Polaris A12MH46AX Bedienungsanleitung

GENERAL

MAINTENANCE

ENGINE

FUEL SYSTEMS

BODY / SUSPENSION

CLUTCH

FINAL DRIVE

TRANSMISSION

BRAKES

ELECTRICAL

NOTES

GENERAL INFORMATION

1.1

CHAPTER 1

GENERAL INFORMATION 1

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

MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE IDENTIFICATION NUMBER (VIN)1.2

ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2

VEHICLE AND ENGINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3

PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3

VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4

2012 SPORTSMAN 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4

2012 SPORTSMAN 500 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6

2012 SPORTSMAN TOURING 500 HO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.8

2012 SPORTSMAN FOREST TRACTOR 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10

MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

CONVERSION TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12

STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13

METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13

SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14

PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15

GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16

1.2

GENERAL INFORMATION

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

MODEL NUMBER INFORMATION

Model Number

The machine model number must be used with any correspondence regarding warranty or service.

Vehicle Identification Number (VIN)

Engine Designation Numbers

EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke,

Electric Start



EH46PLE - Single Cylinder, Liquid Cooled,4 Stroke,

Electric Start

Vehicle and Engine Serial Numbers

The machine model number and serial number are

important for vehicle identification. Be sure to refer to the

engine model number and serial number (A) whenever

corresponding about an engine. This information can be

found on the sticker applied to the top side of the

crankcase (A). An additional number is stamped on the

side of the crankcase beneath the cylinder coolant elbow.

The vehicle serial number is located:

400 / 500 Non Touring Vehicles (B)

500 Touring Vehicles (C)

A12 MN 50 AX

}

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

World

Mfg. ID

Engine

Vehicle Descriptor Vehicle Identifier



Check Digit

Model

Year

BodyStyle Plant NoIndividual Serial Number

* This could be either

a number or a letter

Powertrain

Emissions

4 X A M N 5 0 A * 0 P 0 0 0 0 0 0

1.3

GENERAL INFORMATION

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

Transmission I.D. Location

Publication Part Numbers

Year Model Model No. Owner's

Manual PN Parts

Manual PN

2012 Sportsman Touring 500

H.O. A12DH50AX, AZ 9923410 9923411

2012 Sportsman Touring 500

H.O.

International A12DH50FX 9923438 9923413

2012 Sportsman 400 H.O. A12MH46AX, AZ 9923420 9923421

2012 Sportsman 500 H.O. A12MH50AD, AQ, AX, AZ, 9923420 9923422

2012 Sportsman Forest 500

International A12MH50FF 9923423 9923424

2012 Sportsman Forest Tractor

500 EFI International A12MN50ET 9923430 9923431

The Transmission I.D. number is located

on the RH side transmission case; viewable

from the RH side of the vehicle.

1.4

GENERAL INFORMATION

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

VEHICLE SPECIFICATIONS

2012 Sportsman 400 H.O.

MODEL NUMBER: A12MH46AX, AZ, AF 



ENGINE MODEL: EH460PLE050

Category Dimension

Length 83 in. / 210.8 cm

Width 48 in. / 121.9 cm

Height 48 in. / 121.9 cm

Wheel Base 50.75 in. / 128.9 cm

Ground Clearance 11.25 in. / 28.6 cm

Dry Weight 688 lbs. / 312 kg

Front Rack Capacity 90 lbs. / 41 kg

Rear Rack Capacity 180 lbs. / 81.6 kg

Towing Capacity 1225 lbs. / 555.7 kg

Max. Weight Capacity 485 lbs. / 220 kg

Hitch Tongue Weight 120 lbs. / 34 kg

Unbraked Trailer Towing

Capacity(EU)

Data based on EU

Directive: 76/432/EEC

1786 lbs. / 810 kg

Engine

Platform Fuji 4-cycle, L/C, Single Cyl.

Engine Model Number EH460PLE050

Engine Displacement 455cc

Number of Cylinders 1

Bore & Stroke (mm) 87.9 x 75 mm

Compression Ratio 10.1:1

Compression Pressure 50-90 psi

Engine Idle Speed 1200+/- 200 RPM

Engine Max Speed 7000 RPM

Cooling System / Cap. Liquid / 2.7 qt. (2.5 L)

Overheat Warning HOT on Instrument Cluster

Lubrication Dry Sump

Oil Requirements PS-4 Plus / 2 qt. (1.9 L)

Exhaust System Single Pipe - USFS Approved

Carburetion

Carburetor model Mikuni BST 34mm

Main Jet 160

Pilot Jet / Pilot Air Jet 42.5 / 160

Jet Needle 4IB33-3

Needle Jet P-6M

Pilot / Air Screw 2.75 Turns Out (Initial setting)

Float Height 13mm from carburetor body

Fuel Delivery Fuel Pump (Impulse)

Fuel Capacity / 4.25 gal. (16 L)

Fuel Requirement

(Octane) 87 Octane (minimum)

89 Oxygenated

Electrical

Alternator Output 260 watt @ 3000 RPM

Voltage Regulator 3-Phase PDM

Pod Lighting 1x 12V / 50 Watts

Grill Lighting 2x 12v / 50 Watts

Brake Light 12V / 26.9 watts

Tail Light 12V / 8.26 watts

Ignition System DC / CDI

Ignition Timing 30° ± 2° BTDC @ 5000 RPM

Spark plug / Gap NGK BKR6E / .035 in. (.9 mm)

Battery Maintenance-Free / 12 Amp Hr.

Circuit Breakers 10A - Accessory / 10A - Fan /

15A - Main Harness

Starting Electric

Instrument Cluster Digital Gauge LCD, Analog

Speedometer

1.5

GENERAL INFORMATION

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

JETTING CHART

Drivetrain

Transmission Type In-Line H/L/N/R/P

Transmission Fluid Type 

/ Fluid Capacity AGL Plus 33.8 oz.

(1000 ml)

FrontGearcaseFluidType

/ Fluid Capacity Polaris Demand Drive Hub

Fluid / 8.97 oz / 265 ml

Gear Ratio :

Low (Front/Rear)

Rev (Front/Rear)

High (Front/Rear)

7.70:1/23.91:1

7.00:1/21.74:1

3.41:1/10.57:1

Clutch Type CVT

Belt 3211077

Steering / Suspension

Front Suspension / Shock MacPherson Strut

Front Travel 8.2 in. / 20.8 cm

Rear Suspension / Shock IRS / Progressive Rate

Rear Travel 9.5. / 24.1 cm

Turning Radius 65in./165.1cm(unloaded)

Shock Preload Adjustment

Front / Rear Front -Non Adjustable.

Rear - Ratchet Style- Std.

Toe Out 0-1/16 in. (0-.159 mm)

Wheels / Brakes

Front Wheel Size

Front Tire Model / Size 12x5

NHS 489 / 25 x 8-12

Rear Wheel Size

Rear Tire Model / Size 12x8

NHS 489 / 25 x 10-12

Tire Air Pressure - F / R 5 psi (34.5 kPa)

Brakes - Front & Rear Single Control

Hydraulic Disc

Brake Fluid Polaris DOT 4 Brake Fluid

ALTITUDE AMBIENT TEMPERATURE

Below 40° F

Below 5° C Above +40° F

Above +5° C

Meters

(Feet)

0-1800

(0-6000) 167.5 160

1800-3700

(6000-

12000) 155 150

Table 1-1: Clutching (NON EBS)

Altitude Shift

Weight

Drive

Clutch

Spring

Meters

(Feet)

0-1800

(0-6000) 10WHF

5632283

Blue/ Grey

7042202

1800-3700

(6000-

12000)

20-40 or

10RH

5631356

(20-40)

5630709

(10RH)

1.6

GENERAL INFORMATION

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

2012 Sportsman 500 H.O.

MODEL NUMBER: 

A12MH50AX, AZ, AD, AQ, FF, FY, FX 



ENGINE MODEL: EH500PLE13B

Category Dimension / Capacity

Length 83 in./210.8 cm

Width 48 in./121.9 cm

Height 48 in./121.9 cm

Wheel Base 50.75 in./128.9 cm

Ground Clearance 11.25 in./28.6 cm

Dry Weight 696 lbs./313 kg

(Wet weight model FF, FY,

FX)

776 lbs / 352 kg)

Front Rack/Box Capacity 90 lbs./40.8 kg

Rear Rack Capacity 180 lbs./81.6 kg

Max. Weight Capacity 485 lbs. / 220 kg

Towing Capacity 1225 lbs ./ 555.7 kg

Unbraked Trailer Towing

Capacity (EU)*

NOTE: *Data based on

EU Directive: 76/432/EEC

1786 lbs. / 810 kg

Hitch Tongue Capacity

120 lbs./54.4 kg

Rear rack capacity and

tongue weight not to

exceed 180 lbs./82 kg

ENGINE

Platform Fuji Single Cylinder

Engine Model Number EH500PLE13B

Engine Displacement 498cc

Number of Cylinders 1

Bore & Stroke (mm) 92 x 75 mm

Compression Ratio 10.2:1

Compression Pressure 70-90 psi W/Compression

Release

Engine Idle Speed 1200+/- 200 RPM

Engine Max Operating Rpm 7000 Rpm ± 200 Rpm

Cooling System / Capacity Liquid - 2.7 qt / 2.5 litre

Overheat Warning HOT on Instrument Cluster

Lubrication Pressurized Dry Sump

Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 litre

Exhaust System Single Pipe USFS Approved

Fuel System

Carburetor Mikuni BST 40mm

Main Jet 150

Pilot Jet 40

Jet Needle / Clip Position 6MGH1-94-3

Needle Jet X-6M

Pilot Screw 1 Turn Out (initial)

Pilot Air Jet 40

Float Height 14.7mm ± 1 (.58 ± 0.40")

Fuel Delivery Fuel Pump

Fuel Capacity / Requirement 4.25 gal US / 15.5 liters

87 Octane (minimum)

or 89 Oxygenated

Electrical

Alternator Output 260 w @ 3000 RPM

Voltage Regulator 3-phase PDM

Lights : Pod 50 watts

Grill 2 x 50 watts

Brake 26.9 watts

Tail 8.26 watts

Ignition System DC/CDI Ignition

Ignition Timing 30°± 2° BTDC @ 5000 RPM

Spark plug / Gap BKR6E / .035 in. / 0.9 mm

Battery Maintenance-Free / 12 Amp

Hr.

Circuit Protection 5 / 15 / 20 Amp Fuses

10 Amp Circuit Breaker - Fan

Starting Electric

Instrument Cluster Analog Speedo w/ LCD

1.7

GENERAL INFORMATION

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

Table 1-2: Sportsman 500 H.O.

Drivetrain

Transmission Type Drumshift - H/L/N/R/P

Transmission Capacity AGL Plus 33.8 oz.

(1000 ml)

Front Gearcase Capacity 8.97 oz. / 265 ml

Gear Ratio :

Low (Front/Rear)

Rev (Front/Rear)

High (Front/Rear)

7.70:1/23.91:1

7.00:1/21.74:1

3.41:1/10.57:1

Clutch Type PVT Non-EBS

Belt 3211077

Steering / Suspension

Front Suspension / Shock A-arm / MacPherson Strut

Front Travel 8.2 in. / 20.8 cm

Rear Suspension / Shock Progressive Rate Indepen-

dent - w/ 2" Coil-over

shock

Rear Travel 9.5 in. / 24.13 cm

Ground Clearance 11.25 in. / 28.6 cm

Shock Preload Adjustment

Front / Rear Front -Non Adjustable.

Rear - Ratchet Style- Std.

Turning Radius 65 in./165.10 cm unloaded

Toe Out 0-1/16 in / .0 - .159 mm

Wheels / Brakes

Front Wheel Size

Front Tire Model / Size 12x5

NHS 489 / 25 x 8-12

Rear Wheel Size

Rear Tire Model / Size 12x8

NHS 489 / 25 x 10-12

Tire Air Pressure - F / R 5 psi (34.5 kPa)

Brakes - Front & Rear Single Control

Hydraulic Disc

Brake Fluid Polaris DOT 4 Brake

Fluid

Table 1-3: Sportsman 500 H.O. Jetting

Altitude AMBIENT TEMPERATURE

Below 40 ° F

Below 5 ° C +40 to +80 ° F

+5 to +28 ° C

M e t e r s

(Feet) 0-1800

(0-6000) 155 150

1800-3700

(6000-

12000) 147.5 142.5

Table 1-4: Clutching (EBS and NON EBS)

Altitude Shift

Weight Drive Clutch

Spring

Meter

(Feet)

0-1800

(0-6000) 10 WHF

(5632283) Green / Blue

(7041157)

1800-

3700

(6000-

12000)

10 RH

(5630709) Green / Blue

(7041157)

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