Polaris Sportsman 850 ATV Service Manual 2012–2013 (P/N 9923809)

Polaris factory service manual P/N 9923809 covers the 2012-2013 Sportsman XP 850 HO, XP 850 HO EPS, XP 850 HO EPS INT'L, Touring 850 HO, and Touring 850 HO INT'L. It covers the liquid-cooled, four-stroke SOHC twin-cylinder engine.

Searchable Service Text and Wiring-Sheet Access

Search, bookmarks, and diagram detail: Main service text supports PDF search; text within some diagnostic charts and the appended wiring sheets does not. Chapter and procedure bookmarks aid navigation, but several wiring-section bookmarks have no working destination. Wiring lines are pale, and small pin numbers and wire codes require zooming.

One printable English PDF contains 382 pages: 376 chapter pages, including two notes pages, followed by six wiring-diagram and wire-termination sheets.

Engine Overhaul, EFI Diagnosis, and Driveline Service

These selected service topics show the manual's repair coverage. Further examples include headlight aiming and Touring passenger-seat suspension adjustment.

• Engine and cooling repair: Engine removal and installation, in-chassis top-end work, cylinder-head and valve service, crankcase and oil-pump work, cooling-system pressure testing and bleeding, and water-pump overhaul.

• Transmission and PVT service: Gear-selector and shift-linkage inspection, transmission removal, internal disassembly, shaft service and reassembly, plus XP- and Touring-specific PVT access, drive-belt work, and drive and driven clutch repair.

• AWD, ADC, and final drive: Centralized Hilliard front-gearcase operation, AWD/ADC diagnosis, EPS and non-EPS gearcase removal, ring-gear backlash setting, ADC bleeding, CV-joint and boot service, propshaft U-joints, and XP/Touring rear-gearcase repair.

• Bosch EFI and electrical diagnosis: Fuel-pump and injector service, CPS, T-MAP, IAC, TPS, ECT, and ignition-coil testing, instrument-cluster trouble codes, charging and starting circuits, EPS, and CAN troubleshooting.

• Chassis, steering, and suspension: XP/Touring body removal, separate EPS and non-EPS steering procedures, and ball-joint and A-arm replacement.

• Brake hydraulics: Brake-system bleeding, hand master-cylinder service, caliper overhaul, brake-disc inspection, and dedicated international-model hydraulic layouts.

• Maintenance and reference data: Periodic maintenance charts, lubrication points, throttle/TRS and toe adjustments, component-specific torque tables, capacities, wear limits, clearances, and pressure and electrical test specifications.

This manual is suited to experienced ATV mechanics and advanced owners with the measuring equipment and service tools required for mechanical and electrical diagnosis. For PVT maintenance and repairs, Polaris specifies a trained, certified Polaris Master Service Dealer technician using factory-authorized special tools.

Model Selection and Internal Repair Detail

Factory model and engine assignments distinguish standard, EPS, Touring, and international configurations before a repair procedure or parts reference is selected.

Step-by-step procedures cover engine and transmission disassembly and reassembly. Engine detail includes connecting-rod bearing selection, camshaft and balance-shaft timing, an oil-flow diagram, and a camshaft-timing quick reference. Transmission and Centralized Hilliard front-gearcase exploded views support component identification during internal service.

Rear-gearcase coverage includes bearing and seal replacement. Damage to the matched gears or housing calls for replacement of the complete assembly; gear shimming is outside the documented procedure.

Diagnostic Equipment and Year-Specific Procedures

Digital Wrench®: The Bosch Multi-Port Sequential EFI section covers reading and clearing trouble codes, live engine data, guided diagnostics, ECU calibration-file reflashing, and selected output-state tests. The software is identified as dealer-only and requires the applicable interface hardware.

Diagnostic tool callouts include Digital Wrench kit PU-47063-B, SmartLink kit PU-47471, and fuel-pressure gauge kit PU-43506-A with adapter PS-48762. Mechanical procedures specify drive-clutch puller PA-48595, universal clutch compressor PU-50518, and ball-joint tool PU-50506.

Model-year differences: The EFI chapter distinguishes the 2012 integrated-connector TPS from the 2013 flying-lead TPS; replacing the 2012 sensor requires a wire-harness repair kit. Cooling and engine sections provide separate 2012 and 2013 stator-cover and water-pump-coupler installation details.

Wiring Coverage and Repair Cautions

Brake-system hydraulic views and electrical diagnostic charts supplement the mechanical illustrations. The final full-vehicle wiring sheets are specifically labeled for the 2013 Sportsman 850, 850 EPS, and 850 EPS INT'L, paired with wire-termination tables and fuse/relay layouts.

The engine chapter warns against reusing or deforming piston-pin circlips because loss of retention can cause severe internal engine damage. CV-joint guidance warns that using the shaft as a lever or hammers and sharp tools on boot clamps can damage joints or boots; mixing internal joint components can cause binding and premature failure.

Fuel-system pressure must be relieved before EFI components are opened, the engine must be cool before the radiator cap is removed, and the ATV must be securely supported for brake, suspension, or driveline work. Follow the manual's equipment warnings and assembly specifications for each repair.

EFI Test and Adjustment Specifications

The TPS adjustment procedure specifies a Digital Wrench output reading of 0.71 Vdc for the 2012 integrated-connector sensor and 0.67 Vdc for the 2013 flying-lead sensor. These values distinguish the sensor configurations during calibration.

Fuel-injector resistance is specified as 12 Ω ± 5% at 68°F (20°C). The injector section relates electrical testing to distinguishing an injector fault from a wiring or connection problem.