polaris sportsman (2012)
WORKSHOP, SERVICE, REPAIR MANUAL
POLARIS 400 & 500 SPORTSMAN (2012) - WORKSHOP, SERVICE, REPAIR MANUAL - English Service Manual and Wiring Diagram to ATVs Polaris 400 & 500 Sportsman (2012). CONTENTS: CHAPTER 1 - GENERAL INFORMATION MODEL NUMBER INFORMATION - Model Number - Vehicle Identification Number (VIN) - Engine Designation Numbers - Vehicle and Engine Serial Numbers - Transmission I.D. Location - Publication Part Numbers Vehicle Specifications - 2012 Sportsman 400 H.O. - 2012 Sportsman 500 H.O. - 2012 Sportsman Touring 500 HO - 2012 Sportsman Forest Tractor 500 EFI Specifications MODEL NUMBER: A12MN50ET, EX MISC. NUMBERS/CHARTS - Conversion Table - Standard Bolt Torque Specification - Metric Bolt Torque Specification - SAE Tap Drill Sizes - Metric Tap Drill Sizes - Decimal Equivalents - Paint Codes - Replacement Keys - Glossary Of Terms CHAPTER 2 - MAINTENANCE SPECIAL TOOLS MAINTENANCE - Periodic Maintenance Chart - Maintenance Chart Key - Periodic Maintenance Chart LUBRICANTS / SERVICE PRODUCTS - Polaris Lubricants, Maintenance and Service Products LUBRICATION / FLUIDS - Pre-Ride / Daily Inspection - Lubrication Components - Front Gearcase Lubrication - Transmission Lubrication ADC SYSTEM (IF EQUIPPED) - ADC System Fluid Reservoir Location - ADC Differential Hydraulic Circuit Fluid Change VEHICLE INSPECTION - Shift Link Rod Inspection - Throttle Inspection - Throttle Cable / Electronic Throttle Control (ETC Switch) Adjustment - Fuel System - Fuel Lines - Vent Lines - Choke (Enricher) Adjustment - (500 Carb) - Compression Test - Engine Mounts - Spark Plug - Battery Maintenance - Liquid Cooling System Overview - Coolant Strength / Type - Cooling System Hoses - Radiator/Grill Screen - Cooling System Pressure Test - Coolant Level Inspection - Radiator Coolant Level - Air Filter/Pre-Filter Service - Air Box Sediment Tube - Breather Filter Inspection - Breather Hose - Recoil Housing - Engine Oil Level - Oil and Filter Change - Oil Pump Priming Procedure - Valve Clearance - Intake Valve Clearance Adjustment - Exhaust Valve Clearance Adjustment - Steering - Tie Rod End/Steering Inspection - Camber and Caster - Wheel Alignment - Toe Alignment Adjustment - Exhaust Pipe - Brake System Inspection - Brake Pad Inspection - Hose/Fitting Inspection - Auxiliary Brake Testing - Auxiliary Brake Adjustment (Hydraulic) - Suspension Spring Preload Adjustment - Front Suspension - CV Shaft Boot Inspection - Controls - Wheels - Wheel, Hub, And Spindle Torque Table - Wheel Removal Front or Rear - Wheel Installation - Tire Pressure - Tire Inspection - Frame, Nuts, Bolts, Fasteners CARBURETOR MAINTENANCE - Choke (Enricher) Adjustment (Non EFI) - Pilot Screw - Pilot Screw Adjustment - Idle Speed Adjustment (Non EFI) - Fuel Filter (Non EFI) - Carburetor Draining - Maintenance Schedule CHAPTER 3 - ENGINE SPECIFICATIONS - Torque Specifications - Engine Fastener Torque Patterns - Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted) - Sportsman 500 H.O. Engine Service Data (EH50PLE 498cc Fuel Injected and Carbureted) - Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted) - Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted) SPECIAL TOOLS GENERAL ENGINE SERVICE - Cooling System Specifications - Cooling System - Accessible Components - Engine Removal - Engine Installation Notes - Cylinder Hone Selection/ Honing Procedure - Honing To Oversize - Cleaning the Cylinder After Honing - Crankshaft Straightening - Engine Lubrication - Oil Pressure Test - Oil Flow - Oil Flow Diagram - Engine Exploded Views ENGINE DISASSEMBLY - Cam Chain Tensioner / Rocker Arm / Camshaft Removal - Cam Chain Tensioner Inspection - Rocker Arm / Shaft Inspection - Camshaft Removal - Automatic Compression Release Removal / Inspection - Automatic Compression Release Installation - Camshaft Inspection - Cylinder Head Removal - Cylinder Head Exploded View - Cylinder Head Inspection - Cylinder Head Warpage - Cylinder Head Disassembly - Valve Inspection - Combustion Chamber - Valve Seat Reconditioning - Cylinder Head Assembly - Valve Sealing Test - Valve Clearance Adjustment - Cylinder / Piston Removal and Inspection - Piston Removal - Cylinder Inspection - Cylinder Hone Selection / Honing Procedure - Honing to Oversize - Cleaning the Cylinder After Honing - Piston-to-Cylinder Clearance - Piston / Rod Inspection - Piston Identification - Piston Ring Installed Gap - Crankcase Disassembly - Starter Drive Removal / Inspection - Flywheel and Stator Removal / Inspection - Cam Chain / Tensioner Blade - One Way Valve - Crankcase Separation - Oil Pump Removal / Inspection - Oil Pump Assembly - Counter Balancer Shaft Removal / Inspection - Crankshaft Removal / Inspection - Crankcase Bearing Inspection - Oil Seal / Mechanical Seal Removal (Engine Disassembled) - Crankcase Inspection - Bearing Installation - End Play Inspection / Adjustment - Crankshaft End Play Adjustment - Counter Balancer Shaft End Play Adjustment - Oil Pump Shaft End Play Adjustment ENGINE REASSEMBLY - Pump Shaft Oil Seal Installation - Crankshaft / Counter Balance / Oil Pump Installation - Crankcase Assembly - Water Pump Mechanical Seal Installation - Water Pump Mechanical Seal Removal (Engine Installed) - One Way Valve Installation - Cam Chain Drive Sprocket Installation - Tensioner Blade Installation - Piston Ring Installation - Piston Installation - Cylinder Installation - Cylinder Head Installation - Cam Chain / Camshaft Installation - Camshaft Timing - Camshaft Timing Illustration - Cam Chain Tensioner Installation - Stator, Flywheel and Starter Drive Installation - Rocker Shaft / Rocker Arm Assembly Installation - Thermostat Installation - Oil Pipes - Oil Pump Priming Procedure RECOIL (Accessory) - Recoil Disassembly/Inspection - Recoil Assembly TROUBLESHOOTING - Spark Plug Fouling - Engine - Cooling System CHAPTER 4 - FUEL SYSTEMS CHAPTER 4 - CARBURATION General Information and Specifications - Carburetor Jetting - Mikuni Jet Part Numbers - Special Tools Carburetion - BST 40 Carburetor Exploded View 1 of 2 - BST 40 Carburetor Exploded View 2 of 2 - CV Carburetor System Function - Mikuni CV Carb Operation - Carburetor Venting - Starter System (Choke or Enrichment) - Pilot (Idle and Slow) System - Main System - Float System - Pilot Screw - Air/Fuel Mixture Ratio - Jet Needle - Needle Jet - Throttle Opening vs. Fuel Flow - Carburetor Disassembly – Mikuni CV - Carburetor Cleaning - Carburetor Inspection - Carburetor Assembly - Float Height Adjustment - Needle and Seat Leakage Test - Fuel Level Test CARBUTATED Fuel Tank / Fuel Delivery System - Fuel System Exploded View Fuel Pump (CARBURATED) - Fuel Filter Replacement (Carbureted) FUEL GAUGE SENDING UNIT TEST - Fuel Sending Unit Test Fuel PICK-UP / Sending Unit Replacement (CARB.) - Fuel Pick-up / Sending Unit Replacement Fuel Tank Vent Routing (non INTL) - Fuel Tank Vent Hose Routing 500 H.O. INTERNATIONAL EMISSIONS SYSTEM - Overview Troubleshooting - Fuel Starvation/Lean Mixture CHAPTER 4 - EFI SPECIAL TOOLS - Part Numbers / Descriptions 500 EFI TRACTOR SPEED CONTROL - System Operation Overview - Air Control Body Removal and Disassembly - Air Control Body Assembly and Installation - Air Solenoid Valve Test / Replacement - Exhaust System EFI SERVICE NOTES - General Service Information EFI SYSTEM EXPLODED VIEW EFI SYSTEM - Component Locations/Identification FUEL SYSTEM AND FUEL TANK - Fuel System and Fuel Tank Exploded View ELECTRONIC FUEL INJECTION - General Information - EFI Operation Overview - Initial Priming / Starting Procedure FUEL LINES - Quick Connect Removal/Installation ELECTRONIC CONTROL UNIT (ECU) - Operation Overview - ECU Replacement - ECU Service FUEL PUMP ASSEMBLY - Operation / Testing - FUEL PUMP TEST - Fuel Tank Replacement - Fuel Sending Unit Test - Fuel Pump Replacement FUEL PRESSURE REGULATOR - General Information FUEL FILTER - General Information FUEL INJECTOR - General Information CRANKSHAFT POSITION SENSOR (CPS) - General Information MANIFOLD AIR PRESSURE SENSOR (MAP) - Operation Overview - Map Sensor Test - Map Sensor Replacement INTAKE AIR TEMPERATURE SENSOR (IAT) - Operation Overview - Intake Air Temperature Sensor Test - Intake Air Temperature Sensor Replacement I DLE AIR CONTROL (IAC) - General Information THROTTLE POSITION SENSOR (TPS) - Operation Overview - Throttle Position Sensor Test - Throttle Position Sensor Replacement - Throttle Position Sensor Initialization ENGINE TEMPERATURE SENSOR - General Information - Engine Temperature Sensor Test - Engine Temperature Sensor Replacement FUEL SYSTEM TROUBLESHOOTING - FUEL STARVATION / LEAN MIXTURE EFI DIAGNOSTICS USING ‘BLINK CODES’ - Blink Codes - Operation DIGITAL WRENCH™ OPERATION - Digital Wrench™ Diagnostic Software Overview - Special Tools (also refer to page 3.2) - Diagnostic Software Version - ECU Replacement - Guided Diagnostic Available - Digital Wrench™ Communication Errors - Digital Wrench™ - Diagnostic Connector - Digital Wrench™ Version and Update ID - Digital Wrench™ Updates - Digital Wrench™ Serial Number Location - Digital Wrench™ Feature Map - Engine Controller Reprogramming (Reflash) TROUBLESHOOTING DIAGRAMS - EFI CIRCUIT - Power On - EFI CIRCUIT - Crank Position Sensor - EFI CIRCUIT - Fuel Pump - EFI CIRCUIT - Ignition Coil - EFI CIRCUIT - Idle Air Control - EFI CIRCUIT - Throttle Position Sensor - EFI CIRCUIT - Manifold Absolute Pressure Sensor - EFI CIRCUIT - Engine Coolant Temperature - EFI CIRCUIT - Air Temperature Sensor - EFI CIRCUIT - Malfunction Indicator Light CHAPTER 5 - BODY / STEERING / SUSPENSION GENERAL INFORMATION - Torque Specifications - Special Tools - Decal Replacement - Plastic Insert Removal / Installation BODY - Side Panel Removal - Front Storage Box Lid / Front Rack and Access Panel Removal / Installation - Foot Well Removal / Installation - Front Bumper Removal / Installation - Mud Guard Removal / Installation - Front Fender Removal/Installation - Front Rack / Storage Box Lid Assembly - Front Cab Assembly - Front Bumper Assembly - Rear Rack Assembly - Rear Cab And Seat Assembly - Rear Storage Box Assembly - Winch and Front Bumper Mounting - Headlight Pod Exploded View 500 EFI TRACTOR SEAT ASSEMBLY - Overview - Seat Dampener Repair - Seat Pivot Repair - 500 EFI Tractor Seat Assembly Exploded View 500 EFI TRACTOR STEERING POST AND LOCK - Steering Assembly Exploded View STEERING - Handlebar Block Installation Procedure - Steering / A-arm Exploded View - A-Arm Replacement - Ball Joint Replacement - Steering Post Removal - Steering Post Assembly SUSPENSION - Front Strut Cartridge Replacement - Strut Assembly - Sportsman Rear Suspension Assembly - Torsion Bar Exploded View CHAPTER 6 - CLUTCHING SPECIAL TOOL and SUPPLIES TORQUE SPECIFICATIONS - PVT System Fastener Torques PVT SYSTEM OVERVIEW - General Operation - Drive Clutch Operation - Driven Clutch Operation - PVT Break-In (Drive Belt / Clutches) - Maintenance / Inspection - Clutching Chart - Overheating / Diagnosis PVT EXPLODED VIEWS - PVT Sealing And Ducting Components - Drive Clutch Exploded Views (EBS vs. Non-EBS) PVT SYSTEM SERVICE - Disassembly - Assembly DRIVE BELT - Belt Removal - Belt Inspection - Belt Installation - PVT Break-In (Drive Belt / Clutches) CLUTCH ALIGNMENT - Clutch Alignment Tool Use - Belt Deflection (Tension) CLUTCH CENTER DISTANCE - Setting Center-To-Center Distance DRIVE CLUTCH SERVICE (non EBS) - Exploded View (NON EBS) - Clutch Disassembly - Drive Clutch Spring Inspection - Shift Weight Inspection - Spider Removal - Button To Tower Clearance Inspection - Shift Weight Inspection - Bearing Inspection - Clutch Inspection - Moveable Sheave Bushing Inspection - Clutch Assembly EBS DRIVE CLUTCH SERVICE - EBS Drive Clutch Exploded View - Drive Clutch Disassembly - Spider Removal - Button To Tower Clearance Inspection - Shift Weight Inspection - Drive Clutch Inspection - Moveable Sheave Bushing Inspection - One-Way Clutch Inspection (EBS Drive Clutch) - Drive Clutch Reassembly DRIVE CLUTCH BUSHING SERVICE (NON EBS and EBS) - Bushing Service DRIVEN CLUTCH SERVICE (NON EBS) - Exploded View (NON EBS) - Clutch Disassembly / Inspection - Clutch Assembly DRIVEN CLUTCH SERVICE (EBS) - Driven Clutch Exploded Views (EBS) - Clutch Disassembly - Clutch Assembly Driven Clutch Bushing service - Driven Clutch Bushing Service (NON EBS and EBS) TROUBLESHOOTING CHAPTER 7 - FINAL DRIVE SPECIFICATIONS - Torque Table - Special Tools - Gearcase Fluid / Capacity FRONT HUB - Disassembly - Assembly FRONT GEARCASE REMOVAL AND INSTALLIATION (ADC AND NON ADC) - Gearcase Removal - Gearcase Installation FRONT GEARCASE - CENTRALIZED HILLIARD NON ADC (4x4) - Operation NON ADC - Disassembly / Inspection NON ADC - Reassembly / Inspection NON ADC - Front Gearcase Diagnosis - Setting Ring Gear Backlash NON ADC FRONT GEARCASE - CENTRALIZED HILLIARD ADC - Operation - ADC Gearcase Exploded View - ADC Operation - Front Gearcase Diagnosis - Coil Testing - ADC Differential Hydraulic Circuit Bleeding - Disassembly / Inspection - ADC Gearcase Piston Replacement Procedure - Assembly - Setting Ring Gear Backlash FRONT DRIVE (CV) SHAFT - Inspection - Removal - Installation REAR HUB - Removal - Disassembly - Assembly - Installation REAR DRIVE (CV) SHAFT - Inspection - Removal - Installation CV DRIVE SHAFT SERVICE - Drive Shafts and Propshafts Components - Drive Shaft and CV Joint Handling Tips - Outer CV Joint / Boot Replacement - Inner Plunging Joint / Boot Replacement - Drive Shaft Exploded Views PROP SHAFT - FRONT OR REAR - Removal and Installation U-JOINT SERVICE - Disassembly - Assembly CHAPTER 8 - TRANSMISSION TRANSMISSION - GENERAL - Torque Specifications - Special Tools - Lubrication - Transmission Frame Mounts - Transmission Upper Frame Mount - Transmission Rear Stabilizer Mounts - Transmission Control Arm Bracket Mounts - Shift Linkage Inspection - Gear Selector Removal - Transmission Removal - Transmission Installation - Troubleshooting Checklist 2012 SPORTSMAN TRANSMISSION EXPLODED VIEW - 2012 Sportsman Transmission Exploded View tRANSMISSION dISASSEMBLY / aSSEMBLY - Transmission Disassembly - Snorkel / Output Gear Backlash Procedure - Transmission Assembly CHAPTER 9 - BRAKES SPECIFICATIONS - Torque Table - Component Service Limits SPECIAL TOOLS - Special Tools HYDRAULIC BRAKE SYSTEM - Operation Overview - Overview: Sportsman Forest 500 (INTL A12MH50FF) - Brake Noise Troubleshooting - Brake Bleeding / Fluid Change BRAKE SYSTEM Exploded Views - Sportsman Touring 500 HO Component Exploded View - Sportsman 400 HO, 500 HO and International Forest Component Exploded View - Sportsman Forest Tractor 500 (INTL A12MH50FF) Component Exploded View BRAKE CALIPER EXPLODED VIEWS - Sportsman 400 HO, 500 HO, Touring and Forest 500 (INTL.) Front Caliper Assembly - Sportsman 500 HO Touring Rear Caliper Assembly (non INTL.) - 400, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.) Rear Caliper Assembly - Sportsman Forest 500 (INTL.) Front Caliper Assembly FRONT MASTER CYLINDER All Models - Removal - Installation FRONT BRAKES - Pad Removal - Assembly - Brake Burnishing Procedure FRONT BRAKE DISC - Inspection - Removal / Replacement FRONT CALIPER - Removal - Inspection - Reassembly - Installation REAR BRAKE PAD - Touring Pad Removal - Touring Pad Installation - Sportsman Rear Pad Removal - Sportsman Rear Pad Installation - Brake Burnishing Procedure TOURING REAR CALIPER - Removal - Inspection - Reassembly Sportsman REAR CALIPER - Removal and Inspection - Assembly REAR BRAKE DISC - Inspection REAR MASTER CYLINDER - Sportsman 500 HO Touring Exploded View (Non Intl) - Sportsman 400 HO, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.) - Overview - Touring Rear Master Cylinder Removal and Installation - Sportsman Rear Master Cylinder Removal / Installation - Pedal Removal and Installation TROUBLESHOOTING - Brakes Squeal - Poor Brake Performance - Lever Vibration - Caliper Overheats (Brakes Drag) - Brakes Lock CHAPTER 10 - ELECTRICAL GENERAL INFORMATION - Special Tools - Ignition System / Basic Electrical Components - Electrical Service Notes - Troubleshooting INSTRUMENT CLUSTER - Overview - Instrument Cluster Diagnostic Mode - Setting A New Service Interval - EFI Diagnostic Mode - Speedometer Removal - Speedometer Installation ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING - TEST 1 - No All Wheel Drive - TEST 2 - No Speedometer Display - TEST 3 - No Reverse Speed Limit - TEST 4 - No AWD Hub Safety Limit - TEST 5 - Reverse Speed Limiter / TEST 6 - Speed Sensor - TEST 6 - Vehicle Speed Sensor - Speed Sensor Location - Speed Sensor Testing - TEST 7 - Fuel Gauge Display Not Working - TEST 8 - Shift Indicator Not Working ALL WHEEL DRIVE (AWD) COIL - Operation Overview - Diagnosing System Failures COOLING SYSTEM COMPONENTS - Fan Control Circuit Operation - Fan Control Bypass Test - EFI - Fan Control Bypass Test - H.O. - Fan Motor Current Draw Test - Coolant Temperature Sensor - EFI - Coolant Temperature Fan Switch - H.O. GEAR POSITION INDICATOR SWITCH - Test Diagram ELECTRONIC THROTTLE CONTROL (ETC) SWITCH - Operation Overview - ETC Test IGNITION SYSTEM - Overview - Components of Alternator and DC / CDI Ignition System - EFI Ignition System Testing Flow Chart - Crankshaft Position Sensor Gap - Ignition Troubleshooting - Ignition Output Test Using Gap Tester CHARGING SYSTEM - Current Draw - Key Off - Break Even Test - Alternator Output Test - Charging System Testing Diagrams RELAYS - Operation FUSES/Circuit Breaker - Operation LIGHTING - High Beam Headlight Bulb Replacement - Headlight Housing Replacement - High Beam Headlight Adjustment - Lower Headlamp Removal / Installation - Low Beam Headlight Adjustment (Non Intl) - Lower Headlight Adjustment (Forest Tractor) - Headlamp Switch Test - Brake Light Replacement - Brake Light Switch SPEED SENSOR - Testing - Replacement FUEL SENDER - Testing - ACCESSORY POWER - Wire Connections STARTER SYSTEM - Troubleshooting - VOLTAGE DROP TEST - Starter Lockout Troubleshooting- EFI - Starter Lockout Troubleshooting- H.O. - Starter Lockout Diagram- EFI - Starter Lockout Diagram- Carb - Starter Motor Removal / Disassembly - Brush Inspection / Replacement - Armature Testing - Starter Reassembly - Starter Solenoid Bench Test - Starter Exploded View STARTER DRIVE - Pinion Gear - Anti-Kick Out Shoe, Garter Spring Replacement STARTER SYSTEM TESTING FLOW CHART - Condition: Starter fails to turn motor. BATTERY - Battery Identification - Battery Conductance Analyzer - Battery Activation (Conventional) - Battery Terminals/Bolts - Conventional Battery Inspection / Removal - Conventional Battery Installation - Conventional Battery Testing - Conventional Battery OCV - Open Circuit Voltage Test - Conventional Battery Specific Gravity Test - Battery Load Test - Off Season Storage - Charging Procedure - Low Maintenance Battery - Low Maintenance Battery Charging - Low Maintenance Battery Inspection / Removal - Low Maintenance Battery Installation - Low Maintenance Battery - OCV- Open Circuit Voltage Test - Low Maintenance Battery Load Test - Low Maintenance Battery Charging Procedure - Low Maintenance Battery Off-season Storage TROUBLESHOOTING DIAGRAMS - All Wheel Drive - EFI - Fuel Pump - EFI - Fan Control - EFI SPORTSMAN 500 EFI Forest TRACTOR ELECTRICAL - Head Lamps / Tail Lamps - Exploded View - Hazard / Flasher Module - Rear Tail Lamp / Turn Signal Lamp Replacement - Front Turn Signal Lamp Replacement - Pod Indicator Lamp / Switch Replacement - Trailer Connector and Fuses - Speed Control Diagram WIRING DIAGRAMS
Polaris 400 and 500 Sportsman (2012) - Service Manual - Wiring Diagram
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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