Common Polaris Engine Codes and How to Fix Them

It’s common for Polaris to communicate errors to the user using several codes. These codes can mean a range of problems for different components in the vehicle, including the engine.

Now, the more important question is, how do you read the Polaris engine code?

There are three parts to the code. First, the FMI indicates what kind of problem your vehicle has. The SPN tells you in which part the problem has occurred. And finally, the last part is the error count, indicating the total number of issues currently in the vehicle.

Now, let’s find out some of the most common Polaris engine codes and how to fix them. 

1. Polaris Engine Code 65590

Polaris engine error code 65590 means engine misfire, and this problem has three variations based on the location of the misfire.

Symptoms

Other than the error code, you feel your Polaris does not have enough power. Also, you might experience slower acceleration. Apart from these, your engine will vibrate more than usual.

Reason One: Spark Plugs

An old, damaged, or dirty spark plug can cause an engine to misfire. Or a spark plug that is not correctly gapped can also be the reason behind this.

To diagnose this problem, just visually inspect your spark plug.

Solution

If the spark plug is old or damaged, it must be replaced. If it’s dirty, then you can clean it, and that should solve the issue.

The correct spark plug gap should be 0.9-1mm. So, if the gap is more or less, adjust it using a spark plug adjustment tool. 

Reason Two: Ignition Coil

Ignition coil oversees the air-fuel mixture in your engine. That’s how a faulty ignition coil will cause your engine to misfire.

You can test your ignition coil with a tester. The process is fairly simple.

To test the coil, you must first plug in the tester. You should then connect the ground wire. Connect the coil connector next.

Adjust the spark plug gap to a 0.9-1 mm value. Then you will need to start the engine.

If you can see sparks, that means there are no issues. If not, your ignition coil is faulty. 

Solution

Replacing the ignition coil would be the best solution. Here is a video that might help.

Reason Three: Cylinder Lost Compression

One of the cylinders losing compression can cause engine misfiring. The cylinders usually lose compression because of leaks. 

You can use a compression gauge to check the Polaris cylinder is losing compression. But before checking, you must take out the spark plug and the ignition coil as a safety measure. 

After disabling the plug and the coil, connect the compression gauge to the spark plug socket. Afterward, crank the engine for a few seconds while holding the throttle open. The gauge should give you a measurement of the compression. It should be between 210-250 psi.

Repeat the same process for all the cylinders.

Solution

Make sure all components are examined, including piston rings, gaskets, camshafts, cylinders, valves, and pistons. You should look for cracks, worn areas, holes, damages, and slits. Immediately replace broken cylinders if you discover them.

2. Polaris Engine Code 65591

This error code is similar to the previous error code, 65590. The code directly indicates cylinder 1 has lost compression. 

You need to diagnose the issue with cylinder 2 to identify the issue when you get this code. So, checking cylinder 2 by following the aforementioned process should be enough.

If the cylinder is faulty, as suggested, you must replace it as soon as possible.

3. Polaris Engine Code 65592

Similar to the last code, this code indicates the same problem, but now the issue is with cylinder 2. Follow the same diagnosis and solution if you ever face this engine error code.

4. Polaris Engine Code 520 194

The error code 520 194 indicates a throttle release signal. This can happen for various reasons, so there are a couple of variations to this error code. 

Symptoms

You can expect quite a few symptoms when your Polaris is showing the code 520 194. These symptoms are- 

• Rough idling, 
• Sluggish acceleration, 
• Poor fuel economy,
• Engine stalling.

Reason One: Ice, Dirt, or Corrosion Build-up

The main reason behind the error code is when the throttle lever collects dirt, mud, or ice or gets corroded. So, when you get the error code 520 194, check out your throttle lever first.

To check if the throttle lever is clean, you must open it up first. You’ll have to locate the flat hole at the bottom of the throttle body. Using a flat-headed screwdriver, press the hole that will get the throttle lever loosened. Then you can detach the throttle lever and check if it has accumulated any dirt. 

Solution

If your throttle lever is dirty, you must clean it up. You can use WD-40 Dry Lube to clean the lever, which is widely prevalent among experts.

Reason Two: Throttle Cable Unsettled

You need to check whether the throttle cables are connected correctly. You can do this by checking the throttle control switch. It should have an average slack of 1/16″-1/8″. Cable adjustment may be required if it feels looser than usual.

Solution

There is a long screw in the middle of the TSP wire. You can unscrew the bolt from that using an 8 mm wrench. Then adjust the throttle control switch based on the recommended range. That should fix the issue.

Reason 3: Throttle Switch Stuck

If everything else seems fine, but the code is still there, something could be stuck on the throttle. 

Solution

You must shift to low-range transmission and apply fast, aggressive throttle pressure to engage the clutch. By doing this, you will be able to get the throttle unstuck.

It is essential, however, to keep a firm grip on the throttle and not overdo it. Your Polaris can lose control and roll over as a result.

5. Polaris Engine Code 84

In most cases, error code 84 indicates a problem with the speed sensor. The brake switch might malfunction in other cases.

Symptoms

If this error code appears in your Polaris, you can expect quite a few symptoms. There are several symptoms to look for, including

• Engine check light will be on,
• Power steering light will be on,
• Brake light will be on,
• Speedometer stops working,
• The power steering won’t work.

Reason One: The Speed Sensor

The error code 84 tells you something is wrong with your speed sensor. That means either the connection is loose or the speed sensor is faulty.

To begin with, make sure that the speed sensor is connected correctly. Verify that the sensor is connected correctly. Make sure the wire is not damaged as well.

If there are no issues with the wiring and the connection, you need to test if the speed sensor is working. Allow us to explain the whole process.

You will need a multimeter, a drill, and a two-wire connector for the test.

Detach the speed sensor from your Polaris. You will find a slot through which the sensor is connected to the vehicle. Plug in the two wires in that slot. 

Connect the two wires coming from the connector to the multimeter. Make sure to connect the red wire to the red cable and the black wire to the black cable of the multimeter.

Now, set the multimeter to AC. Take the drill, insert the pointy head into the sensor, and turn it on. Slowly increase the speed as you go. 

As the drill spins faster, the voltage reading should increase on the multimeter. If the readings do not increase over time, then it is faulty.

Solution

Reconnect the sensor if it is not connected correctly. Make sure the speed sensor is connected to the 3-wire harness. For a fix on damaged wiring, contact your mechanic. In the event of a malfunctioning speed sensor, it should be replaced.

Reason Two: The Brake Switch

Sometimes, the brake switch acts up instead of the speed sensor. As a result, if the speed sensor is okay, we recommend checking the brake switch.

To determine what’s wrong with the brake switch, you must visually inspect it. Brake switches are pressurized switches that require proper sealing. The device may malfunction if water gets inside.

The only thing you need to do is make sure the switch is sealed correctly.

Solution

If the switch is not properly sealed, you must take it out and dry it. Reconnect the switch, and the problem should be resolved.

6. Polaris Engine Code 636

This Polaris engine error code means a problem with the crankshaft position sensor. But problems with other components can also trigger these error codes; thus, some variations exist.

Symptoms

The symptoms for Polaris error code 636 is-

• Engine stalling
• Problem starting 
• Rough idling
• Engine dying

Reason

Although the code indicates a problem with the crankshaft position sensor. However, quite a few reasons can trigger the error code 636.

A faulty crankshaft position could be the primary reason for this. In addition, a broken timing belt or ECM could be the culprit. This makes diagnosing it very hard, so it would be best to leave this error code to the professionals.

Still, if you’d like to take a shot at it yourself, you can check the connection of the crankshaft position sensor or any wiring damage.

If that’s okay, then take out the crankshaft position sensor to look for damage. Look for any cracks, damage, or if it’s bent out of shape.

Then you need to do a resistance check. For this, you will need a multimeter. Set the meter to read ohms. Touch the cables of the multimeter to the plugs of the sensor. The reading should be approximately 560 ohms, more or less.

You should also check the condition of the connector for the sensor. If that’s dirty, then the Polaris may not be able to detect the sensor.

Solution

Replace the sensor if the resistance is not in the appropriate range. If it’s damaged, then you must replace it. If you find the connector all dirty, clean it.

If the crankshaft looks fine, but the error code persists, you’d better have your Polaris checked by an expert as soon as possible.

7. Polaris Engine Code 1127

This code tells you something is wrong with the turbocharger boost sensor. The voltage of the sensor is either too high or too low. That’s why two other codes are used to specify the problem. 

Symptoms

Other than the error code, you might also experience- 

• Insufficient power.
• Hesitation or poor acceleration.
• Rough idle.
• Emissions increased or failed.

Reason

The meaning of this code is simple: the boost pressure sensor is defective. There are two ways to verify the functionality of the boost pressure sensor: by testing the voltage or the output signal.

We have explained the voltage testing method below because that’s comparatively simpler. 

First, make sure the sensor body is disconnected from the electrical plug. The sensor does not need to be removed from the manifold when checking the supply voltage. Leave the ignition on.

Then set the multimeter to measure DC voltage. Test the supply voltage between PIN C  and ground A of the sensor. There should be about 5 volts in the supply voltage reading.

Solution

If the voltage is not approximately 5 volts, the sensor could be defective. As a routine check, look for wiring damage or a connection problem. If all seems well, replace the sensor. You can also try cleaning it if it looks dirty.

FAQs

How do I find my Polaris engine code?

You can find the diagnostic code by pushing the “MODE” button on the rider information center. Then you’ll need to cycle to the “DIAG CODE” option by continuously pressing the “MODE” button. Then you’ll find the error codes you are looking for. 

Does Polaris use OBD2?

Yes, OBD2 scanners are compatible with almost all Polaris vehicles. But the Polaris vehicle must have a 4-pin square digital connector. 

Will an engine code reset itself?

No, an engine code will not reset itself. Engine codes represent a specific error in your vehicle’s system. The code will not go away until the problem is fixed. 

Conclusion

Polaris engine codes are beneficial when trying to detect issues with your Polaris engine. A simple fix will reset the error code if the problem can be found and fixed. 

Although most problems are simple, some can be tricky and require a lot of diagnoses. In such cases, it’s better to call in the expert.

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Mark Williams

Founder and Author at Theautomobily

Mark Williams is the founder and author of Theautomobily located in Tucson, AZ. As a Mechanical Engineer,He has 15 years of experience in the automobile industry. Mark's deep understanding of various types of vehicles such as UTVs, ATVs, cars, Trucks, and lawnmowers which allows him to provide valuable insights and information.

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