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

• Factory coverage and document identity: A 382-page PDF for the 2012-2013 Polaris Sportsman XP 850 HO, XP 850 HO EPS, XP 850 HO EPS INT'L, Touring 850 HO, and Touring 850 HO INT'L, identified as Polaris service manual P/N 9923809. Coverage is for the liquid-cooled, four-stroke SOHC twin-cylinder engine.
• Engine and cooling repair: Covers engine removal and installation, in-chassis top-end work, cylinder-head and valve service, camshaft and balance-shaft timing, crankcase and oil-pump work, connecting-rod bearing selection, cooling-system pressure testing and bleeding, and water-pump overhaul.
• Transmission and PVT service: Details 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: Includes Centralized Hilliard front-gearcase operation, AWD/ADC diagnosis, EPS and non-EPS gearcase removal, ring-gear backlash setting, ADC fluid bleeding, CV-joint and boot service, propshaft U-joints, and XP/Touring rear-gearcase repair.
• Bosch EFI and electrical diagnosis: Documents the Bosch Multi-Port Sequential EFI, fuel-pump and injector service, CPS, T-MAP, IAC, TPS, ECT, and ignition-coil testing, instrument-cluster trouble codes, Digital Wrench® functions, charging and starting circuits, EPS, and CAN troubleshooting.
• Chassis, steering, suspension, and brakes: Provides XP/Touring body removal procedures, separate EPS and non-EPS steering service, ball-joint and A-arm replacement, brake-system bleeding, master-cylinder and caliper overhaul, brake-disc inspection, and dedicated international-model hydraulic layouts.
• Maintenance and reference data: Supplies the periodic maintenance chart, lubrication points, throttle/TRS and toe adjustments, component-specific torque tables, capacities, wear limits, clearances, pressure and electrical test specifications, exploded views, diagnostic charts, and wiring documentation.

Match the Exact Machine

The model tables assign engine 1204390 to 2012 machines and 1204616 to 2013 machines. Listed 2012 model numbers are A12ZN85AA/AQ/AZ; A12ZN8EAH/AL/AM/AO/AT and A12ZN8EFK; and A12DN8EAF/AH/AR and A12DN8EFW. For 2013, the manual identifies A13ZN85AA/AQ/AZ; A13ZN8EAD/AH/AK/AL/AT and A13ZN8EFK; and A13DN8EAF/AL/AR and A13DN8EFW. These factory assignments distinguish standard, EPS, Touring, and international configurations before a repair procedure or parts reference is selected.

This manual is suited to experienced ATV mechanics and advanced owners who have the measuring equipment and service tools required for mechanical and electrical diagnosis. For internal PVT repair, Polaris specifically directs the work to a trained, certified Polaris Master Service Dealer technician using factory-authorized special tools.

Diagnostic Equipment and Year-Specific Procedures

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

The manual separates model-year-specific components and procedures. The EFI chapter identifies the 2012 integrated-connector TPS and the 2013 flying-lead TPS, with a wire-harness repair kit required when replacing the 2012 sensor. Cooling and engine sections also provide separate 2012 and 2013 stator-cover and water-pump-coupler installation details.

Diagrams and Repair Cautions

Useful visual references include the engine oil-flow diagram, camshaft-timing quick reference, transmission exploded view, Centralized Hilliard front-gearcase exploded view, brake-system hydraulic views, and full-vehicle wiring sheets. The final full-vehicle sheets are specifically labeled for the 2013 Sportsman 850, 850 EPS, and 850 EPS INT'L and are 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. During final-drive repair, the axle shaft must not be used as a lever, and hammers or sharp tools must not be used on CV boot clamps; improper handling can damage the joint or boot and lead to binding or 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.