Technical Polaris Sportsman 850 ATV Service Manual (2012-2013) – 376 Pages | Pro Service File

Polaris Sportsman 850 Service Manual

Maintaining Polaris 4x4 reliability requires the exact technical benchmarks used by factory technicians to ensure long-term trail performance. This professional-grade documentation provides the critical system logic and maintenance intervals necessary for high-level shop precision. Engineered for heavy-duty overhaul protocols, this archive eliminates guesswork in electronic fuel injection and drivetrain calibration.

Archive Logistics & Data Profile

• Total Pages: 376 pages of deep-tier technical data
• Publication Date: 2012 Polaris Sales Inc.
• Print/Form Number: LIT-9923809
• File Format: High-resolution Digital PDF (Instant Access)

Performance Protection & Investment ROI

• Prevents catastrophic "trial-and-error" failures in the Bosch EFI management system.
• Protects core engine value by utilizing official cold-start valve clearance benchmarks.
• Extends drivetrain lifespan through precise torque-angle specifications on main crankcase fasteners.
• Reduces shop downtime with guided diagnostic trouble code (DTC) interpretation for EPS and Engine systems.

Niche-Specific Series & Regional Coverage

Detailed series coverage includes the 2012 and 2013 model years for the Sportsman 850 HO and 850 HO EPS platforms. This manual actively treats all sub-variants including the standard XP, the extended-chassis Touring editions, and specialized International (INT'L) revisions. Actionable data is provided for all regional codes including A12ZN85, A12DN8E, A13ZN85, and A13DN8E series designations.

Power Plant & Chassis Benchmarks

Integrated Diagnostic Logic

Diagnostics focus on the Bosch Multi-Port Sequential EFI system and the Controller Area Network (CAN). Key features include Instrument Cluster Trouble Code Display for SPN (Suspect Parameter Number) and FMI (Failure Mode Identifier) tracking. Specialized procedures cover the Throttle Release Switch (TRS) logic to prevent engine runaway and a comprehensive EPS troubleshooting matrix for electronic power steering faults.

Component Architectures & Systems

• General Information: VIN and Engine Serial Number indexing, Special Tools, and Metric/SAE bolt standards.
• Electronic Fuel Injection: ECU management, fuel pump assembly, and pressure regulator testing.
• Cooling System: Thermostat operation, water pump mechanical seal service, and system bleeding.
• Engine Service: Top-end overhaul (valves, cams, head) and bottom-end crankcase splitting.
• Transmission & Final Drive: Automatic PVT calibration, gearbox disassembly, and AWD/ADC gearcase service.
• Electrical Array: Stator/Alternator tests, battery maintenance, and instrument cluster pinouts.

Professional Schematic Standards

Technical schematics detail the Pressure Lubrication Circuit and Oil Flow Diagram to ensure zero-starvation during operation. Visual depth includes high-resolution exploded views of the transmission's silent chain drive and the complex internal mechanics of the Front Gearcase with ADC (Active Descent Control). All electrical schematics allow for deep-tier zoom to trace the 3-phase charging system and the CAN High/Low wiring paths between the ECM and cluster.

FAQ

What specific Sportsman 850 HO model variants and serial series are covered in this workshop documentation?

This technical archive provides complete coverage for the 2012 and 2013 Sportsman 850 series, specifically the XP HO and Touring platforms. It actively treats the A12ZN85 and A13ZN85 base models as well as the International (INT'L) configurations and EPS-equipped variants. By referencing the specific VIN and Engine Serial Number locations on the right-hand frame spar, technicians can apply the exact displacement data of 850cc for precise internal component replacement.

How does the CAN network diagnostics protocol assist in troubleshooting electrical faults?

The Controller Area Network (CAN) logic requires a specific resistance benchmark of 60 +/- 10 ohms measured between the Yellow (CAN High) and Green (CAN Low) wires at the diagnostic connector. Understanding this value is critical for resolving "No Engine Speed" or gear position display failures on the instrument cluster. Maintaining this communication integrity ensures the ECM correctly broadcasts data to the EPS and Digital Wrench diagnostic plug, preventing prolonged electrical downtime during system-wide failures.

What are the critical engine benchmarks for maintaining optimal combustion and mechanical timing?

For high-tier shop precision, the engine must maintain a compression pressure between 210 and 250 psi to ensure full power output across the twin-cylinder SOHC architecture. Furthermore, the spark plug gap must be set strictly to .035 in (0.90 mm) to prevent ignition misfires under high-load conditions. Adhering to these factory-verified setpoints protects the internal valve train and ensures the Bosch EFI system operates within its designed stoichiometric parameters.

What fluid capacities are required for a complete drivetrain and gearcase service interval?

Securing long-term drivetrain reliability depends on using the correct volumes for the specialized Polaris gearcases. A standard service requires 37 oz of AGL Plus for the transmission and 9.3 oz of Demand Drive Plus for the front gearcase. Adhering to these specific volumes prevents air cavitation in the AWD system and ensures the active descent control (ADC) and internal silent chains remain fully lubricated under high-torque operation.

Why is the 43 psi fuel pressure benchmark vital for the Bosch EFI system health?

The Bosch Multi-Port Sequential EFI system relies on a consistent fuel pressure of 43 +/- 3 psi (296.5 kPa) to maintain the correct spray pattern and volume at the injectors. If the pressure deviates from this benchmark, the ECU cannot accurately manage the 1200 ± 50 RPM idle speed, leading to lean-run conditions or hard starting. Utilizing the guided pressure test protocols in this manual allows for immediate identification of a failing fuel pump or regulator before it causes permanent cylinder head damage.