Polaris 2012 Sportsman Forest 500 International Manuals

Manuals and User Guides for Polaris 2012 Sportsman Forest 500 International. We have 1 Polaris 2012 Sportsman Forest 500 International manual available for free PDF download: Service Manual

Polaris 2012 Sportsman Forest 500 International Service Manual

Polaris 2012 Sportsman Forest 500 International Service Manual (432 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 21.92 MB

Table of Contents

General Information Chapter 1 1

4
- General
  4
  - Table of Contents
    4
  - Chapter 1 Model Number
    5
- General Information
  5
- Model Number Information
  5
- Vehicle Identification Number (Vin)1.2
  5
- Vehicle Specifications
  7
- Misc. Numbers/Charts
  15
  - Conversion Table
    15
  - Standard Bolt Torque Specification
    16
  - Metric Bolt Torque Specification
    16
  - Metric Tap Drill Sizes
    17
  - Paint Codes
    18
  - Replacement Keys
    18
  - Glossary of Terms
    19
Maintenance Chapter 2 Maintenance 2

20
- Maintenance
  23
- Chapter 2 Periodic Maintenance Chart
  25
- Lubricants / Service Products
  26
  - Polaris Lubricants, Maintenance and Service Products
    26
- Lubrication / Fluids
  26
  - Pre-Ride / Daily Inspection
    26
  - Lubrication Components
    27
  - Front Gearcase Lubrication
    28
  - Transmission Lubrication
    29
- Adc System (if Equipped)
  30
  - Adc System Fluid Reservoir Location
    30
  - Adc Differential Hydraulic Circuit Fluid Change
    30
- Vehicle Inspection
  31
  - Shift Link Rod Inspection
    31
  - Throttle Inspection
    31
  - Throttle Cable / Electronic Throttle Control Adjustment
    32
  - Fuel System
    32
  - Fuel Lines
    33
  - Vent Lines
    33
  - Choke (Enricher) Adjustment - (500 Carb)
    33
  - Compression Test
    33
  - Engine Mounts
    33
  - Spark Plug
    34
  - Battery Maintenance
    34
  - Liquid Cooling System Overview
    35
  - Coolant Strength / Type
    35
  - Cooling System Hoses
    35
  - Radiator/Grill Screen
    36
  - Cooling System Pressure Test
    36
  - Coolant Level Inspection
    36
  - Radiator Coolant Level
    37
  - Air Filter/Pre-Filter Service
    38
  - Air Box Sediment Tube
    39
  - Breather Filter Inspection
    39
  - Breather Hose
    39
  - Recoil Housing
    39
  - Engine Oil Level
    40
  - Oil and Filter Change
    40
  - Oil Pump Priming Procedure
    42
  - Valve Clearance
    42
  - Intake Valve Clearance Adjustment
    43
  - Exhaust Valve Clearance Adjustment
    43
  - Steering
    43
    
    Final Drive
    44
  - Tie Rod End/Steering Inspection
    44
  - Camber and Caster
    44
  - Wheel Alignment
    44
  - Toe Alignment Adjustment
    45
  - Exhaust Pipe
    45
  - Brake System Inspection
    46
  - Brake Pad Inspection
    47
  - Hose/Fitting Inspection
    47
  - Auxiliary Brake Testing
    47
  - Auxiliary Brake Adjustment (Hydraulic)
    48
  - Suspension Spring
    48
- Preload Adjustment
  48
  - Front Suspension
    48
  - CV Shaft Boot Inspection
    48
  - Controls
    49
  - Wheels
    49
  - Wheel, Hub, and Spindle
    49
  - Torque Table2.30
    49
  - Wheel Removal Front or Rear
    50
  - Wheel Installation
    50
  - Tire Pressure
    50
  - Tire Inspection
    51
  - Frame, Nuts, Bolts, Fasteners
    51
- Carburetor Maintenance
  51
  - Choke (Enricher) Adjustment (Non Efi)
    51
  - Pilot Screw
    51
  - Pilot Screw Adjustment
    52
  - Idle Speed Adjustment (Non Efi)
    53
  - Fuel Filter (Non Efi)
    53
  - Carburetor Draining
    54
  - Maintenance Schedule
    55
Chapter 3 Engine

56
- Engine Fastener Torque Patterns
  58
- Specifications
  58
- Torque Specifications
  58
- Sportsman 500 H.o. Engine Service Data
  59
- Sportsman 400 H.o. Engine Service Data
  61
- General Engine Service
  63
  - Cooling System Specifications
    63
  - Cooling System
    64
  - Accessible Components
    65
  - Engine Removal
    65
  - Engine Installation Notes
    67
  - Cylinder Hone Selection/ Honing Procedure
    67
    
    Electrical
    68
  - Honing to Oversize
    68
  - Cleaning the Cylinder after Honing
    68
  - Crankshaft Straightening
    69
  - Engine Lubrication
    69
  - Oil Pressure Test
    69
  - Oil Flow
    70
  - Oil Flow Diagram
    71
  - Engine Exploded Views
    72
- Special Tools
  63
- Engine Disassembly
  73
  - Cam Chain Tensioner / Rocker Arm /Camshaft Removal
    73
  - Cam Chain Tensioner Inspection
    73
  - Rocker Arm / Shaft Inspection
    74
  - Camshaft Removal
    75
  - Automatic Compression Release Removal / Inspection
    76
  - Automatic Compression Release Installation
    76
  - Camshaft Inspection
    77
  - Cylinder Head Removal
    77
  - Cylinder Head Exploded View
    78
  - Cylinder Head Inspection
    79
  - Cylinder Head Warpage
    79
  - Cylinder Head Disassembly
    79
  - Valve Inspection
    80
  - Combustion Chamber
    81
  - Valve Seat Reconditioning
    81
  - Cylinder Head Assembly
    84
  - Valve Sealing Test
    84
  - Valve Clearance Adjustment
    84
  - Cylinder / Piston Removal and Inspection
    85
  - Piston Removal
    86
  - Cylinder Inspection
    87
  - Cylinder Hone Selection / Honing Procedure
    87
  - Honing to Oversize
    88
  - Cleaning the Cylinder after Honing
    88
  - Piston-To-Cylinder Clearance
    89
  - Piston / Rod Inspection
    89
  - Piston Identification
    90
  - Piston Ring Installed Gap
    90
  - Crankcase Disassembly
    91
  - Starter Drive Removal / Inspection
    91
  - Flywheel and Stator Removal / Inspection
    91
  - Cam Chain / Tensioner Blade
    92
  - One Way Valve
    93
  - Crankcase Separation
    93
  - Oil Pump Removal / Inspection
    93
  - Oil Pump Assembly
    95
  - Counter Balancer Shaft Removal / Inspection
    95
  - Crankshaft Removal / Inspection
    96
  - Crankcase Bearing Inspection
    97
  - Oil Seal / Mechanical Seal Removal (Engine Disassembled)
    97
  - Crankcase Inspection
    97
  - Bearing Installation
    98
  - End Play Inspection / Adjustment
    98
  - Crankshaft End Play Adjustment
    98
  - Counter Balancer Shaft End Play Adjustment
    99
  - Oil Pump Shaft End Play Adjustment
    100
- Engine Reassembly
  100
  - Pump Shaft Oil Seal Installation
    100
  - Crankshaft / Counter Balance / Oil Pump Installation
    100
  - Crankcase Assembly
    101
  - Water Pump Mechanical Seal Installation
    101
  - Water Pump Mechanical Seal Removal (Engine Installed)
    102
  - One Way Valve Installation
    103
  - Cam Chain Drive Sprocket Installation
    103
  - Tensioner Blade Installation
    103
  - Piston Ring Installation
    103
  - Piston Installation
    104
  - Cylinder Installation
    104
  - Cylinder Head Installation
    105
  - Cam Chain / Camshaft Installation
    106
  - Camshaft Timing
    106
  - Camshaft Timing Illustration
    108
  - Cam Chain Tensioner Installation
    109
  - Stator, Flywheel and Starter Drive Installation
    109
  - Rocker Shaft / Rocker Arm Assembly Installation
    110
  - Thermostat Installation
    110
  - Oil Pipes
    110
  - Oil Pump Priming Procedure
    110
- Recoil (Accessory)
  111
- Troubleshooting
  113
Carburation and Fuel System Chapter 4 Carburation and Fuel System

118
- Carburetor Jetting
  119
- Chapter 4
  119
- General Information and Specifications
  119
- Mikuni Jet Part Numbers
  119
- Special Tools
  119
- Carburetion
  120
  - Bst 40 Carburetor Exploded View 1 of 2
    120
  - Bst 40 Carburetor Exploded View 2 of 2
    121
  - CV Carburetor System Function
    122
  - Mikuni CV Carb Operation
    122
  - Carburetor Venting
    123
  - Starter System (Choke or Enrichment)
    123
  - Pilot (Idle and Slow) System
    124
  - Main System
    124
  - Float System
    125
  - Pilot Screw
    125
  - Air/Fuel Mixture Ratio
    126
  - Jet Needle
    126
  - Needle Jet
    126
  - Throttle Opening Vs. Fuel Flow
    127
  - Carburetor Disassembly - Mikuni CV
    127
  - Carburetor Cleaning
    128
  - Carburetor Inspection
    128
  - Carburetor Assembly
    129
  - Float Height Adjustment
    129
  - Needle and Seat Leakage Test
    130
  - Fuel Level Test
    130
- Carbutated Fuel Tank / Fuel Delivery System
  131
- Fuel Gauge Sending Unit Test
  132
- Fuel Pump (Carburated)
  132
- Fuel Pick-Up / Sending Unit Replacement (Carb.)
  133
- Fuel Tank Vent Routing (Non Intl)
  136
- 500 H.o. International Emissions System
  137
- Troubleshooting
  138
Carburation and Fuel System Notes

140
- Special Tools
  142
- 500 Efi Tractor Speed Control
  144
  - System Operation Overview
    144
  - Air Control Body Removal and Disassembly
    145
  - Air Control Body Assembly and Installation
    145
  - Air Solenoid Valve Test / Replacement
    145
  - Exhaust System
    146
- Efi Service Notes
  147
- Efi System Exploded View
  148
- Efi System
  149
  - Component Locations/Identification
    149
- Fuel System and Fuel Tank
  151
  - Fuel System and Fuel Tank Exploded View
    151
- Electronic Fuel Injection
  152
  - General Information
    152
  - Efi Operation Overview
    152
  - Initial Priming / Starting Procedure
    152
- Electronic Control Unit (Ecu)
  153
  - Operation Overview
    153
  - Ecu Replacement
    154
  - Ecu Service
    154
- Fuel Lines
  153
  - Quick Connect Removal/Installation
    153
- Fuel Pump Assembly
  155
  - Operation / Testing
    155
  - Fuel Pump Test
    155
  - Fuel Tank Replacement
    156
  - Fuel Sending Unit Test
    157
  - Fuel Pump Replacement
    158
- Fuel Filter
  161
- Fuel Injector
  161
- Fuel Pressure Regulator
  161
- Crankshaft Position Sensor (Cps)
  163
- Manifold Air Pressure Sensor (Map)
  164
  - Operation Overview
    164
  - Map Sensor Test
    164
  - Map Sensor Replacement
    164
- Idle Air Control (Iac)
  165
- Intake Air Temperature Sensor (Iat)
  165
- Throttle Position Sensor (Tps)
  166
  - Operation Overview
    166
  - Throttle Position Sensor Test
    166
  - Throttle Position Sensor Replacement
    168
  - Throttle Position Sensor Initialization
    168
- Engine Temperature Sensor
  169
  - General Information
    169
  - Engine Temperature Sensor Test
    169
  - Engine Temperature Sensor Replacement
    169
- Fuel System Troubleshooting
  170
  - Fuel Starvation / Lean Mixture
    170
- Efi Diagnostics Using 'Blink Codes
  171
  - Blink Codes - Operation
    171
- Digital Wrench™ Operation
  172
- Troubleshooting Diagrams
  180
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension

186
- Chapter 5
  187
- Decal Replacement
  187
- General Information
  187
- Special Tools
  187
- Torque Specifications
  187
- Plastic Insert Removal / Installation
  188
- Body
  189
  - Side Panel Removal
    189
  - Foot Well Removal / Installation
    190
  - Front Bumper Removal / Installation
    191
  - Mud Guard Removal / Installation
    191
  - Front Fender Removal/Installation
    192
  - Front Rack / Storage Box Lid Assembly
    193
  - Front Cab Assembly
    194
  - Front Bumper Assembly
    195
  - Rear Rack Assembly
    196
  - Rear Cab and Seat Assembly
    197
  - Rear Storage Box Assembly
    198
  - Winch and Front Bumper Mounting
    199
  - Headlight Pod Exploded View
    200
- 500 Efi Tractor Seat Assembly
  201
  - Overview
    201
  - Seat Dampener Repair
    201
  - Seat Pivot Repair
    201
  - 500 EFI Tractor Seat Assembly Exploded View
    202
- 500 Efi Tractor Steering Post and Lock
  203
  - Steering Assembly Exploded View
    203
- Steering
  204
  - Handlebar Block Installation Procedure
    204
  - Steering / A-Arm Exploded View
    205
  - A-Arm Replacement
    206
  - Ball Joint Replacement
    207
  - Steering Post Removal
    208
  - Steering Post Assembly
    208
- Suspension
  208
  - Front Strut Cartridge Replacement
    208
  - Strut Assembly
    209
  - Sportsman Rear Suspension Assembly
    210
  - Torsion Bar Exploded View
    211
Chapter 6 Clutching

213
- General Operation
  214
- Pvt System Overview
  214
- Special Tool and Supplies
  214
- Torque Specifications
  214
- Drive Clutch Operation
  215
- Driven Clutch Operation
  215
- Clutching Chart
  216
- Maintenance / Inspection
  216
- Pvt Break-In (Drive Belt / Clutches)
  216
- Overheating / Diagnosis
  217
- Pvt Exploded Views
  218
- Pvt System Service
  219
  - Disassembly
    219
  - Assembly
    220
- Drive Belt
  221
  - Belt Removal
    221
  - Belt Inspection
    222
  - Belt Installation
    222
  - Pvt Break-In (Drive Belt / Clutches)
    222
- Clutch Alignment
  222
- Clutch Center Distance
  224
- Drive Clutch Service (Non Ebs)
  225
  - Exploded View (Non Ebs)
    225
  - Clutch Disassembly
    226
  - Drive Clutch Spring Inspection
    227
  - Shift Weight Inspection
    227
  - Spider Removal
    228
  - Button to Tower Clearance Inspection
    229
  - Shift Weight Inspection
    229
  - Bearing Inspection
    230
  - Clutch Inspection
    230
  - Moveable Sheave Bushing Inspection
    231
  - Clutch Assembly
    232
- Ebs Drive Clutch Service
  233
  - Ebs Drive Clutch Exploded View
    233
  - Drive Clutch Disassembly
    233
  - Spider Removal
    234
  - Button to Tower Clearance Inspection
    235
  - Shift Weight Inspection
    235
  - Drive Clutch Inspection
    236
  - Moveable Sheave Bushing Inspection
    237
  - One-Way Clutch Inspection (Ebs Drive Clutch)
    237
  - Drive Clutch Reassembly
    238
- Drive Clutch Bushing Service (Non Ebs and Ebs)
  239
- Non Ebs Driven Clutch
  242
- Driven Clutch Service (Ebs)
  247
- Driven Clutch Bushing Service
  254
- Troubleshooting
  256
Chapter 7 Final Drive

259
- Gearcase Fluid / Capacity
  260
- Special Tools
  260
- Specifications
  260
- Torque Table
  260
- Front Hub
  261
  - Disassembly
    261
  - Assembly
    261
- Front Gearcase Removal and Installiation (Adc and Non Adc)
  262
  - Gearcase Removal
    262
  - Gearcase Installation
    263
- Front Gearcase - Centralized Hilliard Non Adc (4X4)
  264
  - Operation Non Adc
    266
  - Disassembly / Inspection Non Adc
    267
  - Reassembly / Inspection Non Adc
    270
  - Front Gearcase Diagnosis
    272
  - Setting Ring Gear Backlash Non Adc
    274
- Front Gearcase - Centralized Hilliard Adc
  275
  - Operation
    275
  - Adc Gearcase Exploded View
    276
  - Adc Operation
    277
  - Front Gearcase Diagnosis
    278
  - Coil Testing
    279
  - Adc Differential Hydraulic Circuit Bleeding
    279
  - Disassembly / Inspection
    280
  - Adc Gearcase Piston Replacement Procedure
    284
  - Assembly
    285
  - Setting Ring Gear Backlash
    288
- Front Drive (CV) Shaft
  289
  - Inspection
    289
  - Removal
    289
  - Installation
    291
- Rear Hub
  292
  - Removal
    292
  - Disassembly
    293
  - Assembly
    294
  - Installation
    294
- Rear Drive (CV) Shaft
  295
  - Inspection
    295
  - Removal
    295
  - Installation
    296
- CV Drive Shaft Service
  297
- Prop Shaft - Front or Rear
  304
  - Removal and Installation
    304
- U-Joint Service
  305
  - Disassembly
    305
  - Assembly
    306
Transmission Chapter 8 Transmission

307
- Chapter 8
  308
- Lubrication
  308
- Special Tools
  308
- Torque Specifications
  308
- Transmission - General
  308
- Transmission Frame Mounts
  309
- Transmission Upper Frame Mount
  310
- Transmission Rear Stabilizer Mounts
  311
- Transmission Control Arm Bracket Mounts
  312
- Gear Selector Removal
  313
- Shift Linkage Inspection
  313
- Transmission Removal
  313
- Transmission Installation
  314
- Troubleshooting Checklist
  314
- 2012 Sportsman Transmission Exploded View
  315
- Transmission Disassembly / Assembly
  317
  - Transmission Disassembly
    317
  - Snorkel / Output Gear Backlash Procedure
    322
  - Transmission Assembly
    325
Brakes Chapter 9 Brakes

331
- Chapter 9
  332
- Component Service Limits
  332
- Specifications
  332
- Torque Table
  332
- Hydraulic Brake System
  333
  - Operation Overview
    333
  - Overview: Sportsman Forest 500 (Intl A12Mh50Ff)
    334
  - Brake Noise Troubleshooting
    334
  - Brake Bleeding / Fluid Change
    335
- Special Tools
  333
- Brake System Exploded Views
  337
  - Sportsman Touring 500 Ho Component Exploded View
    337
- Brake Caliper Exploded Views
  340
  - Sportsman 500 Ho Touring Rear Caliper Assembly (Non Intl.)
    340
  - Sportsman Forest 500 (Intl.) Front Caliper Assembly
    341
- Front Master Cylinder All Models
  342
  - Removal
    342
  - Installation
    342
- Front Brakes
  343
  - Pad Removal
    343
  - Assembly
    344
  - Brake Burnishing Procedure
    345
- Front Brake Disc
  345
- Front Caliper
  347
  - Removal
    347
  - Inspection
    348
  - Reassembly
    348
  - Installation
    349
- Rear Brake Pad
  350
  - Touring Pad Removal
    350
  - Touring Pad Installation
    351
  - Sportsman Rear Pad Removal
    352
  - Sportsman Rear Pad Installation
    353
  - Brake Burnishing Procedure
    353
- Touring Rear Caliper
  354
  - Removal
    354
  - Inspection
    355
  - Reassembly
    355
- Sportsman Rear Caliper
  356
  - Removal and Inspection
    356
  - Assembly
    357
- Rear Brake Disc
  359
- Rear Master Cylinder
  360
- Troubleshooting
  364
Chapter 10 Electrical

365
- General Information
  367
- Ignition System / Basic Electrical Components
  367
- Special Tools
  367
- Electrical Service Notes
  368
- Troubleshooting
  368
- Instrument Cluster
  369
  - Overview
    369
  - Instrument Cluster Diagnostic Mode
    371
  - Setting a New Service Interval
    373
  - Efi Diagnostic Mode
    374
  - Speedometer Removal
    375
  - Speedometer Installation
    375
- All Wheel Drive and Speedometer Troubleshooting
  376
- All Wheel Drive (Awd) Coil
  381
  - Operation Overview
    381
  - Diagnosing System Failures
    381
- Cooling System Components
  381
  - Fan Control Circuit Operation
    381
  - Fan Control Bypass Test - Efi
    381
  - Fan Control Bypass Test - H.o
    381
  - Fan Motor Current Draw Test
    382
  - Coolant Temperature Sensor - Efi
    382
  - Coolant Temperature Fan Switch - H.o
    383
- Gear Position Indicator Switch
  383
  - Test Diagram
    383
- Electronic Throttle Control (Etc) Switch
  384
  - Operation Overview
    384
  - Etc Test
    384
- Ignition System
  385
  - Overview
    385
  - Components of Alternator and DC / CDI Ignition System
    386
  - Efi Ignition System Testing Flow Chart
    387
  - Crankshaft Position Sensor Gap
    387
  - Ignition Troubleshooting
    388
  - Ignition Output Test Using Gap Tester
    388
- Charging System
  388
  - Current Draw - Key off
    388
  - Break Even Test
    389
  - Charging System Testing Diagrams
    391
- Relays
  393
- Fuses/Circuit Breaker
  394
- Lighting
  394
  - High Beam Headlight Bulb Replacement
    394
  - Headlight Housing Replacement
    395
  - High Beam Headlight Adjustment
    396
  - Lower Headlamp Removal / Installation
    396
  - Low Beam Headlight Adjustment (Non Intl)
    397
  - Lower Headlight Adjustment (Forest Tractor)
    398
  - Headlamp Switch Test
    398
  - Brake Light Replacement
    399
  - Brake Light Switch
    399
- Fuel Sender
  400
- Speed Sensor
  400
- Accessory Power
  401
- Starter System
  401
  - Troubleshooting
    401
  - Voltage Drop Test
    402
  - Starter Lockout Troubleshooting- Efi
    402
  - Starter Lockout Troubleshooting- H.o
    402
  - Starter Lockout Diagram- Efi
    403
  - Starter Lockout Diagram- Carb
    403
  - Starter Motor Removal / Disassembly
    404
  - Brush Inspection / Replacement
    404
  - Armature Testing
    405
  - Starter Solenoid Bench Test
    406
  - Starter Exploded View
    406
- Starter Drive
  407
- Starter System Testing Flow Chart
  408
- Battery
  409
  - Battery Identification
    409
  - Battery Conductance Analyzer
    409
  - Battery Activation (Conventional)
    410
  - Battery Terminals/Bolts
    410
  - Conventional Battery Inspection / Removal
    411
  - Conventional Battery Installation
    411
  - Conventional Battery Testing
    411
  - Conventional Battery Ocv - Open Circuit Voltage Test
    412
  - Conventional Battery Specific Gravity Test
    412
  - Battery Load Test
    412
  - Off Season Storage
    413
  - Charging Procedure
    413
  - Low Maintenance Battery
    414
  - Low Maintenance Battery Charging
    415
  - Low Maintenance Battery Inspection / Removal
    415
  - Low Maintenance Battery Installation
    415
  - Low Maintenance Battery - Ocv- Open Circuit Voltage Test
    416
  - Low Maintenance Battery Load Test
    416
  - Low Maintenance Battery Charging Procedure
    417
  - Low Maintenance Battery Off-Season Storage
    417
- Troubleshooting Diagrams
  418
- Sportsman 500 Efi Forest Tractor Electrical
  420

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