2012-2013 Polaris Sportsman XP 850 Service & Repair Manual

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE AND ENGINE SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 2012 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2012 SPORTSMAN XP 850 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2012 SPORTSMAN XP 850 HO EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 2012 SPORTSMAN TOURING 850 HO / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2013 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2013 SPORTSMAN XP 850 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2013 SPORTSMAN XP 850 HO EPS / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 2013 SPORTSMAN TOURING 850 HO / INT’L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16

1.2 GENERAL INFORMATION 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE IDENTIFICATION Model Number Designation Example: A13DN8EAF (Model Year 2013) Engine Designation Number 2012: 1204390 / 2013: 1204616 ......................................... Twin Cylinder, 4-Cycle SOHC, Liquid Cooled, Electric Start Vehicle Identification Number (VIN) Designation Example: 4XADN85A0DP000000 GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit 9th digit** 10th digit A = ATV R = RANGER 11 12 13 C = Sportsman 6x6 D = Sportsman Tour E = Trail Boss F = Sportsman Youth G = Sport H = RANGER 6x6 J = RZR XP K = Sport Youth M = Sportsman N = Trail Blazer P = Phoenix R = RANGER Midsize S = RZR T = Sportsman X2 U = RANGER Fullsize V = RZR W = Multi-pass RGR X = Multi-pass RZR Z = Sportsman XP A = 2x4 Chain B = 2x4 Shaft C = 4x4 AC Drive E = 4x4 Shaft / IRS G = 4x4 Chain rear / shaft front H = 4x4 Shaft / IRS J = 2x4 Swing arm Manual N = 4x4 Shaft ADC P = 2x4 / IRS Manual R = 6x6 Shaft / IRS T = 4x4 Shaft / Trailing Arm X = 4x4 Shaft EBS Displacement in cc divided by 10 and rounded to two digits (i.e. 50 = 498cc) - - - - - - - - - - - - For electric vehicles 08 = 48 Volt 12 = 72 Volt A = ORV D = Diesel E = EU On-road F = INT’L G = EV L = LSV M = Military S = Scandinavian V = EU On-road C = Calif. - - OR - - 5 = 550 6 = 570 7 = 760 8 = 850 9 = 875 E = EPS D = Diesel F = D + E * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. World Mfg. ID Vehicle Descriptors Vehicle Identifiers Chassis Driveline Engine Size Engine Modifier Category Check Digit Model Year * Mfg. Location Individual Serial No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A J T 8 7 A 0 D 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013

1.3 GENERAL INFORMATION 1 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. Vehicle and Engine Serial Number Locations Whenever corresponding about a Polaris ATV, be sure to refer to the vehicle identification number (VIN) and the engine serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). The engine serial number can be found on the rear portion of the engine located on the valve cover (see Figure 1-2). VIN Figure 1-1 Engine Serial Number Figure 1-2

1.4 GENERAL INFORMATION 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. VEHICLE INFORMATION Publication Numbers YEAR MODEL MODEL NO. OWNER’S MANUAL PARTS MANUAL 2012 SPORTSMAN XP 850 HO A12ZN85AA, AQ, AZ 9923559 9923564 2012 SPORTSMAN XP 850 HO EPS A12ZN8EAH, AL, AM, AO, AT 9923559 9923565 9923566 2012 SPORTSMAN XP 850 HO EPS INT’L A12ZN8EFK 9923562 9923567 2012 SPORTSMAN TOURING 850 HO A12DN8EAF, AH, AR 9923542 9923549 2012 SPORTSMAN TOURING 850 HO INT’L A12DN8EFW 9923544 9923551 2013 SPORTSMAN XP 850 HO A13ZN85AA, AQ, AZ 9923810 9923813 2013 SPORTSMAN XP 850 HO EPS A13ZN8EAD,AH, AK, AL, AT 9923810 9923815 2013 SPORTSMAN XP 850 HO EPS INT’L A13ZN8EFK 9923822 9923824 2013 SPORTSMAN TOURING 850 HO A13DN8EAF, AL, AR 9923819 9923821 2013 SPORTSMAN TOURING 850 HO INT’L A13DN8EFW 9924153 9923827

1.5 GENERAL INFORMATION 1 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. Special Tools Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, SPX Corporation, by phone at 1-800-328-6657 or on-line at http://polaris.spx.com/ . Key Series Number KEY COVER P/N 5533534 Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278

1.6 GENERAL INFORMATION 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. 2012 SPECIFICATIONS MODEL: 2012 SPORTSMAN XP 850 HO MODEL NUMBER: . . . . . . . . . A12ZN85AA, AQ, AZ ENGINE NUMBER: . . . . . . . . 1204390 MODEL: 2012 SPORTSMAN XP 850 HO EPS / INT’L MODEL NUMBER: . . . . . . . . . A12ZN8EAH, AL, AM, AO, AT, FK ENGINE NUMBER: . . . . . . . . 1204390 * Data based on EU Directive 76/432/EEC Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 759 lbs. / 345 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Weight 150 lbs. / 68 kg Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 767 lbs. / 348 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Unbraked Trailer Towing Capacity (EU)* 1914 lbs. / 868 kg Hitch Tongue Weight 150 lbs. / 68 kg

1.7 GENERAL INFORMATION 1 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. 2012 SPORTSMAN XP 850 HO / EPS / INT’L XP MODELS: A12ZN85AA, AQ, AZ XP EPS MODELS: A12ZN8EAH, AL, AM, AO, AT, FK ENGINE NUMBER: 1204390 CLUTCH CHART Engine Platform Domestic Twin Cylinder, 4-Cycle Engine Number 1204390 SPM850-12 Engine Displacement 850 cc Number of Cylinders 2 Bore & Stroke (mm) 87 x 71.5 mm Compression Ratio 11.0:1 Compression Pressure 210 - 250 psi Engine Idle Speed 1200 ± 50 RPM Engine Max RPM Limit 7600 RPM Cooling System / Cap. Liquid Cooled / 2.7 qt. (2.6 l) Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump Engine Oil Requirement PS-4 Plus / 2 qt. (1.9 l) Exhaust System Stainless Steel Dual Header Pipe w/ Dual Outlet Silencer Fuel System Fuel System Type Bosch Multi-Port Sequential EFI Throttle Body / Size Mikuni Dual Bore / 42 mm Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43 psi (296.5 kPa) Fuel Capacity 5.25 gal. (20 l) Fuel Requirements 87 Octane (minimum) Electrical Alternator Output 475 W @ 1200 RPM / Peak 575 W Voltage Regulator 3-Phase / 32 Amp Head Lights Pod: 12V / 50 Watts Bumper: 12V / 50 Watts x 2 Brake Light 12V / 27 Watts Tail Light 12V / 7 Watts Starting System Electric Ignition System Bosch EFI (ECU Controlled) Spark plug / Gap REA6MC / .035 in. (.90 mm) Battery / Model / AH / CCA YUASA / YTX20HL / 18 AH / 310 Instrumentation XP: Digital / Analog XP EPS: Digital LCD DC Outlet Standard Relays (Located in Relay/Fuse Box) Chassis / Start Solenoid / Fan / EFI / Bumper Lights / EPS Circuit Breaker Fan Motor: 10A Fuses (Located in Relay/Fuse Box) Lights: 20 Amp Drive: 20 Amp Accessory: 20 Amp EFI: 20 Amp Unswitched: 10 Amp EPS: 30 Amp Drivetrain Transmission Type Automatic PVT In-Line H-L-N-R-P Transmission Fluid Type / Fluid Capacity Polaris AGL Plus 37 oz. (1100 ml) Front Gearcase Fluid Type / Fluid Capacity Polaris Demand Drive Plus 9.3 oz. (275 ml) Front Gearcase ADC Reservoir Fluid Type Polaris Demand Drive Plus Rear Gearcase Fluid Type / Fluid Capacity Polaris ATV Angle Drive Fluid 7.1 oz. (210 ml) Clutch Type PVT w/EBS Belt 3211123 Steering / Suspension Toe Out 1/4-1/2 in. (6.4-12.7 mm) Front Suspension Dual A-arm Front Travel 9 in. / 22.9 cm Rear Suspension Dual A-arm w/Rolled IRS Rear Travel 10.25 in. / 26 cm Shock Preload Adjustment Front / Rear Cam Adjustable Wheels / Brakes Front Wheel Size / Bolt Pattern Steel: 14 x 6 / 4-156 Aluminum: 14 x 5.5 / 4-156 Front Tire Model / Size Maxxis AT / 26 x 8 - 14 Carlisle AT 489 II / 26 x 8 - 14 Rear Wheel Size / Bolt Pattern Steel: 14 x 8 / 4-156 Aluminum: 14 x 7.5 / 4-156 Rear Tire Model / Size Maxxis AT / 26 x 10 - 14 Carlisle AT 489 II / 26 x 10 - 14 Tire Air Pressure Front: 7 psi (48 kPa) Rear: 7 psi (48 kPa) Brakes Single Control Hydraulic 3-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1800 (0-6000) 24-63 5632215 Red / Wht 7043349 Red / Wht 3235088 1800-3700 (6000 - 12000) 24-60 5632216 Red / Wht 7043349 Red / Wht 3235088

1.8 GENERAL INFORMATION 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. MODEL: 2012 SPORTSMAN TOURING 850 HO / INT’L MODEL NUMBER: . . . . . . . . . A12DN8EAF, AH, AR, FW ENGINE NUMBER: . . . . . . . . 1204390 * Data based on EU Directive 76/432/EEC Category Dimension Length 86.5 in. / 219.7 cm Width 47.6 in. / 121 cm Height 58.25 in. / 148 cm Wheel Base 57 in. / 145 cm Ground Clearance 11.6 in. / 29.5 cm Turning Radius 96 in. / 244 cm (unloaded) Dry Weight 798 lbs. / 362 kg Front Box Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Unbraked Trailer Towing Capacity (EU)* 1995 lbs. / 905 kg Hitch Tongue Weight 150 lbs. / 68 kg

1.9 GENERAL INFORMATION 1 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. 2012 SPORTSMAN TOURING 850 HO / INT’L TOURING MODELS: A12DN8EAF, AH, AR, FW ENGINE NUMBER: 1204390 CLUTCH CHART Engine Platform Domestic Twin Cylinder, 4-Cycle Engine Number 1204390 SPM850-12 Engine Displacement 850 cc Number of Cylinders 2 Bore & Stroke (mm) 87 x 71.5 mm Compression Ratio 11.0:1 Compression Pressure 210 - 250 psi Engine Idle Speed 1200 ± 50 RPM Engine Max RPM Limit 7600 RPM Cooling System / Cap. Liquid Cooled / 2.7 qt. (2.6 l) Overheat Warning Instrument Cluster Indicator Lubrication Pressurized Wet Sump Engine Oil Requirement PS-4 Plus / 2 qt. (1.9 l) Exhaust System Stainless Steel Dual Header Pipe w/ Dual Outlet Silencer Fuel System Fuel System Type Bosch Multi-Port Sequential EFI Throttle Body / Size Mikuni Dual Bore / 42 mm Fuel Delivery Electronic Fuel Pump (in tank) Fuel Pressure 43 psi (296.5 kPa) Fuel Capacity 5.25 gal. (20 l) Fuel Requirements 87 Octane (minimum) Electrical Alternator Output 475 W @ 1200 RPM / Peak 575 W Voltage Regulator 3-Phase / 32 Amp Head Lights Pod: 12V / 50 Watts Bumper: 12V / 50 Watts x 2 Brake Light 12V / 27 Watts Tail Light 12V / 7 Watts Starting System Electric Ignition System Bosch EFI (ECU Controlled) Spark plug / Gap REA6MC / .035 in. (.90 mm) Battery / Model / AH / CCA YUASA / YTX20HL / 18 AH / 310 Instrumentation Digital / Analog DC Outlet Standard Relays (Located in Relay/Fuse Box) Chassis / Start Solenoid / Fan / EFI / B. Lights / EPS / Rear Diff Circuit Breaker Fan Motor: 10A Fuses (Located in Relay/Fuse Box) Lights: 20 Amp Drive: 20 Amp Accessory: 20 Amp EFI: 20 Amp Unswitched: 10 Amp EPS: 30 Amp Drivetrain Transmission Type Automatic PVT In-Line H-L-N-R-P Transmission Fluid Type / Fluid Capacity Polaris AGL Plus 37 oz. (1100 ml) Front Gearcase Fluid Type / Fluid Capacity Polaris Demand Drive Plus 9.3 oz. (275 ml) Front Gearcase ADC Reservoir Fluid Type Polaris Demand Drive Plus Rear Gearcase Fluid Type / Fluid Capacity Polaris ATV Angle Drive Fluid 7.1 oz. (210 ml) Clutch Type PVT w/EBS Belt 3211123 Steering / Suspension Toe Out 1/4-1/2 in. (6.4-12.7 mm) Front Suspension Dual A-arm Front Travel 9 in. / 22.9 cm Rear Suspension Dual A-arm w/Rolled IRS Rear Travel 10.25 in. / 26 cm Shock Preload Adjustment Front / Rear Cam Adjustable Wheels / Brakes Front Wheel Size / Bolt Pattern Steel: 14 x 6 / 4-156 Aluminum: 14 x 5.5 / 4-156 Front Tire Model / Size Maxxis AT / 26 x 8 - 14 Carlisle AT 489 II / 26 x 8 - 14 Rear Wheel Size / Bolt Pattern Steel: 14 x 8 / 4-156 Aluminum: 14 x 7.5 / 4-156 Rear Tire Model / Size Maxxis AT / 26 x 10 - 14 Carlisle AT 489 II / 26 x 10 - 14 Tire Air Pressure Front: 7 psi (48 kPa) Rear: 7 psi (48 kPa) Brakes Single Control Hydraulic 3-Wheel Disc Brake Fluid Polaris DOT 4 Brake Fluid Altitude Shift Weight Drive Spring Driven Spring Meters (Feet) 0-1800 (0-6000) 24-63 5632215 Red / Wht 7043349 Red / Wht 3235088 1800-3700 (6000 - 12000) 24-60 5632216 Red / Wht 7043349 Red / Wht 3235088

1.10 GENERAL INFORMATION 9923809 - 2012-2013 Sportsman 850 Service Manual © Copyright 2012 Polaris Sales Inc. 2013 SPECIFICATIONS MODEL: 2013 SPORTSMAN XP 850 HO MODEL NUMBER: . . . . . . . . . A13ZN85AA, AQ, AZ ENGINE NUMBER: . . . . . . . . 1204616 MODEL: 2013 SPORTSMAN XP 850 HO EPS / INT’L MODEL NUMBER: . . . . . . . . . A13ZN8EAH, AD, AL, AT, AK, FK ENGINE NUMBER: . . . . . . . . 1204616 * Data based on EU Directive 76/432/EEC Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 759 lbs. / 345 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Hitch Tongue Weight 150 lbs. / 68 kg Category Dimension Length 83.25 in. / 211.5 cm Width 47.6 in. / 121 cm Height 50.75 in. / 129 cm Wheel Base 53 in. / 135 cm Ground Clearance 12 in. / 30.5 cm Turning Radius 84 in. / 213 cm (unloaded) Dry Weight 767 lbs. / 348 kg Front Rack Capacity 120 lbs. / 54 kg Rear Rack Capacity 240 lbs. / 109 kg Max. Weight Capacity 575 lbs. / 261 kg Towing Capacity 1500 lbs. / 680 kg Unbraked Trailer Towing Capacity (EU)* 1914 lbs. / 868 kg Hitch Tongue Weight 150 lbs. / 68 kg

2012-2013 Polaris Sportsman XP 850 Service & Repair Manual

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