Polaris Sportsman 400 H.O. 2012 User Manual

Explains signal words (WARNING, CAUTION, NOTICE) and safety symbols.

Details on training, laws, and regulations for safe ATV operation.

Guidance on wearing appropriate clothing, helmets, eye protection, gloves, and boots.

Warning against modifications that affect speed/power; use of approved accessories.

Warnings about operating without training and age restrictions for safe use.

Safety guidelines for gasoline, exhaust fumes, and pre-operation inspection.

Warnings about alcohol/drugs and carrying passengers for safe operation.

Warnings about operating on pavement, public roads, and at excessive speeds.

Guidance on maintaining control, proper turning, hill climbing, and avoiding stunts.

Safety advice for descending hills and operating on sidehills to avoid hazards.

Guidance on climbing hills, handling stalls, and operating on steep inclines.

Advice for operating on slippery or unfamiliar terrain to prevent accidents.

Warnings on reverse operation, tire maintenance, obstacles, and skidding.

Guidelines for operating in deep water and for proper cargo loading.

Safety advice for frozen water, poor visibility, damaged ATVs, hot exhaust, and unauthorized use.

Explains the general warning label and its key precautions for safe operation.

Information on correct tire pressure and maximum weight capacity.

Warning against carrying passengers to prevent loss of control.

Prohibits operation by anyone under 16 years of age.

Warning about moving parts hazard under the clutch guard.

Limits for rack loads and warning against towing from racks.

Warnings about reverse operation and engaging AWD.

Explains the operation of the Mode/Reverse Override and AWD switches.

Describes the function of engine stop, main key, worklight, and headlight switches.

Explains throttle lever function, safety precautions, and Electronic Throttle Control (ETC).

Details brake lever operation, testing, and fluid level checks for safety.

Guide to checking brake fluid level in the master cylinder before riding.

How to lock and release the parking brake, with safety warnings.

Explains auxiliary foot brake operation, its backup function, and fluid level checks.

Explains choke, fuel valve, fuel tank cap, and fuel filter functions.

Operation of the gear selector and tips for extending drive belt life.

How to engage AWD, its automatic function, and tips for use.

Conditions and procedures for engaging and disengaging the ADC system.

Description of the instrument cluster, speedometer, and rider information center.

Details on gear, AWD, engine hour, service, fuel, and warning indicators.

Description of Odometer, Trip Meter, Hour Meter, Tachometer, and Clock modes.

Steps to enter diagnostic mode and procedures for resetting the clock.

How to manage service intervals and switch between miles/kilometers.

Essential practices for safe ATV operation, including training, age, and conduct rules.

Understanding riding areas, environmental responsibility, and trail etiquette.

Comprehensive checklist for inspecting vehicle condition before operation.

Step-by-step guide for starting the engine, including choke and interlock usage.

Details on activating the starter, handling non-starts, and proper engine warm-up.

Steps for starting, shifting, checking surroundings, and initial driving.

Explains how to steer and lean for smooth turns, with warnings against abrupt maneuvers.

Steps to take when riding on wet, gravel, or slippery terrain, including AWD engagement.

Guidelines for ascending hills, including AWD, weight shift, and speed.

Advice for navigating sidehills safely, including weight shift and steering.

Guidelines for descending hills safely, focusing on speed, braking, and weight shift.

Step-by-step guide for safely turning around on a hill (K-Turn).

Guidelines for operating the ATV in water, including depth limits and post-ride checks.

Advice on checking for and navigating obstacles safely, avoiding large ones.

Safety guidelines for operating the ATV in reverse, including checking for obstacles.

Guidelines for safe cargo hauling, weight distribution, and speed limits.

Details on cargo distribution (1/3 front, 2/3 rear) and towing load attachments.

Steps for safely parking the ATV on an incline, including blocking wheels.

Information on the noise emission control system and modifications.

Regulations and penalties for operating off-road vehicles on public lands.

Explanation of the closed crankcase emission control system.

Details on engine design for emission control and recommended adjustments.

Compliance information for electromagnetic interference.

Guide to regular inspection, adjustment, and lubrication of vehicle components.

Clarifies conditions considered severe use, requiring more frequent servicing.

Explains symbols used in the chart and warnings for improper maintenance.

Covers maintenance intervals for steering, suspension, brakes, fluids, and coolant.

Details intervals for battery, drive fluid, transmission oil, and filters.

Covers maintenance for clutches, wheel bearings, brake fluid, ADC fluid, and spark arrestor.

Details lubrication requirements for engine oil, brake fluid, transmission, and drive fluids.

Specifies Polaris Premium 4 synthetic oil and alternatives for optimal engine performance.

Steps for checking the engine oil level using the dipstick and maintaining the safe range.

Detailed steps for changing engine oil and filter, including torque specs.

Steps to prime the oil pump after oil and filter changes.

Instructions for checking and changing transmission oil level and procedure.

Detailed steps for changing transmission oil, including drain and fill plugs.

Procedures for checking and changing the front gearcase (demand drive) fluid.

Detailed steps for changing the front gearcase fluid, including torque specifications.

How to check the ADC fluid level in the reservoir.

Detailed steps for changing ADC fluid, including bleeding the system.

Explanation of the cooling system and how to maintain coolant levels.

Procedure for checking and adding coolant to the recovery bottle.

Steps for draining and replacing radiator coolant, with safety warnings.

Recommended checks for the hand brake system, including fluid leaks and pad wear.

Checking the brake fluid level for the auxiliary foot brake system.

Procedure to check toe alignment, with warnings against DIY adjustments.

Periodic checks for loose nuts and bolts in the steering assembly.

Steps for removing the side panel.

Steps for removing the footwell.

Guidelines for tire wear, tread depth, and wheel nut tightening.

Information on when to replace tires based on tread depth.

Critical operations for front wheel bearing tightness and spindle nut retention.

Step-by-step guide for removing a wheel from the ATV.

Steps for installing a wheel onto the ATV hub.

Torque specifications for lug nuts and 2-piece flange nuts.

Steps for inspecting, cleaning, and replacing the air filter and pre-filter.

Procedure for inspecting, cleaning, or replacing the breather filter and hose.

Steps for locating, removing, and replacing blown fuses in the fuse panel.

Steps for replacing a headlight lamp, with precautions for handling.

Procedure for adjusting high and low beams for optimal visibility.

Steps for removing and installing the headlight housing assembly.

Procedure for replacing the lower headlamp assembly.

Steps for replacing taillight, brakelight, or worklight lamps.

Information on recommended spark plug types and torque specifications.

How to inspect spark plug condition to diagnose engine operation.

Diagnosing engine health based on normal and wet fouled spark plug conditions.

Steps for handling engine damage after vehicle immersion and drying procedures.

Procedure for purging accumulated carbon from the exhaust pipe/muffler.

Owner responsibilities for PVT system safety and adherence to maintenance.

Details on engine speed, torque, and gear ratios affecting PVT operation.

Guidance on selecting low or high range based on speed, load, and terrain.

Steps to dry the PVT system after water ingestion.

Warnings about connecting/disconnecting battery cables, electrolyte hazards, and gas.

Steps for safely removing the battery from the vehicle.

Steps for correctly installing a new battery, including cable connections.

Recommendations for storing the battery during long periods of non-use.

How to check and maintain the fluid level in conventional batteries.

Instructions for charging conventional batteries, including output limits.

Instructions for charging sealed batteries, including voltage checks and charge times.

Proper methods for washing the ATV by hand or with a garden hose.

Tips to avoid scratches and damage during washing.

Using aerosol furniture polish for vehicle finish care.

Advice on using clean cloths and avoiding automotive products for polishing.

How to clean and protect chrome wheels from corrosion.

Using steel wool to remove light rust from chrome finishes.

Cleaning the exterior and stabilizing the fuel for storage.

Steps for adding fuel treatment and running the engine to disperse it.

Instruction to change oil and filter before storage.

Inspect/clean air filter, clean air box, drain sediment tube, check breather filter.

Inspect and adjust fluid levels (drive, ADC, transmission, brake, coolant) before storage.

Procedure to coat internal engine parts with oil for long-term storage.

Tips for selecting a storage area and using appropriate covers.

Information on auxiliary power outlets and other approved accessories.

Steps for safely securing the ATV for transport, including tie-down points.

Notes that camber and caster are non-adjustable.

How to adjust the rear shock absorber spring tension.

Procedure for adjusting handlebar height for rider preference.

Information on factory calibration, altitude effects, and jetting.

How to adjust the engine idle RPM for optimal performance.

Procedure for adjusting throttle cable freeplay at the handlebar.

Troubleshooting common causes for drive belt wear/burn and their solutions.

Solutions for issues preventing the engine from turning over.

Troubleshooting steps when the engine cranks but won't start.

Common causes and solutions for engine backfiring.

Solutions for engine pinging or knocking due to fuel or timing.

Troubleshooting for irregular engine running, stalling, or misfires.

Solutions for engine stopping or losing power due to various causes.

Steps to address engine overheating, including radiator and fan checks.

List of recommended engine oils and fogging oil.

Recommended lubricants for gearcase and transmission.

Recommended coolant types and mixtures.

List of greases, chain lube, and dielectric grease.

Carbon clean, fuel stabilizer, brake fluid, thread sealant, and charger.

Key specifications including weight, capacities, dimensions, and engine details.

Recommended carburetor jetting for different altitude and temperature conditions.

Clutch spring and weight specifications for different altitudes.

Details the six-month limited warranty on ATV components.

Explains the importance and procedure for registering the ATV for warranty.

Lists exclusions from warranty coverage and limitations on remedies.

Details limitations on implied warranties like merchantability and fitness.

Steps for obtaining warranty service from an authorized Polaris dealer.

Warranty implications of using recommended vs. non-recommended engine oil.

Warranty coverage for the spark arrestor's efficiency.

Policy on warranty coverage for vehicles sold outside the country of purchase.

How to get service when traveling or moving to another country.

Warranty is denied for Polaris products purchased from private citizens outside the country.

Vehicle registration outside purchase country may void warranty if procedures not followed.

Details the emissions warranty period and covered components.

Section to record vehicle service dates, mileage, technician, and performed services.

Blank section for recording vehicle maintenance and service history.