2012 Polaris Sportman 850 MV Parts Catalog Manual

Parts Catalog SPORTSMAN 850 MV M12ZN8EAA/EAI 2012 2012 9923719 Rev. 02 Parts Manual Read the Operator's manual entirely. When you see this symbol, the subsequent instructions and warnings are serious - follow without exception.Your life and the lives of others depend on it! © Copyright 2011 Printed 12/07/11 Cover photo may show optional equipment not supplied with standard unit.

Selected Models Illustrated Parts Lists....................................................4 BODY, CLUTCH COVER....................................................4 BODY, DECALS..................................................................6 BODY, FOIL, FUEL TANK, RESERVE................................8 BODY, FRONT BUMPER and MOUNTING......................10 BODY, FRONT CAB.........................................................12 BODY, FRONT RACK and BRUSHGUARD.....................14 BODY, FRONT RACK SUPPORT....................................16 BODY, FUEL TANK, MAIN................................................18 BODY, FUEL TANK, RESERVE........................................20 BODY, HEADLIGHT POD.................................................22 BODY, LITTER CARRIER AND IR UPFIT........................24 BODY, REAR CAB, FOOTWELLS and SUPPORTS........26 BODY, REAR RACK and BRUSHGUARD........................28 BODY, ROLLBAR and FOOTWELL TUBES.....................30 BODY, SEAT.....................................................................32 BODY, SKID PLATES.......................................................34 BRAKES, BRAKE LINES.................................................36 BRAKES, BRAKE PEDAL and MASTER CYLINDER......38 BRAKES, FRONT BRAKE LEVER and MASTER CYLINDER.......................................................................40 BRAKES, FRONT CALIPER............................................42 BRAKES, REAR CALIPER..............................................44 CHASSIS, MAIN FRAME.................................................46 DRIVE TRAIN, DRIVE COUPLER...................................48 DRIVE TRAIN, DRIVE SHAFT, FRONT...........................50 DRIVE TRAIN, DRIVE SHAFT, REAR.............................52 DRIVE TRAIN, FRONT GEARCASE INTERNALS..........54 DRIVE TRAIN, GEAR SELECTOR..................................56 DRIVE TRAIN, GEARCASE MOUNTING, FRONT..........58 DRIVE TRAIN, GEARCASE MOUNTING, REAR............60 DRIVE TRAIN, MAIN GEARCASE...................................62 DRIVE TRAIN, PRIMARY CLUTCH.................................66 DRIVE TRAIN, PROP SHAFT, FRONT............................68 DRIVE TRAIN, PROP SHAFT, REAR..............................70 DRIVE TRAIN, REAR GEARCASE INTERNALS.............72 DRIVE TRAIN, SECONDARY CLUTCH...........................74 ELECTRICAL, BATTERY.................................................76 ELECTRICAL, BULBS.....................................................78 ELECTRICAL, GAUGES and INDICATORS....................80 ELECTRICAL, HARNESS................................................82 ELECTRICAL, HEADLIGHTS..........................................84 ELECTRICAL, IGNITION SYSTEM.................................86 ELECTRICAL, SWITCHES, SENSORS, ECU and CONTROL MODULES........................................................................88 ELECTRICAL, TAILLIGHTS.............................................90 ENGINE, AIR INTAKE......................................................92 ENGINE, BALANCE SHAFT............................................94 ENGINE, CAM CHAIN.....................................................96 ENGINE, COOLING BYPASS..........................................98 ENGINE, COOLING SYSTEM.......................................100 ENGINE, COOLING SYSTEM and WATER PUMP........102 ENGINE, COOLING SYSTEM, RADIATOR SHIELD.....104 ENGINE, CRANKCASE.................................................106 ENGINE, CRANKSHAFT and PISTON..........................108 ENGINE, CYLINDER HEAD, CAM and VALVES...........110 ENGINE, EXHAUST.......................................................112 ENGINE, MOUNTING....................................................114 ENGINE, OIL SYSTEM..................................................116 ENGINE, SHORT BLOCK..............................................118 ENGINE, STARTING SYSTEM......................................120 ENGINE, THROTTLE BODY..........................................122 ENGINE, VALVE COVER...............................................124 OPTIONS, WINCH.........................................................126 STEERING, CONTROLS, THROTTLE ASM. and CABLE............................................................................128 STEERING, HANDLEBAR and CONTROLS.................130 STEERING, STEERING POST ASM.............................132 SUSPENSION, FRONT A-ARMS..................................134 SUSPENSION, REAR....................................................136 SUSPENSION, SHOCK, FRONT...................................138 SUSPENSION, SHOCK, REAR.....................................140 SUSPENSION, STABILIZER BAR.................................142 TOOLS, TOOL KIT.........................................................144 WHEELS, FRONT and HUB..........................................146 WHEELS, REAR and HUB.............................................148 Part Number Index.....................................................150 Part Description Index..............................................153 © Copyright 2011. All rights reserved. Polaris Industries provides this publication as is without warranty of any kind, either expressed or implied.While every precaution has been taken in the preparation of this manual, Polaris assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. Polaris reserves the right to revise and improve its products as it sees fit.This publication describes the state of this product at the time of its publication, and may not reflect the product in the future. The illustrations in this manual are not intended for safe and proper assembly or disassembly of equipment. The illustrations are intended for ordering parts only. Polaris is registered trademark. All other brands and product names are trademarks or registered trademarks of their respective holders. Printed in the United States of America. 2 Parts Catalog 9923719 Rev. 02 12/07/11 Table of Contents

B BODY, CLUTCH COVER.....................................................4 BODY, DECALS...................................................................6 BODY, FOIL, FUEL TANK, RESERVE.................................8 BODY, FRONT BUMPER and MOUNTING.......................10 BODY, FRONT CAB...........................................................12 BODY, FRONT RACK and BRUSHGUARD.......................14 BODY, FRONT RACK SUPPORT......................................16 BODY, FUEL TANK, MAIN.................................................18 BODY, FUEL TANK, RESERVE.........................................20 BODY, HEADLIGHT POD..................................................22 BODY, LITTER CARRIER AND IR UPFIT.........................24 BODY, REAR CAB, FOOTWELLS and SUPPORTS..........26 BODY, REAR RACK and BRUSHGUARD.........................28 BODY, ROLLBAR and FOOTWELL TUBES......................30 BODY, SEAT.......................................................................32 BODY, SKID PLATES.........................................................34 BRAKES, BRAKE LINES...................................................36 BRAKES, BRAKE PEDAL and MASTER CYLINDER.......38 BRAKES, FRONT BRAKE LEVER and MASTER CYLINDER.......................................................................40 BRAKES, FRONT CALIPER..............................................42 BRAKES, REAR CALIPER................................................44 C CHASSIS, MAIN FRAME...................................................46 D DRIVE TRAIN, DRIVE COUPLER.....................................48 DRIVE TRAIN, DRIVE SHAFT, FRONT.............................50 DRIVE TRAIN, DRIVE SHAFT, REAR...............................52 DRIVE TRAIN, FRONT GEARCASE INTERNALS............54 DRIVE TRAIN, GEAR SELECTOR....................................56 DRIVE TRAIN, GEARCASE MOUNTING, FRONT...........58 DRIVE TRAIN, GEARCASE MOUNTING, REAR..............60 DRIVE TRAIN, MAIN GEARCASE....................................62 DRIVE TRAIN, PRIMARY CLUTCH...................................66 DRIVE TRAIN, PROP SHAFT, FRONT..............................68 DRIVE TRAIN, PROP SHAFT, REAR................................70 DRIVE TRAIN, REAR GEARCASE INTERNALS..............72 DRIVE TRAIN, SECONDARY CLUTCH............................74 E ELECTRICAL, BATTERY...................................................76 ELECTRICAL, BULBS.......................................................78 ELECTRICAL, GAUGES and INDICATORS......................80 ELECTRICAL, HARNESS.................................................82 ELECTRICAL, HEADLIGHTS............................................84 ELECTRICAL, IGNITION SYSTEM...................................86 ELECTRICAL, SWITCHES, SENSORS, ECU and CONTROL MODULES........................................................................88 ELECTRICAL, TAILLIGHTS...............................................90 ENGINE, AIR INTAKE........................................................92 ENGINE, BALANCE SHAFT..............................................94 ENGINE, CAM CHAIN.......................................................96 ENGINE, COOLING BYPASS............................................98 ENGINE, COOLING SYSTEM.........................................100 ENGINE, COOLING SYSTEM and WATER PUMP.........102 ENGINE, COOLING SYSTEM, RADIATOR SHIELD.......104 ENGINE, CRANKCASE...................................................106 ENGINE, CRANKSHAFT and PISTON............................108 ENGINE, CYLINDER HEAD, CAM and VALVES.............110 ENGINE, EXHAUST........................................................112 ENGINE, MOUNTING......................................................114 ENGINE, OIL SYSTEM....................................................116 ENGINE, SHORT BLOCK...............................................118 ENGINE, STARTING SYSTEM........................................120 ENGINE, THROTTLE BODY............................................122 ENGINE, VALVE COVER.................................................124 O OPTIONS, WINCH...........................................................126 S STEERING, CONTROLS, THROTTLE ASM. and CABLE.128 STEERING, HANDLEBAR and CONTROLS...................130 STEERING, STEERING POST ASM...............................132 SUSPENSION, FRONT A-ARMS....................................134 SUSPENSION, REAR.....................................................136 SUSPENSION, SHOCK, FRONT....................................138 SUSPENSION, SHOCK, REAR.......................................140 SUSPENSION, STABILIZER BAR...................................142 T TOOLS, TOOL KIT...........................................................144 W WHEELS, FRONT and HUB............................................146 WHEELS, REAR and HUB..............................................148 Alphabetized Table of Contents 12/07/11 Parts Catalog 9923719 Rev. 02 3

4 Parts Catalog 9923719 Rev. 02 12/07/11 Polaris Illustrated Parts Lists Selected Models BODY, CLUTCH COVER Applies to M12ZN8EAA/EAI [49MVCLUTCHCVR12SP850]

Notes Part Description Qty Part No. Ref. [Incl. Outer Cover,3,4] Asm., Cover, Outer 1 2633919 1. Cover, Clutch Inner 1 5438127 2. Plug, Drain 1 5434264 3. O-Ring 1 5410542 4. Seal, Cover, Clutch 1 5521802 5. Clamp, Narrow Band 4 7081279 6. Screw 10 7518914 7. Duct, Outlet 1 5439157 8. Duct, Air Inlet 1 5436820 9. Boot, Clutch, Inlet 1 5413177 10. Screw 11 7512094 11. Boot, Outlet, Duct 1 5413667 12. Boot, Inlet, Duct 1 5413516 13. Rivet 1 7661855 14. 12/07/11 Parts Catalog 9923719 Rev. 02 5 Illustrated Parts Lists Polaris Selected Models BODY, CLUTCH COVER Applies to M12ZN8EAA/EAI [49MVCLUTCHCVR12SP850]

6 Parts Catalog 9923719 Rev. 02 12/07/11 Polaris Illustrated Parts Lists Selected Models BODY, DECALS Applies to M12ZN8EAA/EAI [49MVDECAL12SP850]

Notes Part Description Qty Part No. Ref. Decal, Warning, Clutch Cover 1 7175488 1. Decal, Clutch, Retaining Bolt 1 7175883 2. 12/07/11 Parts Catalog 9923719 Rev. 02 7 Illustrated Parts Lists Polaris Selected Models BODY, DECALS Applies to M12ZN8EAA/EAI [49MVDECAL12SP850]

8 Parts Catalog 9923719 Rev. 02 12/07/11 Polaris Illustrated Parts Lists Selected Models BODY, FOIL, FUEL TANK, RESERVE Applies to M12ZN8EAA/EAI [49MVFOIL12SP850]

Notes Part Description Qty Part No. Ref. Foil, Bottom 1 5813857 1. Foil, Sump 1 5813858 2. Foil, Filler 1 5813859 3. 12/07/11 Parts Catalog 9923719 Rev. 02 9 Illustrated Parts Lists Polaris Selected Models BODY, FOIL, FUEL TANK, RESERVE Applies to M12ZN8EAA/EAI [49MVFOIL12SP850]

10 Parts Catalog 9923719 Rev. 02 12/07/11 Polaris Illustrated Parts Lists Selected Models BODY, FRONT BUMPER and MOUNTING Applies to M12ZN8EAA/EAI [49MVBUMPER12SP850]

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2012 Polaris Sportman 850 MV Parts Catalog Manual

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