2012 2013 2014 Polaris Sportsman 850 ATV Service Manual

Description

This 2012 2013 2014 Polaris Sportsman 850 ATV Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for your 2012-2014 Polaris Sportsman 850 ATV (XP/Tour/EPS).

Table of Contents

General Information
Maintenance Electronic Fuel Injection
Cooling
Engine
Transmission
PVT
Final Drive
Body
Frame
Steering
Suspension
Brakes
Electrical

Official 2012-2014 Polaris Sportsman 850 ATV Factory Service Manual Index of Topics

2012-2013 Rear Stabilizer Bar, Assembly View
2014 Rear Stabilizer Bar, Assembly View
7044080 / 7044081 Shock Service Information
7044100 / 7044101 Shock Service Information
Active Descent Control (ADC)
ADC Coil
ADC Fluid
ADC, Bleeding
ADC, Coil Resistance
ADC, Operation
Adjustment, Valve Clearance
Air Filter Service
All Wheel Drive (AWD) Coil
Assembly View, 7044080 / 7044081 / 7044100 /
7044101 Shocks
Assembly View, 7044135 Shock
Assembly View, Camshaft
Assembly View, Camshaft Timing
Assembly View, Connecting Rod
Assembly View, Crankcase Complete
Assembly View, Crankcase Lower
Assembly View, Crankcase Upper
Assembly View, Crankshaft
Assembly View, Cylinder Head
Assembly View, Oil Pump
Assembly View, Piston and Rings
Assembly View, Rocker Arm
Assembly View, Valve
Assembly Views, Engine
Assembly, Connecting Rod and Piston
Assembly, Crankcase
Assembly, Crankcase Upper
Assembly, Lower Crankcase
Assembly, Upper Crankcase
Authorization Key
Authorization, Reflash
AWD, Coil Resistance
AWD, Diagnosis
AWD, Operation
B
Balance Shaft
Balance Shaft Installation
Balance Shaft Removal, Inspection
Balance Shaft Timing
Ball Joint Service
Battery Maintenance
Battery Service
Battery Storage
Battery, Installation
Battery, Removal
Bearing Inspection, Crankshaft Main
Bearing Selection Chart, Con Rod
Brake Bleeding
Brake Bleeding, Front Brake System
Brake Bleeding, Rear Brake System
Brake Burnishing
Brake Caliper Assembly
Brake Caliper Exploded View
Brake Caliper Inspection
Brake Caliper Installation
Brake Caliper Piston Bore ID
Brake Caliper Removal
Brake Disc Service
Brake Disc, Inspection
Brake Fitting Inspection
Brake Hose Inspection
Brake Pad Inspection
Brake Pad Installation
Brake Pads
Brake Pedal Inspection
Brake System Inspection
Brake System, Exploded View (850 INT’L)
Brake System, Exploded View (XP 850 /XP 850
EPS/850 TOURING)
Brake System, Operation
Break-In Period
Breather Hose
Bumper Lights Relay
Cam Chain Inspection
Camshaft Bore Inspection
Camshaft Carrier
Camshaft Chain Removal
Camshaft Chain Tensioner Installation
Camshaft Installation
Camshaft Timing
Camshaft Timing, Quick Reference
Camshaft, Removal
Centralized Hilliard, Exploded View
Chain Tensioner, Camshaft
Chain, Cam, Removal
Charging System
Chart, Con Rod Bearing Selection
Chassis Relay
Communication Problems, Digital Wrench
Compression Test
Connecting Rod Assembly
Connecting Rod Bearing Selection Charts
Connecting Rod Inspection
Connecting Rod Installation
Connecting Rod, Assembly View
Controls
Conversion Table
Coolant Level Inspection
Coolant Strength and Type
Cooling System
Cooling System Hoses
Cooling System, Bleeding Procedure
Cooling System, Specifications
Cooling System, Troubleshooting
Counterbalance Shaft
Counterbalance Shaft Installation
Counterbalance Shaft Removal
Counterbalance Shaft Timing
Coupler, Drive
Coupler, Water Pump
Cover, Stator
Cover, Valve, Removal
Crankcase Assembly
Crankcase Assembly View, Complete
Crankcase Assembly View, Lower
Crankcase Assembly View, Upper
Crankcase Assembly, Lower
Crankcase Assembly, Upper
Crankcase Disassembly
Crankcase Disassembly (Lower)
Crankcase Disassembly (Upper)
Crankcase Inspection, Lower
Crankshaft Assembly View
Crankshaft Installation
Crankshaft Position Sensor (CPS)
Crankshaft Removal
Crankshaft, Inspection
Cylinder Head
Cylinder Head Assembly
Cylinder Head Disassembly
Cylinder Head Installation
Cylinder Head Removal
Cylinder Head Torque Procedure
Cylinder Head, Inspection
Cylinder Head, Warp Inspection
Cylinder Inspection
Daily Inspection
Decal Replacement
Decimal Equivalent Chart
Diagnostic Codes, Instrument Cluster
Diagnostic Trouble Code List
Diagnostic Trouble Code Table
Digital Wrench
Engine Controller Reprogramming
Digital Wrench Communication Errors
Digital Wrench Diagnostic Software
Digital Wrench Versions
Digital Wrench, Updates
Digital Wrench, Version and Update ID
Disassembly, Crankcase
Disassembly, Lower Crankcase
Disassembly, Upper Crankcase
Drive Belt, Break-In
Drive Belt, Inspection
Drive Belt, Installation
Drive Belt, Removal (TOURING Models)
Drive Belt, Removal (XP Models)
Drive Clutch, Assembly
Drive Clutch, Bushing Service
Drive Clutch, Button to Tower Clearance
Drive Clutch, Cover Bushing Removal/Installation Drive Clutch, Disassembly
Drive Clutch, Exploded View
Drive Clutch, Moveable Sheave Inspection
Drive Clutch, Operation
Drive Clutch, Service
Drive Clutch, Shift Weights
Drive Clutch, Spider Removal
Drive Clutch, Spring Inspection
Drive Coupler
Drive Shaft / CV Joint, Handling Tips
Drive Shaft Boot Inspection
Driven Clutch, Assembly
Driven Clutch, Disassembly
Driven Clutch, Exploded View
Driven Clutch, Operation
Driven Clutch, Service
E
ECU Replacement
EFI Operation Overview
EFI Priming / Starting Procedure
EFI Relay
EFI, Component Locations
EFI, Diagnostic Trouble Codes
EFI, Exploded View
EFI, Service Notes
Electronic Control Unit (ECU)
Engine Controller Reprogramming
Engine Cylinder Inspection
Engine Installation Notes
Engine Model Number
Engine Oil Pressure Test
Engine Piston Ring Installed Gap
Engine Piston to Cylinder Clearance
Engine Removal
Engine Serial Number
Engine Temperature Sensor
Engine Temperature Sensor Replacement
Engine Temperature Sensor Test
Engine, Accessible Components
Engine, Combustion Chamber
Engine, Cooling System
Engine, Crankcase, Disassembly
Engine, Cylinder Head Assembly
Engine, Cylinder Head Inspection
Engine, Cylinder Head Removal
Engine, Cylinder Head Warp
Engine, Flywheel Removal
Engine, Oil and Filter Change
Engine, Oil Level
Engine, Thermostat
Engine, Troubleshooting
Engine, Valve Inspection
Engine, Valve Sealing Test
Engine, Valve Seat Reconditioning
EPS, Cleaning
Fan Relay
Foot (Auxiliary) Brake Master Cylinder
Foot Master Cylinder, Operation (INT’L Models)
Footwell, Removal / Installation
Footwells
Frame Supports (TOURING Models)
Frame Supports (XP Models)
Frame, Nuts, Bolts, Fasteners
Front A-arm, Removal / Replacement
Front A-arms
Front A-arms, Exploded View
Front Bearing Carrier
Front Bumper
Front Cab
Front Drive Shaft, Installation
Front Drive Shaft, Removal
Front Gearcase ADC Fluid
Front Gearcase Lubrication
Front Gearcase, Assembly
Front Gearcase, Disassembly / Inspection
Front Gearcase, Installation (EPS Models)
Front Gearcase, Installation (Non-EPS Models)
Front Gearcase, Removal (EPS Models)
Front Gearcase, Removal (Non-EPS Models)
Front Propshaft, Service
Front Rack
Front Storage Box
Fuel Filters
Fuel Injectors
Fuel Line
Fuel Lines
Fuel Pressure Regulator
Fuel Pump Replacement
Fuel Pump Test
Fuel Sender Test
Fuel System
Fuel System Diagnostics
Fuel System Troubleshooting
Fuel Tank
Fuel Tank Installation
Fuel Tank Removal
Fuse Box Layout, 2012-2013
Fuse Boxes, 2014
Fused Circuits, 2012-2013
Fused Circuits, 2014
Gear Position Switch
Gear Selector Removal
General Specifications – 2012
General Specifications – 2013
General Specifications — 2014
Guide, Valve
Guided Diagnostics
Hand Brake Master Cylinder, Removal
Hand Master Cylinder, Exploded View
Hand Master Cylinder, Operation (INT’L Models)
Handlebar, Removal / Replacement
Head Lights
Head, Cylinder
Head, Cylinder, Disassembly
Head, Cylinder, Inspection
Headlight Pod
High Beam Lights Relay, 2014
Idle Air Control (IAC)
Ignition Coil
Ignition Coil Replacement
Ignition Coil Tests
Impeller, Water Pump
Inner Plunging Joint / Boot Replacement
Inspection, Cam Chain
Inspection, Camshaft Bore
Inspection, Connecting Rod
Inspection, Counterbalance Shaft
Inspection, Crankcase, Lower
Inspection, Crankshaft Journals
Inspection, Cylinder Head
Inspection, Piston
Inspection, Piston Ring
Inspection, Valve
Installation – 2012
Installation, Camshaft
Installation, Camshaft Chain Tensioner
Installation, Connecting Rod
Installation, Counterbalance Shaft
Installation, Crankshaft
Installation, Cylinder Head
Installation, Piston
Installation, Piston Ring
Instrument Cluster
Instrument Cluster (XP / TOURING Models)
Instrument Cluster (XP EPS Models)
Integrated Throttle Body, Torque Sequence
Key, Reprogramming Authorization
Keys, Replacement
Lash Adjustment, Valve
Leakdown Test
Low Beam Lights Relay, 2014
Lubrication Diagram
Lubrication Grease Points
Main Frame (TOURING Models)
Main Frame (XP Models)
Maintenance and Service Products
Maintenance Quick Reference Chart
Mechanical Seal, Water Pump
Metric Bolt Torque Specification
Model Number
Model Specifications, 2012 Sportsman Touring 850 HO)
Model Specifications, 2012 Sportsman XP 850 HO
Model Specifications, 2012 Sportsman XP 850 HO EPS
Model Specifications, 2013 Sportsman Touring 850 HO
Model Specifications, 2013 Sportsman XP 850 HO
Model Specifications, 2013 Sportsman XP 850 HO EPS
Model Specifications, 2014 Sportsman XP 850 HO
Model Specifications, 2014 Sportsman XP 850 HO Touring
Mud Guards
Oil Flow Diagram
Oil Passage Tube
Oil Pump
Oil Pump Assembly View
Oil Pump Rotor Clearance
Outer CV Joint / Boot Replacement
Periodic Maintenance Chart
Piston Pin Bore Inspection
Piston Removal, Inspection
Piston Ring Inspection
Piston Ring Installation
Piston Ring Installed Gap
Piston Ring, Compressor
Piston to Cylinder Clearance
Piston, Assembly View
Piston, Installation
Power Steering Relay
Power Steering Unit Installation
Power Steering Unit Removal
Power Steering Unit, Cleaning
Pre-Filter Service
Pre-Ride Inspection
Propshaft, U-Joint Service
Publication Part Numbers
Pump, Oil
Pump, Water
Pump, Water, Mechanical Seal Replacement
PVT System, Assembly
PVT System, Disassembly (TOURING Models)
PVT System, Disassembly (XP Models)
PVT System, Maintenance
PVT System, Overview
PVT System, Service
PVT Troubleshooting
PVT, Drain Plug
PVT, Drying
Radiator
Radiator, Removal
Rear A-arm, Removal
Rear A-arms
Rear A-arms, Exploded View
Rear Bearing Carrier
Rear Bumper Covers (XP Models)
Rear Cab
Rear Cab, Removal / Installation (TOURING Models)
Rear Cab, Removal / Installation (XP Models)
Rear Drive Shaft, Installation
Rear Drive Shaft, Removal
Rear Gearcase
Rear Gearcase Lubrication
Rear Gearcase, Assembly
Rear Gearcase, Disassembly and Inspection
Rear Gearcase, Exploded View
Rear Gearcase, Installation (TOURING Models)
Rear Gearcase, Installation (XP Models)
Rear Gearcase, Removal (TOURING Models)
Rear Gearcase, Removal (XP Models)
Rear Propshaft, Service
Rear Rack
Reflash Authorization
Relays
Removal, Camshaft
Removal, Counterbalance Shaft
Removal, Cylinder Head
Removal, Engine, Accessible Components
Removal, Valve Cover
Removal, Valve Guide
Replacement Keys
Reprogramming Authorization
Ring Gear, Starter
Rings, Piston, Assembly View
Rocker Arm
Rocker Arm, Installation
Rocker Arm, Removal and Inspection
Rocker Carrier, Removal
Rocker Cover
Rocker Cover, Removal
RPM Limit
Seat
Seat, Passenger (TOURING Models)
Seat, Passenger, Suspension Removal/Adjustment (TOURING Models)
Sequence, Engine Cover Torque
Shaft, Rocker Arm
Shaft, Rocker Arm Installation
Shift Linkage Inspection
Shift Weights
Shock Assembly Views
Shock Rebuilding Tools, FOX
Shock Service
Shock, FOX, Rebuild Information
Shocks and Springs
Side Panels
Software Version
Spark Plug
Special Tools
Special Tools, Body / Frame
Special Tools, Clutching
Special Tools, Cooling System
Special Tools, EFI
Special Tools, Electrical
Special Tools, Engine
Special Tools, Final Drive
Specification, Cylinder Head Warp
Specification, Cylinder Taper Limit
Specification, Cylinder Warp Limit
Specification, Fuel Pressure
Specification, Oil Pump Rotor Clearance
Specification, Valve Seat Contact Width
Specification, Valve Spring Free Length
Specification, Valve Stem Diameter
Specification, Valve Stem Guide ID
Specifications, Brake Disc Runout
Specifications, Brake Pad Thickness
Specifications, Brakes
Specifications, Clutching
Specifications, Cooling System
Specifications, Engine
Specifications, Engine Lubrication
Specifications, Engine Oil Pressure
Specifications, Final Drive Torque
Specifications, FOX 7044135 Shock
Specifications, Wheel Nut Torque
Speed Sensor, Operation Overview
Speedometer
Sprocket, Cam Chain, Inspection
Standard Bolt Torque Specification
Start Solenoid Relay
Starter Motor, Removal / Replacement
Starter Ring Gear
Starter System
Starter System, Troubleshooting
Stator
Stator Cover
Installation -2012
Installation – 2013-Current
Stator, Installation
Stator, Removal
Steering (Non-EPS Models)
Steering Inspection
Steering Post Installation (Non-EPS Models)
Steering Post Removal (Non-EPS Models)
Steering, Electronic Power Steering (EPS)
Steering, Exploded View (EPS Models)
Steering, Exploded View (Non-EPS Models)
Steering, Inspection
Steering, Tie Rod Replacement
Suspension Inspection
Suspension Spring Preload Adjustment
Tap/Drill Sizes
Temp / Manifold Absolute Pressure Sensor (T-MAP)
Tensioner, Camshaft, Installation
Thermostat
Throttle Body, Torque Sequence
Throttle Cable Adjustment
Throttle Operation
Throttle Position Sensor (TPS)
Throttle Release Switch (TRS)
Tie Rod Ends
Timing, Balance Shaft
Timing, Camshaft
Timing, Counterbalance Shaft
Tire Inspection
Tire Pressure
Toe Alignment
Toe Alignment Adjustment
Torque Patterns, Engine Components
Torque Procedure, Cylinder Head
Torque Specifications, Body / Frame
Torque Specifications, Clutching
Torque Specifications, Cooling System
Torque Specifications, Steering / Suspension
Torque Specifications, Transmission
Torque Specifications, Wheel and Hub
TPS Replacement/Adjustment, 2012
TPS Replacement/Adjustment, 2013
TPS Replacement/Adjustment, 2014
Transmission Lubrication
Transmission, Assembly
Transmission, Disassembly
Transmission, Exploded View
Transmission, Installation
Transmission, Lubrication
Transmission, Removal
Transmission, Shaft Service
Trouble Codes
Troubleshooting, Brake Noise
Troubleshooting, Brakes
Troubleshooting, Clutching
Troubleshooting, Engine
Troubleshooting, Transmission
Tube, Oil Passage
Upper Steering Post Installation (EPS Models)
Upper Steering Post Removal (EPS Models)
Valve Clearance Adjustment
Valve Cover Assembly View
Valve Cover Removal
Valve Cover, Removal
Valve Guide Inspection
Valve Guide, Removal
Valve Inspection
Valve Installation Detail
Valve Sealing Test
Valve Seat Reconditioning
Valve Spring Free Length
Valve Spring Installation Detail
Valve Spring Removal
Valve Stem Diameter
Valve, Assembly View
Vehicle Identification Numbers
Vent Line
Version, Software
VIN Location
VIN Number
Voltage Drop Test
Water Pump
Water Pump Coupler
Water Pump Impeller
Water Pump Mechanical Seal Replacement
Water Pump Removal
Wheel Hubs
Wheel Removal / Installation