replace the cover bushing if more brass than Teflon is visible on the bushing. Refer to bushing replacement in this chapter. 6.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 238: Drive Clutch Reassembly

    “X”, or the marks that were made earlier, on spider aligns with “X”, or the marks that were made earlier on the moveable sheave. 6.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 239: Drive Clutch Bushing Service

    Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter Cover Screw Torque: 100 in. lbs. (11.25 Nm) 6.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 240

    1. Place main adapter (Item 8) on puller. Puller Tool (A,B) Nut (C) Side “A” toward sheave Bushing Piston Pin Puller Main Adapter 6.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 241

    5. Install nut onto puller rod and hand tighten. Turn puller barrel to increase tension as needed. 6. Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free. 6.29 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 242: Non Ebs Driven Clutch

    2. Remove snap ring retainer. 5. Check alignment of tabs on spring. Replace the spring if tabs are misaligned or the spring coils are distorted. 6.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 243

    11. Lube splines with a light film of grease. Do not lubricate the bushings! Used to adjust belt tension. One must always be installed. 6.31 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 244

    9. Remove nut from puller rod and set aside. 10. Remove adapters from puller. 11. Remove bushing and removal tool from adapters. Discard bushing. 6.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 245

    4. Install nut onto puller rod and hand tighten against installation tool. 5. Turn clutch sheave counterclockwise until bushing is seated. 6. Remove nut from puller rod and set aside. 6.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 246

    The least amount of tension will create a slower downshift and a harder upshift. Driven Spring Driven Clutch 6.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 247: Driven Clutch Service (ebs)

    13. Spring Pin 14. Stationary Sheave 15. Bearing 16. Retaining Ring 17. Retaining Ring 18. Inner Spider Plate 19. Spider Dampener 20. Clutch Roller 6.35 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 248

    3. Remove the four screws that secure the cam (helix) assembly using a T25 Torx driver. 6.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 249

    7. Remove the E-clips (F), washers (G), and the clutch rollers (H). Inspect the rollers for wear; replace if worn. 8. Remove the clutch assembly from the holding tool. 6.37 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 250

    13. Inspect the cam (helix) assembly bushing for wear. If the bushing is worn or the shaft does not fit snug into the bushing, replace the cam (helix) assembly. Inspect Bushing 6.38 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 251

    4. Install the roller (A) onto the roller pin (B) on both sides. NOTE: Press only on the outer race of the bearing during installation to prevent from damaging the bearing. 6.39 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 252

    8. Install the clutch rollers (D) onto each side of the outside spider. Install the washers (E) and E-clips (F) to secure the rollers. The rollers should spin freely. 6.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 253

    (helix) side down. Press down on the moveable sheave belt face with both hands and the helix will release. Press Down to Loosen Helix 6.41 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 254: Driven Clutch Bushing Service

    Installation Tool (all clutches) P-90 Driven Clutch Cover 5020631 Bushing Removal Tool Main Puller Adapter 5020632 Adapter Reducer 5010279 Number Two Puller 5020633 Adapter 6.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 255

    8. Remove nut (C) (left hand thread) from puller rod and set aside. 9. Remove adapters from puller. 10. Remove bushing and removal tool from adapters. Discard bushing. 6.43 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 256

    -Dragging brake -Vehicle operated with park brake on. Inspect brake system. -Slow, easy clutch engagement -Fast, effective use of throttle for efficient engagement. 6.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 257

    -Thin spots on belt, worn belt -Replace belt. Refer to belt burnt troubleshooting and Engagement instruct operator. erratic or stabby -Drive clutch bushings stick -Inspect and repair clutches. 6.45 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 258

    CLUTCHING NOTES 6.46...

  • Page 259: Table Of Contents

    ASSEMBLY ............7.48 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual...

  • Page 260: Final Drive, Gearcase Fluid / Capacity

    (41 Nm + 1/4 Turn) Wheel Nuts 5.0 oz. (150 ml) Front Hub Retaining Nut 60 ft.lbs. (81 Nm) Rear Hub Retaining Nut 80 ft.lbs. (108 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 261: Front Hub

    The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 262: Front Gearcase Removal And Installiation (adc And Non Adc), Gearcase Removal

    Replace the circlips on the CV shaft ends prior to reassembly. 5. Pull the hub and strut assembly out and pull the drive- shaft out of the gearcase. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 263: Gearcase Installation

    3. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 264: Front Gearcase - Centralized Hilliard Non Adc (4x)

    FINAL DRIVE FRONT GEARCASE - CENTRALIZED HILLIARD NON ADC (4X4) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 265

    Fill Plug TORQUE 8-30 ft. lbs. (11-40 Nm) Vent Tube Spacer AWD Coil Thrust Plate Coil Pocket Insert  (non serviceable, see parts book) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 266: Operation Non Adc

    “over-running” Ring Gear Magnetic Coil condition.The vehicle is now back to rear wheel drive until the next loss of rear wheel traction occurs. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 267: Disassembly / Inspection Non Adc

    3. Remove the outer cover plate assembly. 6. Remove the torsion spring retainer and torsion spring from the top of the ring gear. Torsion Spring Retainer Torsion Spring 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 268

    Inspect the roll cage (B) for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces. 7.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 269

    14. Remove the bolts retaining the input shaft cover and pinion gear assembly. 15. Remove the snap ring retaining the input shaft assembly. 18. Thoroughly clean the gearcase components before beginning reassembly. 7.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 270

    Insert the rollers as the roll cage is installed. 8. Install the ring gear and roll cage assembly into the gearcase housing. Input Cover Bolt Torque 7-11 ft. lbs. 7.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 271

    NOTE: Verify the square O-ring (arrow) is placed flat on the cover surface. If the O-ring is twisted, fluid leaks may occur. 7.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 272

    Brown/White wires that feed the hub coil wires. There should be a minimum of 11.80-12.0 Volts present for proper operation. AWD Coil Applied Battery Voltage: 11.80-12.0 Vdc 7.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 273

    AWD system. If this is the cause order a new Cover Plate Assembly. Cutaway View of Gearcase Cover Coil U-Shaped Insert 7.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 274

    Ô threads. 3. Turn the screw in until it is lightly seated, then turn the screw out 1/4 turn. 7.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 275

    “wedge” themselves between the external cam / ring gear and output hubs that link both front axles, resulting in true all wheel drive. 7.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 276: Adc Gearcase Exploded View

    Pinion Cover Assembly Hose Clamp Retaining Ring Backlash Adjustment Pinion Gear Assembly Plastic Clip Fill Plug Reservoir Drain Plug Ring Gear Piston Assembly 1/4-20 Screws 7.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 277: Adc Operation

    ADC function. The vehicle returns to rear Operation is controlled by the ECU grounding and wheel drive until the next deceleration. 7.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 278

    11.80-12.0 Volts present for proper operation. Cutaway View of Gearcase Cover AWD Coil Applied Battery Voltage: 11.80-12.0 Vdc Coil U-Shaped Insert 7.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 279: Coil Testing, Adc Differential Hydraulic Circuit Bleeding

    10. Fill reservoir with to a level midway between ‘MAX’ and ‘MIN’ fill lines. Verify no debris is found in reservoir oil. 11. Replace reservoir cap securely and wipe clean any residue. 7.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 280: Disassembly / Inspection

    Replace clutch as an assembly if found to be worn or damaged. 7.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 281

    7. Remove the roller cage (D) and ring gear (E). NOTE: Roller are under spring tension. Use care when removing the roll cage, as rollers will exit the housing with force. 7.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 282

    No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed. See the “FRONT GEARCASE ASSEMBLY” in this chapter for details on backlash setting. 7.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 283

    Replace the input shaft cover O-ring (3) prior to reassembly. 18. Remove the snap ring retaining the input shaft assembly. 20. Inspect the input shaft bushing. Replace case if worn. 7.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 284

    2. Repeat procedure for the other piston. (See photo) PA-48542 3. Remove and discard the inner and outer o-rings from the piston assembly. NOTE: Never re-use o-rings. Always replace with new. 7.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 285

    NOTE: Verify that the o-rings are seated properly and that no o-ring shavings exist outside of the piston area, which is an indication of damage during installation. 7.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 286

    7. Install the input shaft cover assembly, bolts and bracket. Torque to specification. Input Cover Bolt Torque: 7-11 ft. lbs. (9.4-14.9 Nm) 7.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 287

    NOTE: Align output hub in the ring gear recesses. gear. during installation. 7.29 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 288: Setting Ring Gear Backlash

    Torque the screws to specification. Pump Assembly Screw Torque: 17-23 in. lbs. (1.9-2.5 Nm) 7.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 289: Front Drive (cv) Shaft

    5. Safely lift and support the front of the ATV. CAUTION Serious injury could occur if machine tips or falls. 6. Remove wheel. 7.31 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 290

    8. Remove hub nut and hub assembly. 9. Remove cotter pin and nut from lower A-arm ball joint. 7.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 291

    Wheel Nuts (41 Nm + 1/4 Turn) Front Hub Retaining Nut 60 ft.lbs. (81 Nm) Rear Hub Retaining Nut 80 ft.lbs. (108 Nm) 7.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 292: Rear Hub

    4. Loosen the wheel nuts (C). 5. Safely support the rear of the ATV. 6. Remove wheel nuts and wheel. 9. Remove hub. 7.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 293

    4. Inspect bearing housing for wear or damage. Replace housing if damaged. 7.35 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 294

    7. Install retainer nut, wheel and wheel nuts. CAUTION Use an arbor press only on the outer race to avoid bearing damage. 4. Install snap ring into groove. 7.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 295

    1. Remove rear hub. Refer to “REAR HUB REMOVAL” in this chapter. 2. Remove upper carrier bolt. Tip hub outward and remove shaft from carrier. 7.37 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 296

    Aluminum Wheels - 30 ft. lbs. + 1/4 turn (41 Nm + 1/4 turn 8. Grease all fittings thoroughly with Premium U-Joint Lubricant (PN 2871551). 7.38 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 297: Cv Drive Shaft Service, Drive Shafts And Propshafts Components

    Clamp Boot Outer Clamp Prop Shaft Components O-Ring Propshaft Assy. Prop Shaft Cross & Bearing Kit Yoke, Prop to Yoke, Front Gearcase Transmission 7.39 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 298: Drive Shaft And Cv Joint Handling Tips, Outer Cv Joint / Boot Replacement

    IF CV JOINT WAS CLEANED, add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit. 7.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 299

    Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint. 7.41 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 300

    17. Remove excess grease from the CV joint's external surfaces and place the excess grease in the boot. Axle Boot Clamp Tool 8700226 or PU-48951 7.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 301: Inner Plunging Joint / Boot Replacement

    Intermixing the internal components could result in looseness, binding, and/or premature failure of the joint. 7.43 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 302

    The grease provided in the replacement kit is specially formulated for wear resistance and durability. DO NOT use substitutes or mix with other lubricants. 7.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 303

    7.45 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 304: Drive Shaft Exploded Views, Prop Shaft - Front Or Rear, Removal And Installation

    Spring Ring removal. Plunging Joint Gear Side Boot Kit Wheel Side Boot Kit CV Joint 7.46 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 305: U-joint Service

    2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer. 7.47 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 306

    3. Install snap ring to contain bearing cap just installed. Repeat procedure for other side. 7.48 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 307: Table Of Contents

    TROUBLESHOOTING CHECKLIST......... 8.8 2012 SPORTSMAN TRANSMISSION EXPLODED VIEW ......8.9 2012 SPORTSMAN TRANSMISSION EXPLODED VIEW .

  • Page 308: Transmission - General

    Rear Driveshaft Seal 2871699 (Part of 2871702 Kit) Guide Bearing Seal Driver 2871282 (50 mm) Lubrication Refer to Chapter 2 for transmission lubricant type and capacity. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 309: Transmission Frame Mounts

    Transmission Frame Mount Locations A = Frame Long Bolts = 37 ft. lbs / 50Nm B = Side Fasteners = 37 ft. lbs / 50Nm 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 310: Transmission Upper Frame Mount

    Transmission Upper Frame Mount Location A = Upper Bracket-to-Frame Fasteners = 20ft. lbs / 27Nm B = Bracket-to-Transmission Bolt = 37 ft. lbs / 50Nm 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 311: Transmission Rear Stabilizer Mounts

    A = Stabilizer-to-Frame Fasteners = 20ft. lbs / 27Nm B = Stabilizer-to-Transmission Bolt = 37 ft. lbs / 50Nm C = Stabilizer-to-Transmission Fasteners = 37 ft. lbs / 50Nm 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 312: Transmission Control Arm Bracket Mounts

    CONTROL ARM BRACKET A = Bracket Mounting Bolts = 37 ft. lbs / 50Nm B = Bracket Fasteners = 37 ft. lbs / 50Nm 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 313

    15. With the help of an assistant, lift and remove Shift transmission out of rear of frame while pulling the Handle output shaft from the propshaft yoke. 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 314: Transmission Installation, Troubleshooting Checklist

    11. Reconnect the shift rod. 12. Reinstall: • Seat • Side Panels • Rear Rack/Rack Support • Rear Cab Assembly • Left/Right Foot Wells 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 315: Sportsman Transmission Exploded View

    Apply Polaris Crankcase Sealant. 10-14 ft. lbs. (14-19 Nm) ® Apply Loctite 8-12 ft. lbs. 12-18 ft. lbs. the bolt threads. (11-16 Nm) (16-24 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 316

    Lockout Disc Input Shaft Magnetic Plug Chain Shift Fork Compression Spring Shift Rail Tensioner Pin Torsion Spring Chain Tensioner Cam Chain Tensioner Shoe 8.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 317: Transmission Disassembly / Assembly, Transmission Disassembly

    10. Remove the shift shaft (J), detent pawl (K) and the shift gears (L and M). IMPORTANT: Note the timing marks on the shift gears (L and M) for reassembly purposes. 8.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 318

    12. Note location of chain tensioner cam (N). If fully extended, chain is worn beyond service limit and should be replaced along with the chain tensioner shoe. 8.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 319

    17. Remove the shift drum (V) from the gearcase by moving the drum up and to the right to clear the shift shaft. 8.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 320

    28. Remove the retaining ring, washer, 38T sprocket and needle bearing from the reverse shaft (see Figure 8- 24. The reverse shaft should slide out of the silent chain 8.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 321

    31. Remove the seal from the snorkel shaft to access the snorkel tube for removal. 34. Use an arbor press to remove the snorkel tube from the snorkel shaft. Seal Removed 8.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 322: Snorkel / Output Gear Backlash Procedure

    38. Remove all seals from the gearcase halves and clean the cases in preparation for assembly. 8.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 323

    5. Install the output gear assembly. Be sure to properly screw hole opening to reference your starting point. mesh the snorkel shaft bevel gear with the output bevel gear. 8.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 324

    11. Once the backlash is set, apply Loctite 242® to the threads and install the locking screw to secure the snorkel tube. 8.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 325: Transmission Assembly

    Input Shaft Shift Fork Rail Reverse Shaft 8.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 326

    (4) output gear assembly retaining screws. Apply Loctite 242® to the threads of the screws. Torque the screws to specification. Oil Deflector Retaining Screws: 20-30 in. lbs. (2.3-3.4 Nm) 8.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 327

    • Assemble the tensioner cam and tensioner shoe The tensioner cam will lift the shoe to provide and place them into the transmission. chain tension. 8.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 328

    14. Install the lockout disc onto the shift drum shaft. Be sure to install the lockout disc with the raised edge facing outward. Lockout Disc 8.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 329

    Transmission Shown in Neutral 21. Install the transmission gear selector switch and secure the switch with the retaining ring. O-Rings 8.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 330

    TRANSMISSION NOTES 8.24...

  • Page 331: Table Of Contents

    SPORTSMAN REAR PAD REMOVAL ........9.22 SPORTSMAN REAR PAD INSTALLATION ........9.23 BRAKE BURNISHING PROCEDURE .

  • Page 332: Torque Table, Component Service Limits

    Brake Disc Thickness .180-.195” / 4.57-4.95 mm .170” / 4.318 mm Brake Disc Thickness Variance .002” / .051 mm Brake Disc Runout .010” / .254 mm 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 333: Hydraulic Brake System

    If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake fail 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 334: Brake Noise Troubleshooting

    Wrong pad for Change to a softer or or dust. conditions harder pad (if available) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 335: Brake Bleeding / Fluid Change

    9. Tighten bleeder screw securely and remove bleeder hose. Torque the bleeder screw to specification. Bleeder Screw Torque: 25-30 in.lbs. (2.80-3.40 Nm) 10. Repeat procedure Steps 5-9 for the remaining caliper(s). 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 336

    Diaphragm 13. Wiggle and press down on the cap to be sure it fits evenly and snug. Cap Must be Even 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 337: Brake System Exploded Views, Sportsman Touring 500 Ho Component Exploded View

    5) Dual Input Master Cylinder and Bleed Screw: 25-30 in. lbs. (2.8-3.4 Nm) 6) Front and Rear Caliper Bleed Screws: 36-60 in. lbs. (4.07-6.78 Nm) *All Bleed Screws: 25-30 in.lbs. (2.80-3.40 Nm) 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 338

    BRAKES Sportsman 400 HO, 500 HO and International Forest Component Exploded View 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 339

    BRAKES Sportsman Forest Tractor 500 (INTL A12MH50FF) Component Exploded View 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 340: Brake Caliper Exploded Views, Sportsman 500 Ho Touring Rear Caliper Assembly (non Intl)

    BRAKES BRAKE CALIPER EXPLODED VIEWS Sportsman 400 HO, 500 HO, Touring and Forest 500 (INTL.) Front Caliper Assembly Apply Polaris DOT approved Brake Fluid to Component Disc brake caliper lube A. Socket Set Screw B. Bleeder Screw   C. Caliper Asm.

  • Page 341: Sportsman Forest 500 (intl.) Front Caliper Assembly

    B. Bleeder Screw   C. Caliper Asm.  D. Boot  E. Square O-rings  F. Piston G. Caliper Mount  H. Brake PAds 9.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 342

    25 in. lbs. (3 Nm) Torque Inner Bolt First 4. Follow proper bleeding procedures. Check all connections for leaks and repair if necessary. 9.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 343: Front Brakes, Pad Removal

    Remove excess fluid from reservoir as required. 6. Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. 4. Remove caliper from mounting bracket. 9.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 344

    .180” / 4.6 mm WARNING If pads are contaminated with grease, oil, or liquid soaked do not use the pads. Use only new clean pads. 9.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 345: Front Brake Disc

    Do not allow pads or disc to become hot or warping may result. Repeat this procedure 10 times. 9.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 346

    Rear - 27 ft.lbs. (37 Nm) CAUTION Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal. 9.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 347: Front Caliper

    NOTE: Be sure to clean seal grooves in caliper body. Clean Components 2. Push upper pad retainer pin inward and slip brake pads past edge. Loosen pad adjuster. 9.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 348

    3. Inspect the brake disc and pads as outlined for brake pad replacement in this section. See “BRAKE PAD INSPECTION” earlier in this chapter. 9.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 349

    9. Install wheels and torque wheel nuts to specification. Refer to Chapter 2. 18 ft.lbs. (24 Nm) Brake Caliper Mounting Bolt Torque: 18 ft.lbs. (24 Nm) 9.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 350: Rear Brake Pad, Touring Pad Removal

    Support caliper so as not to kink or bend brake line. 8. Clean the caliper with brake cleaner or alcohol. 9.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 351

    8. It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise. 9.21 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 352: Sportsman Rear Pad Removal

    4. Remove caliper mounting bolts and lift caliper off of disc. = In. / mm. Rear Brake Pad Thickness Service Limit: .180” (4.6 mm) 9.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 353: Sportsman Rear Pad Installation

    Repeat this procedure 10 times. 18 ft.lbs. (24 Nm) Caliper Mount Bolt Torque: 18 ft.lbs. (24 Nm) 9.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 354: Touring Rear Caliper

    3. Remove the two caliper mounting bolts and the caliper. 4. Loosen the adjuster screw and remove the brake pads. 5. Remove mounting bracket, pin assembly and dust boot. 9.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 355

    3. Inspect the brake disc and pads as outlined for brake pad replacement in this section. See “BRAKE PAD INSPECTION” earlier in this chapter. 9.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 356: Sportsman Rear Caliper, Removal And Inspection

    7. Clean disc, caliper body, and pistons with brake cleaner or alcohol. 3. Remove the two caliper mounting bolts and the caliper. 9.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 357

    Rear Caliper Piston Bore I.D. Inner Bore Service Limit: .94” (23.88 mm) Outer Bore Service Limit: 1.5” (38.1 mm) 10. Inspect caliper piston bore for scratches, severe 9.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 358

    Make sure the brake is not dragging when lever is released. If the brake drags, re-check assembly and installation. Slide Pin Torque: 30-35 ft.lbs. (41-48 Nm 9.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 359: Rear Brake Disc

    = In. / mm. Brake Disc Thickness Variance: Service Limit: .002” (.051 mm) Between Measurements 3. Mount dial indicator and measure disc runout. 9.29 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 360: Rear Master Cylinder, Sportsman 500 Ho Touring Exploded View (non Intl)

    D. Bushing(s)  E. Washer(s)  F. Cotter Pin  G. Foot Pedal  H. Spring  I. Front Brake Line J. Banjo Fitting 9.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 361: Sportsman 400 Ho, 500 Ho, Tractor 500 (intl.), Forest 500 (intl)

    BRAKES Sportsman 400 HO, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.) REAR RESERVOIR REAR MASTER CYLINDER BRAKE MOUNT PLATE CLEVIS RETURN SPRING WASHER COTTER PIN BUSHING COTTER PIN FOOT PEDAL Overview • Test for brake drag after any brake system service and investigate cause if brake drag is evident.

  • Page 362: Touring Rear Master Cylinder Removal And Installation

    4. To install the rear master cylinder, mount the master cylinder to the frame and torque bolts to specification. Master Cylinder to Frame Bolt Torque: 8 ft.lbs. (11 Nm) 9.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 363

    E. Bushing  F. Washer  G. Cotter Pin  H. Foot Pedal  I. Mount Plate Bolts  J. Mount Plate K. Spring 9.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 364: Pedal Removal And Installation

    • Parking brake left on • Residue build up under caliper seals • Operator riding brakes Brakes Lock • Alignment of caliper to disc 9.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 365: Table Of Contents

    BRAKE LIGHT SWITCH ..........10.35 10.1 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 366: Table Of Contents

    TROUBLESHOOTING DIAGRAMS ........10.54 SPORTSMAN 500 EFI FOREST TRACTOR ELECTRICAL ..... 10.56 10.2...

  • Page 367: Ignition System / Basic Electrical Components

    Timing Light 2870836 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness Polaris MDX-610P Battery Conductance SPX PN: PU-50296 Analyzer 10.3 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 368: Electrical Service Notes

    • Excessive crankshaft runout - should not exceed be tested. Disconnect it from the wiring harness or .0024” power supply. • Faulty ECU • Faulty CPS • Low Battery 10.4 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 369: Instrument Cluster

    • Hour meter - logs the total hours the engine has been in operation. • Clock - displays hours and minutes. ILL. 2 10.5 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 370

    • Specifies what position the shift lever and transmission are in. This area is blank if a fault occurs. 8. Mode Indicator • Indicates which modes are being utilized. 10.6 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 371: Instrument Cluster Diagnostic Mode

    ATV. This information is only displayed briefly. Screen 1: The first screen indicates battery voltage. Refer to Ill. 2. AWD On Ill. 2 10.7 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 372

    75 Ohms in Reverse Set at 50 hours from factory 10.8 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 373: Setting A New Service Interval

    3. Press the mode button again to set the desired service increment. 4. Release the button and wait for the wrench icon to stop flashing. The new service interval is now set. 10.9 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 374: Efi Diagnostic Mode

    Codes ‘12’ and ‘61’ indicate the beginning and end of the check sequence. NOTE: The ‘check engine’ icon (mil) will flash the codes during this mode. Record flash sequences. 10.10 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 375

    The bezel is a snap-on assembly and is a serviceable part. NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens. 10.11 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 376

    ELECTRICAL ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 - No All Wheel Drive 10.12 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 377

    ELECTRICAL TEST 2 - No Speedometer Display TEST 3 - No Reverse Speed Limit 10.13 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 378

    ELECTRICAL TEST 4 - No AWD Hub Safety Limit 10.14 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 379

    Hall Sensor Probe Harness (PN 2460761) 1. Disconnect the 3 wire harness from the speed sensor and remove the sensor from the transmission. 10.15 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 380

    ELECTRICAL TEST 7 - Fuel Gauge Display Not Working TEST 8 - Shift Indicator Not Working 10.16 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 381: All Wheel Drive (awd) Coil, Cooling System Components, Fan Control Circuit Operation, Diagnosing System Failures

    10.17 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 382: Fan Motor Current Draw Test, Coolant Temperature Sensor - Efi

    Verify the cooling system is full and purged of air. Refer to Maintenance Chapter 2 for cooling system information. 10.18 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 383: Coolant Temperature Fan Switch - H.o, Gear Position Indicator Switch, Test Diagram

    Verify the cooling system is full and purged of air. Refer to Maintenance Chapter 2 for cooling system information. 10.19 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 384: Etc Test

    4. Hold throttle cable with fingers at point “A” as shown below and release throttle lever. If the ETC system is functioning properly, the engine will lose spark and stop. 10.20 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 385: Ignition System

    Overview The Sportsman has incorporated into it's design a DC/ CDI ignition system. The DC/ ignition system relies on battery power for ignition. EFI - Instead of generating DC voltage via flywheel magnetic induction, a 12 Vdc current is supplied from the Ignition/Fuel Pump Relay to the Ignition coil.

  • Page 386: Components Of Alternator And Dc / Cdi Ignition System

    ELECTRICAL Components of Alternator and DC / CDI Ignition System 10.22 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 387: Efi Ignition System Testing Flow Chart

    ELECTRICAL EFI Ignition System Testing Flow Chart Crankshaft Position Sensor Gap 10.23 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 388: Charging System, Ignition Output Test Using Gap Tester, Current Draw - Key Off, Ignition Troubleshooting

    Current Draw Off: Maximum of .01 DCA (10 mA) • Sheared flywheel key • Flywheel loose or damaged • Faulty ECU 10.24 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 389

    9. Repeat test, observing ammeter and tachometer. With lights on, charging should occur at or below 2000 RPM. 10.25 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 390

    Y1 to Ground, Y2 to Ground, Y3 to Ground. NOTE: Any measurement other than Infinity (open) will indicate a failed or shorted stator leg. 10.26 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 391: Charging System Testing Diagrams

    Whenever charging system problems are suspected, proceed with the following system check after verifying that all wires are in good condition, connected and not kinked or pinched. SPORTSMAN FOREST TRACTOR 500 EFI SPORTSMAN 500 Carbureted 10.27 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 392

    ELECTRICAL 10.28 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 393

     switched on by the ECU,  enables power to fan.  Red / Black (Carb) R/B - 12 Vdc to fan switch 10.29 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 394: Fuses/circuit Breaker, High Beam Headlight Bulb Replacement

    4. Turn the headlight lamp socket counter-clockwise and remove. Turn Harness Assembly Loosen Tighten 5. Carefully remove headlamp bulb from housing. 10.30 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 395: Headlight Housing Replacement

    7. Carefully pull the assembly up and out of pod. 8. Reverse the steps to install the new housing and reassemble the pod. 10.31 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 396: High Beam Headlight Adjustment, Lower Headlamp Removal / Installation

    Lower Headlight - Turn knob clockwise 5. Adjust beam to desired position. Lower Headlamp Removal / Installation HIGH Remove Install 10.32 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 397: Low Beam Headlight Adjustment (non Intl)

    2. Loosen the phillips screw located at the rear of the headlamp. 3. Tilt the headlamp upward or downward. 4. Tighten the screw. 10.33 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 398: Lower Headlight Adjustment (forest Tractor), Headlamp Switch Test

    5. Once the adjustment is completed, plug the .55” (14mm) access hole with a compartment plug (PN 5412981). 6. Repeat procedure to adjust the other lower headlight. 10.34 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 399: Brake Light Replacement, Brake Light Switch

    Replace switch if there is no continuity or greater than .5 ohms resistance when the brake is applied with slight pressure. 10.35 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 400: Speed Sensor, Fuel Sender

    3. Push new sensor into gearcase housing. Install bolt and tighten to specification. Speed Sensor Bolt Torque 8-12 ft. lbs. (11-17 Nm) 10.36 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 401: Accessory Power, Starter System

    • Faulty starter drive gears or starter motor gear Power Point • Faulty flywheel gear or loose flywheel Acc #1 (Located Below Head Lamps) Acc. 2 10.37 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 402: Voltage Drop Test, Starter Lockout Troubleshooting- H.o, Starter Lockout Troubleshooting- Efi

    • Key switch for proper function Should all these items be found in working order, the ECU or starter motor may be at fault. 10.38 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 403: Starter Lockout Diagram- Efi, Starter Lockout Diagram- Carb

    ELECTRICAL Starter Lockout Diagram- EFI Starter Lockout Diagram- Carb Internal Harness Serviceable 10.39 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 404: Starter Motor Removal / Disassembly, Brush Inspection / Replacement

    2. Remove nut, flat washer, large phenolic washer, two small phenolic washers, and O-Ring from brush terminal. Inspect the O-Ring and replace if damaged. 10.40 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 405

    1/8” (.3 cm) above armature coil laminates. Rotate ° armature 360 . If hacksaw blade is drawn to armature on any pole, the armature is shorted and must be replaced. 10.41 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 406: Starter Solenoid Bench Test

    The resistance should be 3.7 ohms ± 5 % Refer to “Electric Starter System Testing” in this section to further test the solenoid. 10.42 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 407: Starter Drive

    Make sure the end washer is positioned properly so that it will hold the lock ring in its groove. 10.43 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 408: Starter System Testing Flow Chart

    If all of these indicate a good condition, yet the starter still fails to turn, the starter must be removed for static testing and inspection. 10.44 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 409: Battery Conductance Analyzer, Battery Identification

    Top View Electrolyte Level Indicator Polaris MDX-610P SPX PN: PU-50296 Sealed Low Maintenance Battery No Caps (Non- Removable) Top View Electrolyte Level Indicator 10.45 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 410

    NOTE: New Battery: Battery must be fully charged before use or battery life will be significantly reduced 10-30% of the battery's full potential. 10.46 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 411: Conventional Battery Inspection / Removal, Conventional Battery Installation, Conventional Battery Testing

    4. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not overfill the battery. 10.47 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 412: Conventional Battery Ocv - Open Circuit Voltage Test, Conventional Battery Specific Gravity Test

    9.5 75% Charged 12.10V 12.20V volts during the test, replace the battery. 50% Charged 11.90V 12.0V 10.48 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 413: Off Season Storage, Charging Procedure

    7. Route cables so they are tucked away in front and LECTROLYTE behind battery.  1.265  1.225  1.200  1.150  1.100  1.050 10.49 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 414: Low Maintenance Battery

    Refer to capacity table. 3. Charge battery using a variable rate charger. 10.50 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 415: Low Maintenance Battery Charging, Low Maintenance Battery Inspection / Removal, Low Maintenance Battery Installation

    At least 13 11.5-12.0 hours, 25-50% Needs Charge verify state of charge 11.5 V At least 20 0-25% Needs Charge or less hours 10.51 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 416: Low Maintenance Battery - Ocv- Open Circuit Voltage Test, Low Maintenance Battery Load Test

    9.5 volts during the test, replace the battery. NOTE: Subtract .01 from the specific gravity reading ° at 40 10.52 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 417: Low Maintenance Battery Charging Procedure, Low Maintenance Battery Off-season Storage

    ELECTROLYTE FREEZING POINTS PECIFIC RAVITY OF REEZING OINT LECTROLYTE ° 1.265 ° 1.225 ° 1.200 ° 1.150 ° 1.100 ° 1.050 10.53 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 418

    ELECTRICAL TROUBLESHOOTING DIAGRAMS All Wheel Drive - EFI Fuel Pump - EFI 10.54 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 419

    ELECTRICAL Fan Control - EFI 10.55 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 420

    The flash rate will double when a single lamp is detected on the flash output in turn or hazard mode. 10.56 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 421

    3. Test the new bulb. Install the orange lens cover. 4. Install the screws and tighten sufficiently. 10.57 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 422

    5. Install the upper pod, screws and tighten sufficiently. Trailer Connector and Fuses The Sportsman 500 EFI Tractor is equipped with an integrated trailer connector that is fuse-protected. Use the diagram provided to troubleshoot any potential trailer wiring issues. 10.58 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual ©...

  • Page 423

    25 Mph), the solenoid valve is closed by the ECU and the operation repeats. Should the vehicle speed reach 67 Kph (42 Mph), the ‘check engine’ light will illuminate on the LCD gauge to indicate there is a problem with the system. 10.59 9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual © Copyright 2011 Polaris Sales Inc.

  • Page 424

    ELECTRICAL NOTES 10.60...

  • Page 425

    Located By Battery...

  • Page 427

    Located By Transmission Breakout / Resistor Module...

  • Page 429

    Located By Battery...

  • Page 431

    Located By Transmission Breakout / Resistor Module...

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