Polaris 800 quad. has code 41, says intake air temp sensor. I found a BOSCH sensor in the boot infront of air box. Dealer had one, so I replaced it ($93). Code 41 still there.
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Ok the 6 amp fuse is for the ecm the 15 amp fuse is for the cluster one of the 20 amp is main power the outher 20 amp should be for the starter and charging circuit .your over heating problem could be in the fan temp sensor you will find it on the left side of the machine on top of the thermostat housing , take and disconnect the plug on it and jumper the two wires togather with key on fan should come on if it does replace fan temp sensor .if not visibly pull each fuse out and look to see if is burnt odds of the fan being bad is very uncommon. This will be all good if is an EFI 800 hope that is helpfull
This is only a hunch based on my experience with a 2003 Polaris Sportsman 700.
The air intake to the air box is tucked up under the body panel. It is located in such a manner that when going through water, the steam builds up at the top of the body panel, smothering out the fresh air and replacing it with hot wet steam.
Re-route your air intake out from under the body to a location that will not trap the steam and remain fresh, cool and dry. This goes for any ATV with this issue as a possibility for the symptoms.
FROM THE WEB>>> Code 27 is "TPS SET ERROR"..take it to the dealer. Throttle Position Sensor reading is off...the newer models check the TPS reading at a startup..and set that as a baseline...if the reading is outside the normal range it throws the code. Try not to touch the gas pedal when starting.
41 intake air temp sender: open or short circuit + sensor voltage (ECU) 46 Barometric pressure sensor : circuit high output. check connections first . sensors are pretty solid built seldom bad. the 41 is prolly dirty also. use air compressor to clean and contact cleaner if needed . lightly on air hose. be gentle with air sensor.
I found a list that might apply. Not specific to Polaris, but general for electrical. Code 021 reads accelerator fault safety lock out inspect accelerator resistance and wiring
Here's the complete list. http://www.electricforum.com/cars/ne...ror-codes.html
Hope this gives you something to look at
I also found this list specifically for Polaris:
21 Loss of Synchronization 22 TPS Circuit: Open and Short To Ground 22 TPS Circuit: Short To Battery 23 RAM Error: Defective ECU 25 Transmission Input - Invalid Gear 26 Vehicle Speed Sensor - Implausible 41 Air Temp Sensor: Open or Short Circuit to Sensor Voltage (ECU) 41 Air Temp Sensor: Short Circuit to Ground 42 Engine Temperature Sensor Circuit: Short To Ground 42 Engine Temperature Sensor Circuit: Open or Short to Battery 45 Barometric Pressure Sensor: Circuit Low Input 46 Barometric Pressure Sensor: Circuit High Input 51 Injector 1: Open Load 51 Injector 1: Short Circuit to Ground 51 Injector 1: Short Circuit to Battery 52 Injector 2: Open Load 52 Injector 2: Short Circuit to Ground 52 Injector 2: Short Circuit to Battery 54 Engine Temperature Lamp: Open Load 54 Engine Temperature Lamp: Short Circuit to Ground 54 Engine Temperature Lamp: Short Circuit to Battery 55 Diagnostic Lamp: Open Load 55 Diagnostic Lamp: Short Circuit to Ground 55 Diagnostic Lamp: Short Circuit To Battery 56 Pump Relay Open Load 56 Pump Relay Short Circuit to Ground 56 Pump Relay Short Circuit to Battery 58 Cooling Fan: Open Load 58 Cooling Fan: Short Circuit to Ground 58 Cooling Fan: Short Circuit to Battery 61 End of Diagnostic
Here is the lowdown on Polaris Sportsman 700-800 T-Bap wiring:
Symptoms of broken Temp/Baro sensor wires:
1. The ATV will run very erratic at idle.
2. The "CHECK ENGINE" will sometimes come on.
3. Diagnostic codes 41 and or 45 will be present.
4. Fuel mileage will be poor.
5. Exhaust will smell really rich. Sometimes even black smoke can be seen from it running so rich.
How to test if the Temp/Baro sensor wiring is broken:
1. Turn the key switch on and off 3 times leaving it on the 3rd time. This puts the ECU into diagnostic mode. If codes are present their numbers will be displayed on the instrument cluster. When all codes have been displayed "End" will appear on the cluster.
2. Remove the seat and locate the sensor on the air intake tube. Unplug the wiring to the sensor by pressing down on the tab on the top of the connector. DON'T PULL THE CONNECTOR BY IT'S WIRES!!! Pull back the vinyl tubing that covers the 4 wires going to the connector. Gently pull on each wire with your fingers. The wire should have no stretch and feel solid. All the wires should feel the same. If one or two of them feel weak and stretchy chances are you have a broken wire. Is what happens is the wire breaks inside the insulation so it appears to still be connected.
Why do the Temp/Baro sensor wires break in the first place?
1.The problem with the current Polaris wiring is too short and Polaris used 7/32 stranded 22AWG wire. This wire has a very low strand count and should not be used in applications where vibration occurs.
2.The next problem is the mounting location of the sensor it is in a vibration prone spot on top the air intake tube going from the air box to the throttle body. Next time you're bored take the seat off and rev it up in neutral. That intake boot and sensor vibrate to the point where it looks blurry. The combination of these engineering flaws causes the cable to break in a big hurry.
The Polaris repair kits keep breaking. Why?
1. The replacement kits from Polaris use the same 7/32 strand wire that can't withstand vibration.
find a heavy duty one on the internet or ebay................
Did you replace the air filter? Do that.
This sounds a little deep for "good advice" on here.. three dealers couldn't fix it...??? I have fixed bikes that other dealers couldn't in the past... this sounds like an issue that will be fixed by someone that has had this same experience...(that's how I did it!)
Good Luck!!!!
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