2012 Polaris Assault 800 Check Engine Code 524007

You’re geared up, the sled is unloaded, and there’s a fresh blanket of powder just waiting for you. You turn the key on your 2012 Polaris Assault 800, and there it is—the dreaded check engine light. Your dash flashes a code: 524007. That single code can bring a perfect day to a screeching halt.

We’ve all been there. That sinking feeling in your gut when a fault code threatens your ride is something every off-roader knows. But don’t load that sled back on the trailer just yet.

We promise this guide will demystify the situation. Here at FatBoysOffroad, we believe in empowering you to handle these issues yourself. This article is your complete roadmap to understanding, diagnosing, and fixing the 2012 Polaris Assault 800 check engine code 524007. We’ll give you the step-by-step instructions, pro tips, and confidence to get back on the snow where you belong.

What is Fault Code 524007 Telling You? Decoding the EGT Sensor Warning

First things first, let’s translate what your sled is trying to say. Polaris fault code 524007 points directly to a problem within the Exhaust Gas Temperature (EGT) sensor circuit. This isn’t just a random sensor; it’s a critical component for your engine’s health and performance.

The EGT sensor’s job is to measure the temperature of the exhaust gases leaving your engine. It sends this data to the Engine Control Unit (ECU), which then makes real-time adjustments to the fuel mixture and timing. This process is vital for two reasons: maximizing power and preventing catastrophic engine damage from overheating.

When you see code 524007, it’s often accompanied by a Failure Mode Identifier (FMI) number. This gives you a massive clue about the specific problem:

FMI 3: Voltage Above Normal / Shorted to High. The ECU is seeing a voltage signal that’s impossibly high, suggesting a short circuit to a power source.
FMI 4: Voltage Below Normal / Shorted to Low. The ECU is reading a voltage that’s too low, often indicating a short circuit to ground.
FMI 5: Current Below Normal / Open Circuit. This is very common. It means there’s a break in the circuit somewhere—a broken wire, a bad connection, or a failed sensor.

Essentially, the ECU has lost its eyes on the exhaust temperature and is throwing a flag to protect your engine.

Common Problems with 2012 Polaris Assault 800 Check Engine Code 524007

When the EGT sensor circuit fails, your sled’s ECU goes into a self-preservation state. It no longer has reliable data, so it takes protective measures that you will definitely feel from the handlebars. This is one of the most common problems with 2012 Polaris Assault 800 check engine code 524007.

You’ll likely experience one or more of these symptoms:

Check Engine Light (CEL): This is the most obvious sign. The light will stay on, and the code will be present.
Limp Mode: The ECU will drastically reduce engine power and limit RPMs to prevent damage. Your powerful 800 will feel sluggish and weak.
Poor Performance: Even if not in full limp mode, you may notice bogging, hesitation, or inconsistent power delivery.
Hard Starting: Without accurate temperature data, the ECU may struggle to provide the correct fuel mixture for a clean start.

These symptoms are your sled’s way of screaming for help. Ignoring them can lead to more severe engine issues down the line, so it’s best to address the code promptly.

Tools and Safety First: Prepping for Your Diagnosis

Before you start tearing into your sled, let’s get organized and prioritize safety. A little prep work makes the whole job smoother and safer. This is one of the most important 2012 Polaris Assault 800 check engine code 524007 tips we can offer.

Safety Warning: The EGT sensor is located in the exhaust. Always let the engine and exhaust system cool down completely before starting any work. A hot exhaust pipe will cause severe burns instantly.

Your Diagnostic Toolkit:

Basic Hand Tools: A good socket set, combination wrenches (specifically for the sensor size), and a Torx bit set for removing panels.
Digital Multimeter: This is non-negotiable. A simple Digital Volt-Ohm Meter (DVOM) is your best friend for testing the sensor and wiring.
Lighting: A headlamp or a good flashlight will help you see into the tight spaces of the engine bay.
Shop Supplies: Have some zip ties, electrical tape, and a can of electronics-safe contact cleaner on hand.
Dielectric Grease: Perfect for protecting electrical connections from moisture and corrosion.
Service Manual (Optional but Recommended): Having the official manual for your sled provides exact specs and diagrams.

Once you have your tools and a cool engine, disconnect the battery’s negative terminal as an extra safety precaution.

How to Fix 2012 Polaris Assault 800 Check Engine Code 524007: A Step-by-Step Guide

Alright, let’s get our hands dirty. Follow this logical process, and you’ll pinpoint the problem efficiently. This is your complete 2012 Polaris Assault 800 check engine code 524007 guide to a successful DIY repair.

Step 1: Locate the EGT Sensor

First, you need to find your target. The EGT sensor is a small probe screwed directly into the exhaust pipe. On the 2012 Assault 800, you’ll typically find it on the main expansion chamber (the large, tuned part of the exhaust pipe) after the “Y-pipe” where the two exhaust ports merge.

Follow the wires. You’ll see a wire with a protective heat sleeve running from the sensor to a connector clipped to the chassis.

Step 2: The Visual Inspection: Your First Line of Defense

Many EGT sensor issues are caused by simple physical damage. Before you grab your multimeter, use your eyes. A thorough visual check can often solve the mystery in minutes.

Carefully trace the wiring harness from the sensor all the way to where it joins the main sled harness. Look for:

Melted Wires: Has the wire come loose and made contact with the hot exhaust pipe?
Chafed or Rubbed Wires: Check anywhere the wire runs near the frame, engine mounts, or steering components. Vibration can easily wear through the insulation.
Pinched or Stretched Wires: Look for any signs that the wire has been pulled too tight or crushed by a panel.
Corroded Connectors: Unplug the sensor’s electrical connector. Are the pins green, white, and crusty? Moisture can ruin a good connection.

If you find any obvious damage, you’ve likely found your culprit. Repair the damaged wire with a quality butt connector and heat shrink tubing, or clean the connector with contact cleaner and apply dielectric grease.

Step 3: Testing the EGT Sensor with a Multimeter

If the visual inspection looks clean, it’s time to test the sensor itself. This is where your multimeter proves its worth.

Keep the sensor’s electrical connector unplugged.
Set your multimeter to the Ohms (Ω) setting, usually the 2k Ohm range is a good place to start.
Touch the two multimeter probes to the two metal pins inside the sensor’s side of the connector.
At room temperature (around 68°F / 20°C), a good EGT sensor should have a resistance reading of approximately 200-220 Ohms. (Note: Always consult your service manual for the exact specification for your model).

If your reading is wildly different—such as “OL” (Open Loop/infinite resistance) or 0 Ohms (a dead short)—the sensor has failed internally and needs to be replaced.

Step 4: Replacing the EGT Sensor

If your tests confirm a bad sensor, replacement is straightforward. Using the correct size wrench, carefully unscrew the old sensor from the exhaust pipe. It might be tight, so a little penetrating oil can help (just be sure to wipe it off before starting the engine).

Apply a very small amount of high-temp anti-seize compound to the threads of the new sensor, being extremely careful not to get any on the sensor probe itself. Thread it in by hand to avoid cross-threading, then tighten it to be snug. Plug in the new connector and route the wire carefully, using zip ties to secure it away from any hot or moving parts.

Best Practices for a Long-Lasting Repair: Your 2012 Polaris Assault 800 Care Guide

Fixing the problem is great, but preventing it from happening again is even better. Adopting some 2012 Polaris Assault 800 check engine code 524007 best practices will ensure your repair lasts.

When installing a new sensor or repairing wiring, always focus on proper routing. Leave a little slack so engine vibration doesn’t stress the wire, but use zip ties to secure it firmly away from the exhaust pipe and any sharp edges on the frame.

Using a dab of dielectric grease inside the electrical connector is a pro tip that prevents moisture intrusion and corrosion, which is a common failure point on snowmobiles that see a lot of snow and water.

Finally, think about the bigger picture. A properly functioning EGT sensor ensures your engine runs efficiently. This means it’s burning fuel as cleanly as possible. This approach to maintenance is not only good for your sled’s performance but is also a more sustainable and eco-friendly way to enjoy the sport.

Frequently Asked Questions About Polaris Code 524007

Can I still ride my sled with code 524007 active?

It is strongly not recommended. Your sled will most likely be in a reduced-power “limp mode” to protect the engine. Continuing to ride without the ECU knowing the exhaust temperature could lead to a lean fuel condition and potentially catastrophic engine damage like a melted piston.

How much does a new EGT sensor for a 2012 Assault 800 cost?

Prices can vary, but you can typically expect an OEM (Original Equipment Manufacturer) sensor to be in the range of $100-$150. Aftermarket options may be available for slightly less, but for a critical component like this, we often recommend sticking with OEM for the best fit and reliability.

Do I need to clear the code after replacing the sensor?

In most cases, no. After you’ve successfully replaced the sensor or repaired the wiring, the ECU will recognize the valid signal on the next startup. The check engine light should turn off and the code will clear itself after one or two warm-up cycles.

What if I replace the sensor and the code comes back?

If a new, tested sensor doesn’t fix the problem, the issue lies elsewhere in the circuit. Go back and meticulously re-inspect the wiring harness between the sensor and the ECU. A hidden break or short in the harness is the most likely culprit. In very rare cases, it could indicate an issue with the ECU itself, which is a job best left for a professional dealer technician.

Tackling a check engine light can feel intimidating, but you’ve got this. By following this how to 2012 Polaris Assault 800 check engine code 524007 guide, you’ve learned what the code means, how to test for it, and how to fix it right. Now you can get that sled buttoned up with confidence.

Stay safe out there, and enjoy the ride!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.