2017 Polaris Ranger 1000 Xp Crew Error Code 91

There’s nothing quite like the feeling of gearing up, loading the crew, and hitting the trail in your Ranger 1000 XP. But that excitement can grind to a halt when the check engine light flicks on and your rig suddenly feels like it’s lost all its power. You look down at the dash and see it: Error Code 91.

You’re not alone. This is a common hiccup for many owners, but it doesn’t have to mean an expensive trip to the dealer. We promise this guide will demystify the 2017 Polaris Ranger 1000 XP Crew error code 91 and give you the confidence and know-how to tackle it yourself.

In this FatBoysOffroad deep dive, we’ll walk you through exactly what this code means, the tools you’ll need, a step-by-step diagnostic process, and the most common fixes to get you back to kicking up dust in no time.

What Exactly is Error Code 91 and Why Is It On My Dash?

Let’s get straight to the point. On your Polaris, error code 91 translates to “Throttle Position Sensor (TPS) Circuit Low Voltage.” It sounds complicated, but the concept is pretty simple once you break it down.

Think of the Throttle Position Sensor (TPS) as the communication link between your foot and the engine. When you press the gas pedal, a butterfly valve inside the throttle body opens up. The TPS is a small electronic sensor attached to this valve that tells the engine’s brain, the ECU (Engine Control Unit), exactly how far open that valve is.

The ECU uses this information to deliver the perfect amount of fuel and spark for smooth acceleration. “Circuit Low Voltage” means the signal the ECU is receiving from the TPS is weaker than expected, or completely gone. When the ECU gets confused or receives bad data, it plays it safe by putting the vehicle into a protective “limp mode,” which is why you feel that drastic loss of power.

Common Symptoms of a TPS Fault

Limp Mode: The most obvious sign. Your Ranger will have severely limited power and won’t accelerate properly.
Erratic Idle: The engine might idle too high, too low, or hunt up and down.
Sputtering or Hesitation: When you press the gas, the machine might hesitate, sputter, or backfire before slowly picking up speed.
Poor Fuel Economy: An incorrect throttle reading can cause the engine to run rich, wasting fuel.

Essential Tools and Safety Prep for the Job

Before you dive in, let’s get your workspace and tools in order. A little preparation makes the job smoother and safer. This is one of the most important 2017 Polaris Ranger 1000 XP Crew error code 91 best practices you can follow.

First, park your Ranger on a level surface, turn it off, and remove the key. For any electrical work, it’s always a smart move to disconnect the negative terminal on your battery to prevent any accidental shorts.

Your Must-Have Tool List:

Digital Multimeter: This is non-negotiable. You cannot accurately diagnose this issue without one.
Basic Socket & Wrench Set: You’ll need these to access panels and components.
Torx Bit Set: Polaris loves using Torx fasteners, so a good set is essential.
Electrical Contact Cleaner: A spray can of this is perfect for cleaning dirty connectors.
Dielectric Grease: To protect electrical connections from moisture and corrosion after you’re done.
Zip Ties & Wire Cutters: For tidy wire management.
Flashlight or Headlamp: Good lighting is key to spotting damaged wires.

How to Fix 2017 Polaris Ranger 1000 XP Crew Error Code 91: A Step-by-Step Guide

Alright, let’s get our hands dirty. We’ll start with the simplest checks and work our way to the more technical tests. Following this order can save you a ton of time and frustration.

Step 1: The Visual Inspection (Find the Easy Fix)
Before grabbing any tools, just use your eyes. You’d be surprised what a thorough visual check can uncover. First, you need to locate the throttle body and the TPS.
On the 1000 XP engine, the throttle body is located between the airbox and the engine intake. The TPS is a small, black plastic sensor mounted to its side with a three-wire connector plugged into it.

Carefully inspect the wiring harness leading to the TPS. Look for any signs of rubbing, melting, fraying, or breaks. Wires can easily get chafed against the frame or engine components, causing a short. This simple step is a core part of any good 2017 Polaris Ranger 1000 XP Crew error code 91 care guide.
Step 2: Check the Connector and Pins
The connector is the most common point of failure. Over time, vibrations, mud, and water can cause a poor connection. Unplug the connector from the TPS. You may need to press a small tab to release it.
Inspect both the male and female ends. Are the pins clean and shiny, or are they green with corrosion? Are any of the pins bent, broken, or pushed back into the connector? Spray both ends with your electrical contact cleaner and use a small brush if needed to remove any gunk. Let it dry completely.
Step 3: Test the TPS with a Multimeter (The Moment of Truth)
This is where we confirm if the sensor itself is the problem. Set your multimeter to the DC Voltage setting (V with a straight line and dots). You’ll be “back-probing” the wires, which means sliding the multimeter probes into the back of the connector while it’s still plugged into the sensor. This allows you to read the voltage while the circuit is active.
The three wires typically have these functions (wire colors can vary, so a service manual is your best friend):
- 5-Volt Reference: Power from the ECU.
- Ground: The return path for the circuit.
- Signal: The variable voltage wire that sends the throttle position back to the ECU.
With the key ON (engine OFF), test for the 5-volt reference by placing your black probe on a good chassis ground and the red probe on the reference wire. You should see a steady reading close to 5 volts. If you don’t, you have a wiring issue between the ECU and the sensor, not a bad sensor.
Next, test the signal wire. Keep the black probe on a ground. Place the red probe on the signal wire. At idle (foot off the gas), you should see a low voltage, typically around 0.5V to 0.7V. Now, slowly and smoothly press the gas pedal all the way. The voltage should climb in a smooth, steady line to around 4.5V at full throttle. If the voltage jumps around, drops to zero, or doesn’t change, you’ve found your culprit: a failed TPS.

Common Problems with 2017 Polaris Ranger 1000 XP Crew Error Code 91 and Their Solutions

Based on our diagnostic steps, here are the most common culprits and how to fix them. This is your ultimate 2017 Polaris Ranger 1000 XP Crew error code 91 guide to resolving the issue for good.

Problem #1: A Dirty or Loose Connection

The Fix: This is the best-case scenario! After cleaning the connector with contact cleaner, apply a small dab of dielectric grease to the seal before plugging it back in. This prevents future moisture intrusion. Ensure it clicks firmly into place. Clear the code and see if it returns.

Problem #2: A Damaged Wire or Harness

The Fix: If you found a broken or chafed wire, you need to repair it properly. Don’t just twist them together and wrap them in electrical tape. For a lasting repair, use a butt connector with heat-shrink tubing or, even better, solder the wires and cover them with heat-shrink. Repairing a wire instead of replacing an entire harness is a much more sustainable 2017 Polaris Ranger 1000 XP Crew error code 91 solution.

Problem #3: A Failed Throttle Position Sensor

The Fix: If your multimeter test confirmed the TPS is bad, replacement is your only option. They are typically held on by two Torx screws. Simply remove the old one, install the new one, and plug it in. It’s a straightforward parts swap once you’ve done the proper diagnosis.

The Benefits of Fixing Error Code 91 Yourself

Tackling this job on your own offers some serious advantages. Understanding the benefits of 2017 Polaris Ranger 1000 XP Crew error code 91 repair goes beyond just getting back on the trail.

Save a Ton of Money: A new TPS might cost you under $100. A trip to the dealer for diagnosis and labor could easily run you several hundred dollars.
Gain Valuable Experience: You’ll learn more about how your machine works, building confidence for future DIY projects.
Minimize Your Downtime: Why wait a week for a service appointment when you can have it fixed in an afternoon?
Improve Your Ranger’s Health: A properly functioning TPS ensures your engine runs efficiently, which is better for performance, longevity, and even fuel consumption—an eco-friendly 2017 Polaris Ranger 1000 XP Crew error code 91 bonus!

Frequently Asked Questions About 2017 Polaris Ranger 1000 XP Crew Error Code 91

Can I still drive my Ranger with error code 91?

You can, but it’s not a good idea. The machine will be in “limp mode” with very little power, making it unsafe and unpredictable, especially on hills or in technical terrain. It’s designed to help you limp back to the truck or shop, not to continue your ride.

How much does it cost to fix error code 91?

The cost varies wildly. It could be $0 if it’s just a loose connection you clean and re-seat. If you need a new TPS, expect to pay between $50 and $100 for the part. A dealer repair involving diagnostics and labor will be significantly more expensive.

Do I need to reset the ECU after fixing the problem?

In most cases, the code will clear itself after a few successful start-and-run cycles once the underlying fault is corrected. For a quicker reset, you can disconnect the negative battery terminal for about 15 minutes.

Facing an error code can be intimidating, but code 91 is one you can absolutely conquer with the right approach and a little patience. By following these diagnostic steps, you’re not just throwing parts at a problem; you’re acting like a true technician. You’re understanding the system, testing the components, and making an informed repair.

So grab your multimeter, follow this guide, and get your Ranger back to performing the way it was meant to. Happy wrenching, and we’ll see you 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.