Polaris Code 5 746 1 - Your Complete Diagnostic & Repair Guide

You’re geared up, the trail is calling, and you’re ready to kick up some dirt. You turn the key on your Polaris, the engine roars to life, but then… the dreaded check engine light illuminates your dash. Your heart sinks as the machine sputters into limp mode. You check the display and see it: polaris code 5 746 1. It’s a frustrating moment that can stop a great day of riding in its tracks.

We’ve all been there. A cryptic code flashes on the screen, leaving you stranded and scratching your head. But don’t call the dealer or throw in the towel just yet.

We promise this comprehensive guide will demystify that code, empower you to diagnose the root cause with confidence, and walk you through the exact steps to get your machine running strong again. In this article, you’ll learn what the code means, the most common culprits, how to test them with basic tools, and how to perform the repair yourself.

What Exactly is Polaris Code 5 746 1? Decoding the Warning

First things first, let’s translate what your Polaris is trying to tell you. Fault codes aren’t just random numbers; they’re a specific language. The code 5 746 1 is a two-part message.

The “746” is the SPN (Suspect Parameter Number), which points directly to the Exhaust Gas Temperature (EGT) Sensor. The “5” is the FMI (Failure Mode Identifier), which tells us the specific problem: Current Below Normal or Open Circuit.

In simple terms, your machine’s brain, the ECU (Engine Control Unit), is trying to get a reading from the EGT sensor, but it’s getting nothing back. It’s like trying to make a phone call and getting a dead line. The circuit is open, or the signal is so low it’s considered non-existent.

Why the EGT Sensor is So Important

The EGT sensor is a critical safety and performance component. It constantly measures the temperature of the exhaust gases leaving your engine.

This information allows the ECU to make real-time adjustments to the fuel mixture and timing. If the exhaust gets too hot, it can lead to catastrophic engine damage like melted pistons or a burned-out turbo. When the ECU loses this signal, it plays it safe and puts the vehicle into a power-reducing limp mode to protect your engine from harm.

Common Symptoms: How Your Machine Tells You There’s a Problem

While the code itself is the biggest clue, your machine will likely give you other signs that something is wrong. Recognizing these can help confirm you’re on the right track.

Check Engine Light (CEL): This is the most obvious indicator. It’s your machine’s way of saying, “Hey, look at me! Something needs attention.”
Limp Mode / Reduced Power: To prevent damage from potentially high exhaust temperatures, the ECU will drastically cut power. Your machine will feel sluggish and won’t rev out like it normally does.
Hesitation or Stumbling: Without accurate EGT data, the ECU is guessing on the fuel mixture, which can cause the engine to run rough, especially under load.

The Usual Suspects: Top Causes of Fault Code 5 746 1

Now that we know what the code means, let’s hunt down the cause. In our experience at the shop, this code is almost always traced back to one of three things. This is one of the most important polaris code 5 746 1 tips we can share: start with the simplest and most common culprits first.

The EGT Sensor Itself: Failure Over Time

The EGT sensor lives in a brutal environment—the exhaust pipe. Extreme heat cycles, vibration, and contaminants can simply cause it to fail internally. This creates the “open circuit” the code is warning you about.

Damaged Wiring: The Off-Roader’s Nemesis

This is arguably the most common cause. Your Polaris wiring harness is routed all over the machine, often near hot exhaust components and moving suspension parts. A wire can easily get:

Melted by touching the exhaust pipe.
Chafed by rubbing against the frame or a plastic panel.
Pinched or broken from a hard impact or improper routing.
Chewed by a rodent looking for a nest during storage.

Corroded or Loose Connectors: A Simple but Sneaky Culprit

The connection between the EGT sensor and the main wiring harness is exposed to mud, water, and dirt. Over time, moisture can get inside the plug, causing corrosion on the pins. This green or white crusty buildup acts as an insulator, blocking the electrical signal and triggering the code.

Your Step-by-Step Polaris Code 5 746 1 Guide to Diagnosis

Alright, time to get your hands dirty. Grab some basic tools and let’s troubleshoot this thing. Before you start, make sure the engine and exhaust are completely cool to the touch. Safety first, always.

Tools You’ll Need:

Flashlight
Basic socket/wrench set
Digital Multimeter
Zip ties
Contact cleaner and dielectric grease (recommended)

Step 1: The Visual Inspection (Your First Line of Defense)

Your eyes are your best diagnostic tool. Start by locating the EGT sensor. It looks like a small spark plug with a wire coming out of it, threaded directly into the exhaust pipe, usually just after the cylinder head or before the muffler.

With your flashlight, carefully trace the wire from the sensor all the way back to where it plugs into the main harness. Look for anything that seems out of place: melted insulation, shiny copper showing through, sharp kinks, or sections that are rubbing hard against another component.

Step 2: Check the Connector

Find the electrical plug connecting the sensor to the harness. Disconnect it. You might need a small flathead screwdriver to gently release the locking tab.

Look inside both ends of the connector. Are the metal pins clean and shiny? Or do you see any green or white powder (corrosion), dirt, or moisture? A bad connection here is a very common problem with polaris code 5 746 1.

Step 3: Testing the EGT Sensor with a Multimeter

If the wiring and connector look perfect, it’s time to test the sensor itself. Set your digital multimeter to the Ohms (Ω) setting, usually 20k or auto-ranging.

Unplug the sensor from the main harness.
Touch the two probes of your multimeter to the two pins on the sensor side of the plug. Polarity doesn’t matter for this test.
You should see a resistance reading. This value can vary by model and ambient temperature, but you’re looking for a specific number (consult your service manual for exact specs, but it’s often in the range of 200-400 Ohms at room temp).

If your multimeter reads “OL,” “Open,” or “1,” it means the circuit inside the sensor is broken. The sensor is bad and needs to be replaced. This is a definitive test.

Step 4: Testing the Wiring Harness

If the sensor tests good, the problem lies in the wiring between the connector and the ECU. This is a bit more advanced, but manageable.

Set your multimeter to the continuity setting (it usually looks like a sound wave symbol). It will beep when you touch the probes together. You’ll need to locate the main ECU plug and identify the two wires coming from the EGT sensor connector.

Test each wire for continuity from the EGT plug to the ECU plug. If one of them doesn’t beep, you have a broken wire somewhere in the harness that needs to be found and repaired.

How to Fix Polaris Code 5 746 1 and Get Back on the Trail

Once you’ve found the culprit, the fix is usually straightforward. Here’s how to polaris code 5 746 1 repair it correctly.

Solution 1: Cleaning and Securing the Connection

If you found corrosion in the connector, this is your fix. Spray both ends of the plug generously with electrical contact cleaner. Use a small brush or Q-tip to gently scrub away any stubborn buildup. Let it dry completely, then apply a small dab of dielectric grease to the inside of the connector before plugging it back in. This prevents future moisture intrusion and is a key part of any good polaris code 5 746 1 care guide.

Solution 2: Repairing Damaged Wires

If you found a broken or chafed wire, don’t just twist it together and wrap it in electrical tape. That will fail on the trail. For a lasting repair, you need to solder the wires together and seal the connection with heat-shrink tubing. Ensure the repaired section is secured with zip ties away from any heat sources or sharp edges.

Solution 3: Replacing the EGT Sensor

If your sensor tested bad, replacement is the only option.

Let the exhaust cool completely.
Spray the threads of the old sensor with a good penetrating oil (like PB B’laster) and let it soak for a few minutes.
Using the correct size wrench, carefully unscrew the old sensor.
Apply a small amount of high-temp anti-seize compound to the threads of the new sensor, being careful not to get any on the sensor tip.
Thread the new sensor in by hand, then tighten it to the torque spec listed in your service manual (usually not very tight).
Plug it in, and you’re good to go.

Best Practices for Preventing Future Fault Codes

An ounce of prevention is worth a pound of cure. Adopting a few polaris code 5 746 1 best practices can save you headaches down the road.

This approach promotes sustainable machine health by reducing component failures and waste. A properly running engine is also more efficient, which is a more eco-friendly way to ride, as it minimizes unburnt fuel and emissions. The benefits of polaris code 5 746 1 maintenance are clear: more ride time, less wrench time.

Inspect Your Harness: Every time you wash your machine or do an oil change, take a few minutes to visually inspect critical wiring harnesses for signs of wear.
Use Dielectric Grease: Proactively apply dielectric grease to major electrical connectors like those for the ECU, voltage regulator, and critical sensors.
Secure Loose Wires: Use high-quality zip ties to secure any wiring that looks like it could rub against the frame or get too close to the exhaust.

Frequently Asked Questions About Polaris Code 5 746 1

Can I keep riding my Polaris with code 5 746 1 active?

It’s not recommended. Limp mode is activated for a reason: to protect your engine from potentially catastrophic damage. While you can likely “limp” it back to the truck or camp, you should not continue to ride it for fun until the issue is resolved.

How much does a new Polaris EGT sensor cost?

Prices can vary depending on your specific model, but you can typically expect an OEM EGT sensor to cost between $100 and $200. Aftermarket options may be available for less.

Do I need to clear the code after I fix the problem?

Often, the code will clear itself after a few successful ride cycles where the ECU gets a good reading from the new or repaired circuit. You can also clear it immediately by disconnecting the machine’s battery for about 10-15 minutes.

Fixing the polaris code 5 746 1 is well within the reach of a determined DIYer. By following this guide, you can save yourself a costly trip to the dealer and gain the satisfaction of fixing your own machine. Take your time, be methodical, and you’ll be back on the trail in no time.

Stay safe, wrench smart, and happy riding!

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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.