There’s nothing quite like the feeling of gearing up for a trail ride on your Sportsman 1000 XP. But that excitement can come to a screeching halt when you turn the key and are greeted by a check engine light and a cryptic error code on your display.
You see the numbers flashing: 520207. Your heart sinks a little. Is this a trip-ending problem? An expensive fix? It’s a frustrating moment we’ve all faced, and it can derail your entire day.
We promise this guide will demystify the 2017 polaris sportsman 1000xp touring code 520207 for you. Here at FatBoysOffroad, we believe in empowering owners to understand and handle their own machines. We’re going to give you the knowledge and a clear, step-by-step plan to diagnose and resolve this issue right in your own garage.
In this article, you’ll learn exactly what this code means, the most common causes, the tools you’ll need to investigate, and how to systematically track down the problem. Let’s get your rig back to 100% and ready for the trail.
Decoding the Dreaded 520207: What Your Sportsman is Trying to Tell You
First things first, don’t panic. An error code is just your ATV’s way of communicating. The code 520207 is a standard Polaris diagnostic trouble code (DTC) that points directly to the All-Wheel Drive (AWD) system.
Specifically, it relates to the AWD Control Circuit. To get more specific, Polaris codes often have a second number, the FMI (Failure Mode Identifier). For 520207, the most common FMI you’ll see is 5.
So, what does 520207 FMI 5 mean?
- SPN 520207: AWD Control Circuit
- FMI 5: Current Below Normal / Open Circuit
In plain English, your machine’s computer (the ECU) is trying to send power to the electromagnetic coil in your front differential to engage the AWD, but it’s not detecting a complete electrical circuit. It’s like flipping a light switch, but the bulb doesn’t light up because a wire is cut or the bulb itself is burnt out. Your ECU sees this “open” circuit and throws the code.
Common Culprits: Why Your 2017 Polaris Sportsman 1000XP Touring Code 520207 is Flashing
Now that we know we’re hunting for an electrical problem in the AWD system, we can narrow down the list of suspects. Based on our experience in the shop, the issue is almost always one of these four things. These are the most common problems with 2017 polaris sportsman 1000xp touring code 520207.
- Damaged Wiring Harness: This is the number one cause. Wires running to the front differential can get snagged by branches, pinched by the frame, or frayed from rubbing against suspension components.
- Corroded or Loose Connector: The plug connecting the wiring harness to the front differential lives in a harsh environment. Mud, water, and vibration can lead to corrosion on the pins or a connection that has simply worked its way loose.
- A Failed AWD Coil: Inside the front differential is an electromagnetic coil. While robust, it can fail over time, creating the open circuit that triggers the code. This is less common than wiring issues but is a definite possibility.
- A Blown Fuse: While less likely to cause this specific FMI 5 code (which points to an open circuit, not an over-current), it’s always a quick and easy check to rule out.
Tools of the Trade: Gearing Up for the Diagnosis
You don’t need a full professional workshop to tackle this job. A few basic tools will get you through the diagnostic process. Having these on hand before you start will make everything go much smoother.
- Digital Multimeter: This is non-negotiable. You must have one to test for resistance and continuity. A basic one from any auto parts or hardware store is perfect.
- Socket and Ratchet Set: For removing any plastic panels or skid plates to access the wiring.
- Torx Bit Set: Polaris loves using Torx fasteners, so having a set is essential for any owner.
- Electrical Contact Cleaner: A spray can of this will be your best friend for cleaning dirty connectors.
- Dielectric Grease: Crucial for protecting electrical connections from moisture and corrosion after you’re done.
- Zip Ties: For tidying up wiring and securing it away from moving parts.
Step-by-Step Guide: How to Fix 2017 Polaris Sportsman 1000XP Touring Code 520207
Alright, let’s get our hands dirty. Follow this 2017 polaris sportsman 1000xp touring code 520207 guide methodically. Don’t skip steps, as the problem is often found in the simplest places.
Step 1: Safety First and Initial Access
Before you do anything, park your Sportsman on a level surface, put it in Park, and turn the ignition off. For any electrical work, it’s always a best practice to disconnect the negative terminal of your battery to prevent any accidental shorts.
You may need to remove a front skid plate or side panel to get a clear view of the front differential and the wiring harness leading to it. Take your time and keep track of your hardware.
Step 2: The Visual Inspection
Your eyes are your most powerful diagnostic tool. Start at the front differential and locate the two-wire harness that plugs into it. Slowly and carefully trace that harness back as far as you can see.
Look for anything that seems out of place:
- Wires that are stretched tight or pinched between the frame and another component.
- Sections where the outer sheathing is rubbed through, exposing the inner wires.
- Obvious breaks, cuts, or signs of rodent damage (they love chewing wires!).
Many times, you’ll find the problem right here. A simple wire repair can save you hours of further testing.
Step 3: Check and Clean the Connector
If the wiring looks good, the next stop is the connector itself. Carefully unplug the harness from the front differential. It might have a locking tab you need to depress.
Inspect both the male and female ends of the plug. Look for any green or white crusty buildup—that’s corrosion. Also check for bent or pushed-out pins. Spray both sides generously with your electrical contact cleaner and use a small brush if needed to clean the pins. Once it’s dry, apply a small dab of dielectric grease to the inside of the connector before plugging it back in firmly. Sometimes, this is all it takes.
Step 4: Test the AWD Coil with a Multimeter
If the code persists, it’s time to test the coil itself. This is the moment of truth that separates a simple wiring fix from a more involved part replacement. This is a key part of our how to 2017 polaris sportsman 1000xp touring code 520207 process.
- Set your digital multimeter to the Ohms setting (Ω). The 200 Ω range is usually perfect.
- With the harness still unplugged, touch one multimeter probe to each of the two metal pins on the differential side of the connector. The polarity doesn’t matter.
- You are looking for a specific resistance reading. For most Polaris models of this era, the reading should be around 21.9 Ohms +/- 1.5 Ohms. A reading between 20-24 Ohms is generally considered healthy.
- If you get a reading of “OL,” “1,” or infinity, it means the circuit inside the coil is broken. The coil is bad and will need to be replaced.
Step 5: Check the Harness for Continuity
If your coil tested good (you got a reading in the low 20s), the problem lies in the wiring harness between the connector and the ECU. To confirm this, you can perform a continuity test. This requires finding the other end of the harness, which can be tricky. But a simple check is to test for voltage at the plug.
Reconnect the battery, turn the key on, and engage the AWD switch. Carefully use your multimeter (set to DC Volts) to test for voltage at the harness-side plug. You should see battery voltage (around 12V). If you don’t, you have a confirmed break in the wire somewhere upstream.
Beyond the Basics: Pro Tips and Best Practices for AWD Care
Fixing the problem is great, but preventing it from happening again is even better. This simple 2017 polaris sportsman 1000xp touring code 520207 care guide can save you future headaches.
One of the key benefits of 2017 polaris sportsman 1000xp touring code 520207 diagnosis is understanding your machine’s weak points. The AWD wiring is one of them. After a repair, use zip ties to securely route the harness away from any sharp edges, exhaust pipes, or moving suspension parts. Leave a little slack for movement, but keep it snug and safe.
Choosing to repair a damaged wire instead of replacing the entire harness is also a more sustainable 2017 polaris sportsman 1000xp touring code 520207 approach. It reduces waste and saves you a lot of money. A quality, heat-shrink butt connector creates a durable, weather-resistant fix that’s as good as new. This is an eco-friendly 2017 polaris sportsman 1000xp touring code 520207 solution that any DIYer can be proud of.
Frequently Asked Questions About Code 520207
Can I still ride my Sportsman 1000 with code 520207 active?
Technically, yes. The machine will run and drive fine in two-wheel drive. However, your All-Wheel Drive system will not engage. We don’t recommend tackling challenging terrain where you rely on 4×4 until the issue is resolved.
Is replacing the front differential coil a difficult job?
It’s a moderately difficult task for a DIY mechanic. It requires draining the front differential fluid, removing the cover, and carefully swapping the part. We strongly recommend having a factory service manual on hand to guide you through the process if you determine the coil is bad.
How much does it cost to fix this issue?
The cost varies wildly. If it’s a broken wire or corroded connector, the fix might only cost you a few dollars in supplies and an hour of your time. If the internal coil has failed, the part itself can cost between $100 and $200, plus several hours of labor if you take it to a shop.
Tackling an electrical gremlin like the 2017 polaris sportsman 1000xp touring code 520207 can feel intimidating, but it doesn’t have to be. By following a logical process of inspecting, cleaning, and testing, you can pinpoint the exact cause and get your machine back in top form.
Remember to work safely, take your time, and trust your tools. You’ve got this. Now get out there and enjoy the trails!
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