Polaris Code 516246 - Your Complete Guide To Fixing Fuel Gauge Errors

There’s nothing more frustrating than glancing at your Polaris dash mid-ride, only to be greeted by a glowing check engine light. Your heart sinks a little when you see the fuel gauge is flatlined on empty, even though you just topped it off. You pull up the diagnostics, and a cryptic number stares back: polaris code 516246.

We’ve all been there. A mysterious code can instantly turn a great day on the trails into a head-scratching session filled with worry about expensive shop bills.

But I promise you, this is one code you can absolutely tackle yourself. This guide will demystify error 516246, walk you through what causes it, and give you the exact, step-by-step process to diagnose and fix it with basic tools. We’ll cover everything from simple visual checks to multimeter tests, so you can get that fuel gauge working and clear that code for good.

What Exactly is Polaris Code 516246? Decoding the Dash Light

Let’s get straight to the point. When your Polaris displays code 516246, it’s telling you there’s a specific electrical problem with the fuel level sensor circuit.

In technical terms, this code corresponds to SPN 96, FMI 4.

SPN 96 points directly to the Fuel Level.
FMI 4 means “Voltage Below Normal, or Shorted to Low Source.”

In simple English, your machine’s brain, the Engine Control Module (ECM), is trying to read the fuel level. However, the electrical signal it’s receiving from the sensor is either non-existent (an open circuit) or way too low (a short circuit). The result? The ECM throws its hands up, triggers the check engine light, and your fuel gauge stops working.

Common Causes: Why Your Machine is Throwing This Code

Before you start ordering expensive parts, take a breath. The issue is often simpler and cheaper than you think. Off-road machines live a rough life of vibrations, mud, and water, which is hell on electrical systems. Here are the most common problems with polaris code 516246, from most to least likely.

The Usual Suspects

Damaged Wiring: This is the number one culprit. Wires can get pinched by the frame, chafed by plastic panels, melted by a hot exhaust pipe, or even chewed by critters.
Corroded or Loose Connectors: The main plug going to your fuel pump assembly is constantly exposed to the elements. A little bit of moisture can cause green or white corrosion on the pins, breaking the connection.
A Failed Fuel Level Sensor: The sending unit itself, which is part of the fuel pump assembly inside your tank, can fail. The float arm or the resistor it wipes against can wear out over time.
A Bad Ground Connection: Every circuit needs a good ground to work. If the ground wire for the fuel pump assembly is broken or corroded, it can cause all sorts of electrical gremlins, including this code.
A Faulty ECM (Very Rare): While possible, a bad ECM is extremely unlikely to be the cause. You should exhaust every other possibility before even considering this.

Tools of the Trade: What You’ll Need for the Job

You don’t need a full professional shop to diagnose this issue. Having the right tools on hand makes the job faster, safer, and much less frustrating. This is a great project for any weekend DIYer.

A basic socket and wrench set (metric)
Torx and Allen key sets (essential for Polaris models)
A Digital Multimeter. This is non-negotiable for electrical diagnosis. Even a budget-friendly one will do the job perfectly.
A good flashlight or headlamp
Plastic trim removal tools (to avoid scratching your plastics)
Electrical contact cleaner
Dielectric grease (to protect your connections from future corrosion)
Pro Tip: Have your machine’s service manual handy. It will have wiring diagrams and specific resistance values that are invaluable.

How to Diagnose and Fix Polaris Code 516246: A Step-by-Step Guide

Alright, let’s get our hands dirty. Follow this polaris code 516246 guide step-by-step. Don’t skip ahead, as the simplest fix is often the first one you’ll check. This is the core of how to fix polaris code 516246.

Step 1: Safety First!

We’re dealing with electrical systems and potentially the fuel tank. Safety is paramount.

Work in a well-ventilated area. Avoid enclosed garages where fuel fumes can build up.
Disconnect the negative terminal of your battery. This prevents any accidental shorts while you’re working.
No smoking, sparks, or open flames anywhere near your work area.

Step 2: The Visual Inspection (The 5-Minute Fix)

Start with your eyes. Follow the wiring harness leading away from the top of your fuel tank. You’re looking for anything that looks out of place.

Check for wires that are pinched between the frame and body panels, stretched tight, or rubbing against a sharp edge. Pay close attention to the area around the engine and exhaust for any melted insulation.

Step 3: Check the Connectors

Locate the main electrical connector for the fuel pump assembly. On most models, you’ll need to remove a seat or a plastic panel to access it.

Unplug the connector and inspect both the male and female ends. Are the pins clean and shiny? Or are they covered in green/white crusty corrosion? Are any of the pins bent or pushed back into the connector? If you see any corrosion, spray it liberally with electrical contact cleaner and use a small brush to clean it off. Once it’s clean and dry, apply a small dab of dielectric grease to the seal before reconnecting it. This simple step can solve the problem 90% of the time.

Step 4: Testing the Circuit with a Multimeter

If the visual inspection didn’t reveal the culprit, it’s time to grab your multimeter. This is where you confirm if the problem is in the wiring or the sensor itself.

Set your multimeter to the continuity setting (it usually has a sound icon).
Consult your service manual to identify the ground wire for the fuel level sensor at the connector.
Touch one probe to that ground pin and the other probe to a clean, bare metal spot on the vehicle’s frame. The meter should beep, indicating a good ground path. If it doesn’t, you have a broken ground wire that you need to find and repair.
Next, check for a short. Set your meter to measure resistance (Ohms). Test between the signal wire pin and the ground pin in the harness (the side going to the ECM, not the pump). You should see a very high resistance reading (OL). If you see low resistance, it means the signal wire is shorted to ground somewhere in the harness.

Step 5: Testing the Fuel Level Sensor Itself

If the wiring and ground check out, the problem is likely the sending unit in the tank. To confirm, you’ll test its resistance.

Set your multimeter to Ohms (Ω). Connect your probes to the two pins on the fuel pump assembly side of the connector that correspond to the level sensor. You should get a resistance reading. Now, carefully (and slowly) rock the machine from side to side to make the fuel slosh around and move the float inside the tank. You should see the resistance value change smoothly. If the reading jumps all over the place or reads “OL” (open loop), the sensor is bad and the entire fuel pump assembly will need to be replaced.

The Benefits of Fixing Polaris Code 516246 (And Best Practices)

Fixing this code isn’t just about turning off a light on the dash. It’s about restoring a critical function of your machine. This is where you’ll see the real benefits of polaris code 516246 resolution.

Confidence on the Trail: The biggest benefit is peace of mind. Knowing exactly how much fuel you have means you can plan longer rides without the fear of getting stranded miles from anywhere.
Protecting Your Investment: Ignoring electrical issues can sometimes lead to bigger problems down the line. Fixing it properly maintains your machine’s health and resale value.
Sustainable and Eco-Friendly Riding: This might sound like a stretch, but hear me out. An accurate fuel gauge is a tool for efficiency. It allows for better trip planning, which reduces the chance of carrying unnecessary extra fuel cans and helps you manage fuel consumption more effectively. This is a key part of any eco-friendly polaris code 516246 approach.

Adopting good polaris code 516246 best practices, like periodically checking your wiring for chafing and using dielectric grease on major connections, is part of a solid preventative maintenance routine and a great polaris code 516246 care guide.

When to Call a Pro: Don’t Go Beyond Your Comfort Zone

There is absolutely no shame in knowing your limits. While this is a very doable DIY job, you should consider taking it to a certified technician if:

You are not comfortable with electrical diagnostics or using a multimeter.
You have traced the wiring and tested the sensor, and the problem still persists (it could be a rare ECM issue).
You are not comfortable or equipped to safely remove the fuel pump assembly from the fuel tank.

A good mechanic can diagnose and fix this issue quickly. Your safety and peace of mind are worth more than saving a few bucks.

Frequently Asked Questions About Polaris Code 516246

Can I still ride my Polaris with code 516246 active?

Yes, in most cases, the machine will run perfectly fine. This code affects the fuel level reading system, not the engine’s performance or the fuel delivery from the pump. The only risk is not knowing your true fuel level and running out of gas unexpectedly.

How much does it cost to fix this code?

The cost can range from $0 to several hundred dollars. If it’s a loose or corroded connector you clean yourself, your only cost is a can of contact cleaner. If you need to replace the entire fuel pump assembly, the part itself can cost $200-$400, plus a couple of hours of shop labor if you don’t do it yourself.

Will just clearing the code fix the problem?

No. Clearing the code only temporarily removes it from the dash. As soon as the ECM runs its diagnostic check again (usually within seconds of starting the machine), it will detect the same electrical fault and the code will immediately return. You must fix the root cause.

Tackling an error code like 516246 can seem intimidating, but it’s really just a process of elimination. By following these steps, you can systematically find the source of the problem and get it fixed. You’ll save money, learn more about your machine, and gain the satisfaction of doing it yourself.

So grab your tools, have patience, and get that fuel gauge working. The trail is waiting. Ride safe out there!

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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.