2012 Polaris Assault 800 Check Engine Code 524007 3

There’s nothing that kills the thrill of a perfect powder day faster than a flashing check engine light on your dash. You’re all geared up, the sled is warmed up, but that blinking light on your 2012 Polaris Assault 800 is staring you down, throwing a cryptic code: 524007 3.

You’ve probably been there. That feeling of frustration, wondering if your day is over before it even started. Is it serious? Is it expensive? Can I fix it myself?

We promise this guide will demystify the 2012 polaris assault 800 check engine code 524007 3. We’re here to take you from confused rider to confident DIY mechanic. You’ll learn exactly what this code means, how to pinpoint the cause, and how to fix it with common tools you likely already have.

In this comprehensive guide, we’ll walk you through a step-by-step diagnostic process, cover the common problems that trigger this code, and give you the pro tips to get your sled back on the snow where it belongs. Let’s get that wrench turning.

What Exactly is Check Engine Code 524007 3 Telling You?

First things first, let’s translate that number into plain English. Polaris, like other manufacturers, uses a standardized system for fault codes called SPN/FMI. It looks intimidating, but it’s actually a very logical system.

Think of it like a mailing address for a problem in your engine.

SPN 524007: This part of the code points to a specific component. In this case, it’s the Exhaust Gas Temperature (EGT) Sensor.
FMI 3: This is the “Fault Mode Identifier.” It tells you the type of problem. FMI 3 means “Voltage Above Normal, or Shorted to High.”

So, putting it all together, the 2012 polaris assault 800 check engine code 524007 3 means your sled’s computer (ECU) is seeing a voltage signal from the EGT sensor that is too high. The ECU knows this reading is impossible under normal conditions, so it flags it as a fault.

This almost always points to an electrical circuit issue, not a problem with the actual temperature of your exhaust.

Common Symptoms and Why You Can’t Ignore This Code

When this code pops up, your Assault 800 will likely give you more clues than just a number on the screen. Understanding these symptoms is a key part of our 2012 polaris assault 800 check engine code 524007 3 guide.

You’ll probably experience one or more of the following:

The Obvious Check Engine Light (CEL): The “CHK ENG” message on your gauge cluster is your first warning.
Limp Mode: This is the most significant symptom. To protect the engine from potential damage, the ECU will drastically reduce engine power and limit RPMs. Your powerful 800 will feel sluggish and weak.
Poor Performance: Even if it doesn’t go into full limp mode, the sled may run rough, hesitate, or feel “off.”

The EGT sensor’s job is critical. It acts as a safety guard, monitoring exhaust temps to prevent a catastrophic engine meltdown from a lean fuel condition or overheating. When the ECU can’t get a reliable reading from it, it plays it safe by restricting power. Ignoring this code isn’t just an option—you risk serious, and expensive, engine damage if there’s an underlying issue the sensor can no longer warn you about.

Tools and Parts You’ll Need for the Job

Before you dive in, let’s get your workstation prepped. The good news is you don’t need a full professional shop to tackle this job. Here are the essential tools and potential parts you’ll want on hand.

Essential Tools:

Basic Socket & Wrench Set: For removing panels and the sensor itself.
Torx Bit Set: Polaris uses Torx fasteners all over their machines.
Pliers: Needle-nose pliers are especially handy for connectors.
Digital Multimeter (DMM): This is non-negotiable. A basic DMM is essential for accurately testing the sensor and wiring.
Pick or Small Screwdriver: For cleaning electrical connectors.

Helpful Supplies & Potential Parts:

Electrical Contact Cleaner: A must-have for cleaning dirty or corroded connectors.
Zip Ties: For securing repaired wiring away from heat sources.
Wiring Repair Supplies: A soldering iron, solder, and heat-shrink tubing for a professional-grade wiring fix.
New EGT Sensor: The most common culprit. The Polaris part number for many 2012 800 models is 4012988, but always verify with your VIN before ordering.

Step-by-Step Guide to Diagnosing the 2012 polaris assault 800 check engine code 524007 3

Alright, let’s get to the heart of it. Follow these steps methodically. Do not skip a step! Most of the time, the issue is simple and found early in the process. This is one of the most important how to 2012 polaris assault 800 check engine code 524007 3 tips we can offer.

Step 1: The Visual Inspection – Your First Line of Defense
More often than not, the problem is something you can see. The EGT sensor’s wiring harness lives in a hostile environment, right next to a hot exhaust pipe.
First, locate the EGT sensor. It’s a small probe threaded directly into the side of your exhaust pipe (the Y-pipe or the main pipe). Now, carefully trace its wire loom back towards the main harness. Look for:
- Melted Wires: Has the wire loom touched the hot exhaust and melted through?
- Chafed or Rubbed Wires: Check anywhere the harness runs near the frame or other components. Vibration can easily rub through the insulation.
- Pinched Wires: Look for any spots where the wire might be pinched between the frame and a side panel.
If you find a damaged wire, you’ve likely found your problem. Jump ahead to the section on wiring repair.
Step 2: Checking the Connections
If the wiring looks good, the next most common issue is a poor connection. Follow the EGT sensor wire to its connector—a small, weatherproof plastic plug.
Disconnect it carefully. Inside, inspect the metal pins and sockets. Are they green with corrosion? Covered in dirt or dielectric grease? Are any of the pins bent or pushed back into the connector?

Use your electrical contact cleaner and spray both sides of the connector thoroughly. Use a small pick to gently scrape away any stubborn corrosion. Make sure the pins are straight, then reconnect it with a firm “click.” Clear the codes and run the sled to see if the light comes back.
Step 3: Testing the EGT Sensor with a Multimeter
If the visual inspection and connector cleaning didn’t solve it, it’s time to test the sensor itself. This is where your Digital Multimeter becomes your best friend.
Set your DMM to the Ohms (Ω) setting, usually in the 2k range. With the sensor unplugged, touch one probe to each of the two pins on the sensor side of the connector.

A good EGT sensor on a 2012 800 should have a resistance of approximately 210-220 Ohms at room temperature (around 70°F / 20°C). If you see a reading way outside this range, or if your meter reads “OL” (Open Loop/Infinite Resistance), the sensor is bad and needs to be replaced.
Step 4: Testing the Wiring Harness
If your sensor tested good, the final possibility is a problem in the wiring harness between the connector and the ECU. This is a bit more advanced, but manageable.
You’re checking for two things: continuity (the wire is intact) and a short (the wire is touching something it shouldn’t be).

To check for a short to high (which is what FMI 3 indicates), you would need to test for voltage on the signal wire with the key on. A simpler check is to inspect for continuity between each of the two wires in the harness side of the EGT connector and a known good ground on the chassis. There should be no continuity. If your meter beeps, you have a short to ground in the harness that needs to be found and repaired.
Pro-Tip & Safety Warning: If you’re not comfortable with advanced electrical diagnostics, this is the point where calling a qualified technician is the best move. It’s better to be safe than to risk damaging your ECU.

The Fix: How to Replace Your EGT Sensor and Repair Wiring

Once you’ve diagnosed the issue, the fix is usually straightforward. Following these 2012 polaris assault 800 check engine code 524007 3 best practices will ensure a lasting repair.

Replacing a Faulty EGT Sensor

If your sensor failed the resistance test, replacement is the only option. It’s a simple process:

Ensure the exhaust is completely cool to the touch.
Apply a small amount of penetrating oil to the threads where the sensor enters the pipe and let it sit for a few minutes.
Using the correct size wrench (often 13mm or 1/2 inch), carefully unscrew the old sensor.
Thread the new sensor in by hand to avoid cross-threading, then tighten it snugly with the wrench. Do not overtighten.
Plug in the new sensor, secure the wiring away from the pipe, and you’re done.

Best Practices for a Sustainable Wiring Repair

Found a broken or melted wire? Don’t just twist them together and wrap them in electrical tape. That’s a temporary fix that will fail from vibration and moisture. For a truly sustainable 2012 polaris assault 800 check engine code 524007 3 repair, do it right.

The best method is to solder the wires back together and protect the connection with heat-shrink tubing. This creates a strong, permanent, and weatherproof seal. Once repaired, use zip ties to intelligently route the harness, ensuring it has plenty of clearance from the hot exhaust pipe and any sharp edges on the frame.

Frequently Asked Questions About Polaris Code 524007 3

Can I ride my sled with code 524007 3?

You can, but you shouldn’t. The sled will be in limp mode, meaning you’ll have severely reduced power. More importantly, the ECU has lost its primary engine temperature safety sensor, putting your motor at risk if another issue (like a lean fuel condition) occurs.

How much does it cost to fix this code?

If you do it yourself, your only cost is parts. A new EGT sensor typically costs between $80 and $120. If the issue is just a dirty connector or a simple wire repair, it could cost you nothing but time. Taking it to a dealer will add 1-2 hours of labor cost to the price of the part.

Is the EGT sensor the same on all Polaris models?

No. While many 800cc models from that era use the same sensor, there can be variations. Always confirm the correct part number for your specific year and model using your sled’s VIN before purchasing.

Why does my new EGT sensor not fix the problem?

If you replaced the sensor and the code immediately returns, it strongly suggests the problem was never the sensor itself. Go back and re-check the wiring harness and connectors. The fault lies in the circuit between the sensor and the ECU.

Get Back on the Snow: Final Thoughts

Dealing with the 2012 polaris assault 800 check engine code 524007 3 can seem daunting, but it’s a very common and very fixable issue. By following a logical diagnostic path—Inspect, Test, Repair—you can save yourself a trip to the dealer and gain valuable experience working on your own machine.

Remember to work methodically, never skip a step, and always prioritize a quality repair over a quick fix. A proper wiring repair or a new sensor will give you peace of mind and ensure your Assault 800 is ready to rip for many seasons to come.

Now you have the knowledge and the step-by-step plan. Grab your tools, tackle that code, and get back to chasing that deep powder. Stay safe and ride on!

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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.