You’re geared up for a day on the trails, you turn the key on your trusted 2016 Polaris Sportsman 570, and then you see it—the dreaded check engine light. Your dashboard flashes a code: 168 3. It’s a frustrating moment that can stop a great day of riding in its tracks.
We’ve all been there. A cryptic code pops up, and your mind starts racing through worst-case scenarios and expensive repair bills. But you’ve come to the right place. We promise to demystify this specific error and give you a clear, actionable plan to diagnose and fix the root cause yourself.
In this complete 2016 polaris 570 sportsman 168 3 code guide, we’ll break down what the code means, walk you through safe and simple diagnostic steps using basic tools, and show you how to perform the most common repair. Let’s get you back on the trail with confidence.
What Does the 2016 Polaris 570 Sportsman 168 3 Code Actually Mean?
Think of error codes as a language your ATV uses to tell you what’s wrong. The key is knowing how to translate it. The code 168 3 isn’t just a random number; it’s a specific message from your machine’s brain, the Engine Control Unit (ECU).
Let’s break it down:
- SPN 168: This part of the code points to the System Voltage. It’s telling you the problem is within the main electrical charging system.
- FMI 3: This specifies the type of fault. It means Voltage Above Normal, or Shorted to High Source.
In plain English, the 2016 polaris 570 sportsman 168 3 code means your Sportsman’s electrical system is overcharging. The ECU has detected that the voltage being sent to the battery is dangerously high, typically spiking above 15.5 volts.
A healthy system should operate between 13.5 and 14.8 volts while running. Anything higher is a serious problem that can cause a cascade of expensive failures if left unchecked. This is one of those codes you need to address immediately.
Common Problems and Symptoms of an Overcharging System
An overcharging condition isn’t subtle. Besides the check engine light, your ATV will likely show other signs of electrical distress. Being aware of these common problems can help you confirm the diagnosis and understand the urgency.
Keep an eye (and ear) out for these red flags:
- Extremely Bright or Flickering Headlights: One of the first things you might notice is that your headlights seem brighter than a supernova, or they flicker erratically as you rev the engine. This is a classic sign of too much voltage.
- A Swollen or Leaking Battery: This is a critical safety warning. Excess voltage literally boils the electrolyte inside your battery, causing it to swell, hiss, or leak sulfuric acid. If you see this, stop immediately and handle the battery with extreme care.
- A “Rotten Egg” Smell: The smell of sulfur near your battery is a dead giveaway that it’s being cooked by overcharging.
- Burnt Out Bulbs or Fuses: The electrical system is designed for a specific voltage range. When that’s exceeded, weaker components like light bulbs and fuses are the first to fail.
- Poor Engine Performance: Modern ATVs rely heavily on stable voltage for fuel injection, spark, and sensor readings. An overcharging system can cause erratic running, stalling, or a no-start condition.
Ignoring these symptoms is one of the worst things you can do. The ultimate risk is frying expensive components like your dashboard display, wiring harness, or the ECU itself—turning a relatively simple fix into a four-figure nightmare.
Essential Tools and Safety Gear for Your Diagnosis
Before you dive in, let’s get your workspace set up. The good news is that you don’t need a professional shop full of expensive equipment. This is a job you can absolutely tackle with a few key tools. This is the first step in our “how to 2016 polaris 570 sportsman 168 3 code” troubleshooting process.
Must-Have Tools:
- Digital Multimeter: This is your single most important tool. You don’t need a high-end one; a basic model that can read DC voltage is perfect for this job.
- Socket and Wrench Set: You’ll need 8mm, 10mm, and 13mm sockets or wrenches for battery terminals and component mounting bolts.
- Wire Brush: A small brush is essential for cleaning corrosion off battery terminals and ground points.
- Dielectric Grease: A small tube of this will protect your electrical connections from moisture and corrosion when you put everything back together.
Safety First, Always:
- Safety Glasses: Non-negotiable. You are working around a battery that could potentially leak acid. Protect your eyes.
- Mechanic’s Gloves: Nitrile or similar gloves will protect your hands from dirt, grease, and potential battery acid contact.
How to Diagnose the 2016 Polaris 570 Sportsman 168 3 Code: A Step-by-Step Guide
Now it’s time to play detective. We’ll follow a logical process, starting with the simplest checks and moving to the definitive test. This methodical approach ensures you don’t waste time or money replacing parts you don’t need.
Step 1: The Visual Inspection (Start Simple)
Before you grab any tools, use your eyes. Many electrical issues are caused by simple, visible problems. Pop the seat and front plastics to get a clear view of the battery and wiring.
- Check the Battery Terminals: Are they tight? A loose connection can cause all sorts of weird readings. Are they clean? Look for fuzzy, white, or blue-green corrosion. If you see any, disconnect the battery (negative cable first!) and clean the terminals and cable ends with a wire brush.
- Inspect the Battery Case: Look closely at the battery. Do you see any bulging or swelling on the sides? Any signs of moisture or leaking from the seams or caps? A damaged battery is a failed battery.
- Trace the Wires: Follow the main positive and negative battery cables. Check the main ground connection where the negative cable bolts to the frame. Ensure it’s clean and tight. Look over the wiring harness leading from the front of the machine for any obvious signs of damage, like melted plastic, chafed insulation, or breaks.
Step 2: Testing Your Battery and Charging System with a Multimeter
This is the test that will give you a definitive answer. Set your multimeter to the DC Voltage setting (V with a straight line, or VDC). A reading of “20” is a good range to select.
Test 1: Static Voltage (Engine Off)
With the engine completely off, touch the red probe of your multimeter to the positive (+) battery terminal and the black probe to the negative (-) terminal. A fully charged, healthy battery should read between 12.6V and 12.8V. A reading below 12.4V suggests a weak or discharged battery.
Test 2: Charging Voltage (Engine Running)
Now, start the Sportsman and let it idle. Keep the multimeter probes connected to the battery terminals. A healthy charging system should be putting out 13.5V to 14.8V at idle.
Test 3: The Overcharge Test (The Moment of Truth)
This is the most important test for code 168 3. While watching the multimeter, slowly increase the engine RPMs to around 3,000 (a fast idle). The voltage should rise slightly and then stabilize, staying firmly below 14.9V.
If you see the voltage climbing past 15V, 16V, or even higher as you increase the RPMs, you have confirmed an overcharging condition. You can now be 99% certain the voltage regulator has failed.
Step 3: Pinpointing the Culprit – The Voltage Regulator
The job of the voltage regulator/rectifier is to take the wild AC power generated by the stator and convert it to clean DC power, “regulating” it to a safe voltage to charge the battery and run the machine. When it fails, it loses its ability to regulate, sending uncontrolled high voltage through the system.
While a bad stator or wiring can cause charging problems, they almost never cause an overcharging condition. That symptom points directly at a failed regulator.
The Most Common Fix: Replacing Your Voltage Regulator
Now that you’ve confirmed the diagnosis, it’s time for the fix. Replacing the voltage regulator on a Sportsman 570 is a straightforward job. It’s one of the best benefits of 2016 polaris 570 sportsman 168 3 code diagnosis—the repair is very DIY-friendly.
The voltage regulator is a metal block with cooling fins, typically located at the front of the ATV, often behind the radiator, to get good airflow.
- Disconnect the Battery: ALWAYS disconnect the negative battery cable before starting any electrical work.
- Locate the Regulator: Find the finned metal box with two electrical plugs attached to it.
- Unplug the Connectors: Carefully unplug the two wiring harness connectors. They have locking tabs you’ll need to press to release them. Inspect the connectors for any signs of melting or corrosion.
- Unbolt the Old Regulator: Remove the two bolts holding the regulator to the frame.
- Clean the Mounting Surface: Use a rag or light scuff pad to clean the spot on the frame where the regulator was mounted. A clean, metal-to-metal contact is crucial for proper grounding and heat dissipation.
- Install the New Regulator: Bolt the new regulator securely in place.
- Apply Dielectric Grease: Squeeze a small amount of dielectric grease into the electrical connectors on the new regulator. This prevents moisture intrusion and ensures a solid connection.
- Reconnect and Re-Test: Plug the wiring harness back in, reconnect your battery (positive cable first this time), and repeat the multimeter test (Step 2). You should now see a stable voltage in the 14.0V to 14.8V range, even when you rev the engine.
Once confirmed, clear the code (often done by disconnecting the battery for a few minutes or through the dash display options) and go for a test ride.
Best Practices for a Healthy Electrical System: A Pro Care Guide
Fixing the problem is great, but preventing it from happening again is even better. Adopting a few 2016 polaris 570 sportsman 168 3 code best practices will extend the life of your entire electrical system.
- Keep It Clean: Periodically check and clean your battery terminals and main ground connection. Corrosion creates resistance, which makes electrical components work harder and fail sooner.
- Use a Battery Tender: If your ATV sits for long periods, use a smart battery tender (not a simple trickle charger). This keeps the battery optimally charged without overcharging it, which significantly extends its life.
- Seal Your Connections: Any time you unplug an electrical connector, it’s a good idea to add a dab of dielectric grease before plugging it back in, especially on a machine that sees mud and water.
This approach to maintenance is also the most sustainable 2016 polaris 570 sportsman 168 3 code strategy. By preventing component failure, you reduce waste and avoid replacing parts unnecessarily. A well-cared-for machine is an eco-friendly 2016 polaris 570 sportsman 168 3 code solution, as it prevents acid leaks and saves resources.
Frequently Asked Questions About the 2016 Polaris 570 Sportsman 168 3 Code
Can I still ride my Sportsman with code 168 3?
It is strongly not recommended. Continuing to ride with an overcharging condition can cause irreversible damage to your battery, ECU, and other electronics. The risk of being stranded far from the trailhead is also very high.
How much does a new voltage regulator cost?
Prices vary, but you can typically expect to pay between $50 and $150 for a quality aftermarket or OEM voltage regulator. Given the potential cost of the components it protects, it’s a very worthwhile investment.
Is this a difficult repair for a DIYer?
Not at all. If you can use a basic socket set and a multimeter, you can absolutely do this job. It typically takes less than an hour and is one of the more satisfying repairs you can do yourself.
Could a bad battery cause this code?
It’s highly unlikely. While a bad battery can cause many electrical problems (like under-charging or no-start issues), it is almost never the cause of an overcharging fault. The code 168 3 is a clear signal that the system is producing too much voltage, a problem that originates before the battery.
Tackling the 2016 polaris 570 sportsman 168 3 code doesn’t have to be intimidating. By following this guide, you’ve learned how to translate the code, diagnose the problem with confidence, and perform the most common repair. You not only saved a trip to the dealer but also gained valuable experience working on your own machine.
Now that you’ve got it fixed, get your gear on and get back out there. The trails are waiting! Ride safe and have fun.
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