2016 Polaris Ranger 900 Xp Error Code 746 5

There’s nothing more frustrating than gearing up for a day on the trail, turning the key on your Ranger 900 XP, and being greeted by a check engine light. When the engine just cranks and refuses to start, and you see the 2016 polaris ranger 900 xp error code 746 5 on your display, it can bring your entire adventure to a screeching halt.

But don’t reach for your phone to call a tow truck just yet. At FatBoysOffroad, we’re all about empowering you to handle these jobs in your own garage. This problem is often simpler than it looks, and with the right approach, you can diagnose and fix it yourself.

We promise this guide will give you the confidence and knowledge to tackle this issue head-on. We’ll break down exactly what this code means, walk you through a logical, step-by-step diagnostic process, and show you how to get your Ranger roaring back to life. Let’s get those tools out and get to work.

What Does Error Code 746 5 Actually Mean on Your Ranger?

Seeing a string of numbers on your dash can be confusing, but fault codes are just your machine’s way of telling you where to look. The code 746 5 is a standard SAE diagnostic code used by Polaris and other manufacturers.

Let’s break it down:

SPN 746: This points directly to the Fuel Pump Driver Circuit.
FMI 5: This specifies the fault type as Current Below Normal or Open Circuit.

In plain English, your Ranger’s Engine Control Unit (ECU) is trying to send power to the fuel pump, but it’s not detecting a complete circuit. It’s like flipping a light switch, but the wire to the bulb is cut, the bulb itself is burned out, or the switch is broken. The ECU knows something is wrong and throws the 2016 polaris ranger 900 xp error code 746 5 to alert you.

Common symptoms you’ll experience with this code include:

The engine cranks but will not start (most common).
You don’t hear the familiar 2-3 second “whirr” or “hum” of the fuel pump priming when you turn the key to the ON position.
The engine starts but sputters and dies shortly after.
A persistent check engine light (CEL).

Safety First: Before You Grab Your Tools

Anytime you work on a fuel system, safety is non-negotiable. Fuel vapors are highly flammable, so take these precautions seriously before you start any diagnostic work.

Disconnect the Battery: Always disconnect the negative battery terminal first to prevent any accidental sparks.
Ventilate Your Workspace: Work in a well-ventilated garage with the doors open or, even better, outside.
No Sparks or Flames: This is an absolute rule. No smoking, no welding, no grinding, and keep any potential sources of ignition far away.
Fire Extinguisher Ready: Have a Class B (or ABC) fire extinguisher within arm’s reach, just in case.
Wear Protective Gear: Safety glasses and nitrile gloves are your best friends here.

Your Diagnostic Toolkit: What You’ll Need

You don’t need a full professional shop to solve this issue. Most of the work can be done with a few essential tools. Having these ready will make the process much smoother.

Digital Multimeter: This is the most important tool for this job. You’ll need it to check for voltage and continuity. A basic one will do just fine.
Basic Socket and Wrench Set: For disconnecting the battery and potentially removing panels.
T-25 Torx Bit/Driver: You’ll likely need this to unbolt and tilt the bed for access to the fuel pump.
Test Light: A simple 12V test light can be a quick alternative to a multimeter for checking for power.
Wire Care Supplies: Wire strippers, butt connectors, heat shrink tubing, and quality electrical tape are good to have for potential wiring repairs.
Zip Ties: Perfect for tidying up your repair and securing wiring harnesses.

How to Fix the 2016 Polaris Ranger 900 XP Error Code 746 5: A Step-by-Step Guide

We’re going to approach this logically, starting with the easiest and most common fixes first. Don’t skip steps! This methodical approach is the fastest way to find the root of the problem.

Step 1: The Easiest Check – Fuses and Relays

Before you start tearing things apart, always check the simple stuff. A blown fuse or a bad relay is a common cause and a five-minute fix.

Locate the fuse box, typically under the driver’s side of the dashboard. Open the cover and find the fuse labeled for the fuel pump (it’s often a 15A fuse). Pull it out and inspect it. If the metal strip inside is broken, you’ve found your culprit. Replace it with a fuse of the exact same amperage.

Next, find the fuel pump relay. A great pro tip is to find an identical relay in the fuse box that powers a non-essential component (like the horn or accessory power). Swap the fuel pump relay with the identical one. If your Ranger starts, you’ve found the bad relay. Just be sure to buy a new one to replace the one you borrowed.

Step 2: Listen for the Prime – A Simple Audio Test

This is a quick and easy test. Go to a quiet area, put your ear near the fuel tank (located under the passenger seat area), and have a friend turn the key to the “ON” position (not all the way to “START”).

You should hear a distinct 2-3 second humming sound as the fuel pump pressurizes the system. If you hear nothing, it’s a strong confirmation that the pump is either dead or not receiving power, which aligns perfectly with code 746 5.

Step 3: Inspect the Wiring Harness (The Most Common Culprit)

Off-roading is brutal on wiring. Vibration, mud, water, and impacts can cause wires to rub through their insulation, a condition known as chafing. This is one of the most common problems with 2016 polaris ranger 900 xp error code 746 5.

Start at the fuel pump’s electrical connector, which is on top of the fuel tank. You will likely need to lift or tilt the bed to get good access. Visually trace the harness as it runs from the pump along the frame towards the front of the vehicle. Pay close attention to these areas:

Where the harness bends or goes around a sharp edge of the frame.
Anywhere the harness is secured with a zip tie or clamp (these can rub).
Near hot components like the exhaust.

Look for any breaks, exposed copper wire, or green, crusty corrosion inside connectors. If you find a damaged section, that’s almost certainly your issue. This is where your wire repair supplies come in handy.

Step 4: Test for Power at the Pump Connector

If the wiring looks okay, it’s time to confirm if power is actually reaching the pump. This is where your multimeter becomes essential.

Access and Disconnect: Get to the fuel pump connector on top of the tank and disconnect it.
Set Your Multimeter: Set your multimeter to DC Volts (V⎓).
Test for Voltage: Identify the power and ground wires in the connector (the side coming from the vehicle’s harness, not the pump itself). The power wire is often gray with a red stripe, and the ground is black, but consult your service manual to be sure. Place the red probe of your multimeter on the power pin and the black probe on the ground pin.
Turn the Key: Have a helper turn the key to the “ON” position. For 2-3 seconds, you should see a reading of approximately 12 volts on your multimeter.

Decision time: If you get 12V for a few seconds, it means the fuse, relay, and wiring are doing their job. The problem is very likely a dead fuel pump. If you get no voltage, the problem is “upstream” in the wiring, relay, or fuse you may have missed.

Step 5: Check the Ground Connection

A bad ground is just as bad as a broken power wire. An electrical circuit needs a clean path back to the battery to function. Find where the fuel pump’s ground wire (usually black) bolts to the vehicle’s frame. Unbolt it, clean the contact point and the wire’s terminal with a wire brush until they are shiny, and re-secure it tightly.

Best Practices for Prevention: Your Care Guide

Once you’ve fixed the issue, you want to prevent it from happening again. Following this 2016 polaris ranger 900 xp error code 746 5 care guide can save you a lot of future headaches.

Regular Inspections: Every time you wash your Ranger, take a minute to visually inspect the main wiring harnesses for any signs of rubbing or damage.
Use Dielectric Grease: Apply a small amount of dielectric grease to the pins of the fuel pump connector before you plug it back in. This helps seal out moisture and prevent corrosion.
Secure Loose Wires: If you see any part of the harness sagging or flopping around, secure it with a zip tie. Just make sure the zip tie isn’t so tight that it cuts into the wires over time.
Sustainable Repairs: Adopting a sustainable mindset is one of the best 2016 polaris ranger 900 xp error code 746 5 best practices. Instead of just throwing parts at the problem, finding and fixing a single broken wire is a more eco-friendly and cost-effective solution.

Frequently Asked Questions About Error Code 746 5

Can I still drive my Ranger with code 746 5 active?

Almost certainly not. This code indicates a failure in the fuel delivery circuit. Your engine either won’t start at all or will be incredibly unreliable and could shut off at any moment, which is unsafe. This is a “fix before you ride” issue.

How much does it cost to fix this error?

The cost can vary dramatically. If it’s a blown fuse, you’re looking at less than a dollar. If it’s a simple wiring repair you do yourself, the cost is just your time and a few cents for a connector. A new fuel pump relay might be $15-$30. A complete replacement fuel pump assembly is the most expensive part, typically running from $150 to over $300.

My multimeter shows 12V at the pump connector, but it still won’t prime. What now?

This is the classic sign of a failed fuel pump. The vehicle’s electrical system is delivering the necessary power, but the electric motor inside the pump assembly has burned out or failed. It’s time to replace the fuel pump.

Is it possible the ECU is bad?

While it’s technically possible for the fuel pump driver circuit inside the ECU to fail, it is extremely rare. This should be the absolute last thing you consider after you have 100% ruled out all wiring, fuse, relay, and fuel pump issues.

Diagnosing an electrical fault like the 2016 polaris ranger 900 xp error code 746 5 can seem intimidating, but it’s all about a logical process of elimination. By starting with the simplest solutions and working your way through the circuit, you can accurately pinpoint the failure without guesswork.

You’ve got the knowledge and the plan. Now you can approach this problem with confidence, save yourself a costly trip to the dealer, and gain valuable experience working on your own machine. That’s what being a DIYer is all about.

Ride safe, wrench smart, and we’ll see you out on the trails.

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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.