Polaris General Code 746 - Your Complete DIY Diagnostic & Fix Guide

There’s nothing quite like the feeling of being deep on a trail, miles from anywhere, when that dreaded check engine light flickers on. Your Polaris General’s display flashes, and you see it: code 746. Your heart sinks a little, and a dozen questions flood your mind. What does it mean? Is my ride over? Is this going to be an expensive fix?

Agree with this? You’re not alone. This is a common scenario for many General owners. But here’s the good news: we promise to be your co-pilot for this problem. You don’t have to panic or immediately call for a tow. This comprehensive guide is designed to solve this exact issue for you.

We’ll walk you through everything you need to know about the polaris general code 746. You’ll learn what causes it, how to diagnose it with basic tools, and the exact steps to fix it yourself. Let’s get your rig healthy and back on the trail where it belongs.

What Exactly is Polaris General Code 746?

First things first, let’s demystify this code. When your General throws a code 746, it’s telling you there’s a problem with the Exhaust Gas Temperature (EGT) sensor circuit. More specifically, it’s usually accompanied by an FMI (Failure Mode Identifier) of 3, which means “Voltage Above Normal or Shorted to High Source.”

In simple terms, your machine’s brain, the Engine Control Unit (ECU), is seeing a voltage reading from the EGT sensor that is higher than it should be. This usually points to an open circuit—like a broken wire or a disconnected plug.

The Critical Role of the EGT Sensor

So, what does this little sensor do? The EGT sensor is a crucial component screwed into your exhaust pipe, usually before the catalytic converter. Its one and only job is to measure the temperature of the exhaust gases leaving your engine.

The ECU uses this information to protect your engine and exhaust components from overheating. If things get too hot, the ECU can adjust the fuel mixture or even put the machine into a reduced-power “limp mode” to prevent catastrophic failure. Ignoring this code is not one of our recommended polaris general code 746 tips.

Common Symptoms and Causes Behind the Fault

While the check engine light is the most obvious sign, code 746 can bring a few friends to the party. Understanding these symptoms and their root causes is the first step in any good diagnostic process. This is a core part of our polaris general code 746 guide.

Symptoms You Might Experience

Check Engine Light (CEL): This is your primary alert.
Limp Mode: The machine may drastically reduce power to protect itself. You’ll notice it feels sluggish and won’t reach top speed.
Poor Performance: Even if not in full limp mode, you might feel a general lack of power or hesitation.
Increased Fuel Consumption: The ECU may enrich the fuel mixture as a safety precaution, causing you to burn more gas.

The Most Common Problems with Polaris General Code 746

The good news is that the list of potential culprits is relatively short. In our experience at the shop, it’s almost always one of these three things:

A Damaged Wiring Harness: This is the number one cause. The EGT sensor wiring runs in a very hot, high-vibration area. Wires can easily get chafed, melted on the exhaust, or pinched against the frame.
A Bad Connector: The plug connecting the sensor to the main harness can become corroded, filled with mud or water, or the pins can get pushed out, leading to a poor connection.
A Failed EGT Sensor: While less common than wiring issues, the sensor itself can fail internally, causing the open circuit that triggers the code.

Your Step-by-Step Polaris General Code 746 Diagnostic Guide

Alright, time to get your hands dirty. Don’t be intimidated. With a few basic tools and a methodical approach, you can pinpoint the problem. Follow these steps on how to polaris general code 746 diagnostics.

Safety First & Tools You’ll Need

Before you start, make sure the machine is parked on a level surface and the engine is completely cool. The exhaust system gets extremely hot. It’s also a good practice to disconnect the negative battery terminal.

Here are the tools for the job:

A good quality multimeter with settings for Ohms (resistance) and continuity.
Basic socket and wrench set (including a 17mm or correctly sized open-end wrench for the sensor).
Torx bit set for removing panels.
Flashlight or headlamp.
Electrical contact cleaner.
Zip ties.

Step 1: The All-Important Visual Inspection

Start with your eyes. Locate the EGT sensor—it’s threaded into the exhaust pipe, typically just after the manifold. Once you find it, trace its wire harness back as far as you can see.

Look for any obvious signs of damage. Is the wire resting on the hot exhaust? Is it stretched tight or pinched? Are there any visible breaks or melted spots on the protective sheathing? Pay close attention to where the harness bends or passes near frame components.

Next, find the electrical connector. Unplug it and inspect both the male and female ends carefully. Look for green or white crusty corrosion, bent pins, or any signs of dirt or moisture inside. Most issues are found right here.

Step 2: Test the EGT Sensor with a Multimeter

If the visual inspection doesn’t reveal the culprit, it’s time to test the sensor itself. Set your multimeter to measure resistance (Ω).

Place one probe on each of the two pins inside the sensor’s side of the connector. At room temperature (around 70°F / 21°C), a good EGT sensor should typically read between 200-250 Ohms. If you get an “OL” (Open Loop) reading or a reading of zero, the sensor is bad and needs to be replaced.

Step 3: Test the Wiring Harness

If the sensor tests good, the problem lies in the wiring between the sensor plug and the ECU. This is where patience is key.

You’ll need to perform a continuity test. This test checks if a wire is intact from one end to the other. You will need to locate the main ECU plug (check your service manual for its exact location and pinout diagram).

With the ECU and sensor plugs disconnected, use your multimeter on the continuity setting (it usually beeps). Touch one probe to a pin on the sensor-side plug and the other probe to the corresponding pin on the ECU-side plug. You should hear a beep, indicating a solid connection. Test both wires. If one doesn’t beep, you have a broken wire somewhere in the harness that needs to be found and repaired.

How to Replace the EGT Sensor and Clear the Code

If your diagnostics point to a failed sensor, the replacement is straightforward. One of the main benefits of polaris general code 746 troubleshooting yourself is the money you’ll save on labor.

Step 1: Remove the Old Sensor

Make absolutely certain the exhaust is cold. Spraying a little penetrating oil on the threads where the sensor enters the exhaust pipe can make removal much easier. Let it soak for about 10-15 minutes.

Using the correct size open-end wrench, carefully turn the sensor counter-clockwise to loosen and remove it. Be firm but steady to avoid stripping the nut.

Step 2: Install the New Sensor

Your new sensor may come with anti-seize compound already on the threads. If not, apply a very small amount to the threads, being careful not to get any on the sensor tip itself.

Thread the new sensor in by hand to avoid cross-threading. Then, use your wrench to snug it down. The general rule is snug plus an additional quarter-turn; do not overtighten it.

Reconnect the electrical plug, making sure it clicks securely into place. Use zip ties to route the new wire safely away from any heat sources or moving parts.

Step 3: Clear the Code

Once the repair is complete, reconnect your battery. In many cases, the code will clear itself after you start the machine and let it run for a few minutes. If it doesn’t, simply disconnecting the negative battery terminal for about 15 minutes will reset the ECU and clear the code.

Best Practices for Long-Term Electrical Health

Fixing the problem is great, but preventing it from happening again is even better. This is where a good polaris general code 746 care guide comes into play.

A Sustainable Polaris General Code 746 Prevention Plan

We use the word “sustainable” here to mean creating a long-lasting, reliable repair. Following these polaris general code 746 best practices will save you headaches down the road.

Secure All Wiring: After any repair, use high-quality zip ties to secure wiring harnesses away from the exhaust and engine block. Leave a little slack for engine movement, but don’t let them dangle.
Use Dielectric Grease: Apply a small dab of dielectric grease to the inside of electrical connectors, like the EGT sensor plug. This keeps moisture and dirt out, preventing corrosion.
Perform Regular Inspections: Every time you change your oil, take five extra minutes to shine a flashlight on your main wiring harnesses. Look for early signs of wear and tear before they become a problem.

Eco-Friendly Repair Practices

Being a responsible DIYer also means taking care of our environment. When working on your machine, remember these simple, eco-friendly polaris general code 746 tips.

Dispose of old parts, like the faulty sensor, according to your local waste management regulations.
If you use chemical cleaners or penetrating oils, ensure you have proper ventilation and dispose of the empty aerosol cans correctly.

Frequently Asked Questions About Polaris General Code 746

Can I still ride my General with code 746 active?

It is strongly not recommended. The ECU triggers this code for a reason: to protect your engine. Continuing to ride could result in running overly rich (damaging the catalytic converter) or having the machine go into limp mode at an inconvenient or unsafe time.

How much does it cost to fix code 746?

The cost varies greatly. If you do it yourself, you’re only looking at the cost of the part. A new EGT sensor typically costs between $80 and $150. If the issue is just a loose wire, the fix is free! Taking it to a dealer for diagnosis and repair could run anywhere from $250 to over $400, depending on their labor rates.

I replaced the sensor, but the code came back. What now?

This almost always means the problem was never the sensor to begin with. The fault lies in the wiring harness between the sensor and the ECU. You’ll need to go back and perform the continuity tests described in the diagnostic section to find the break or short in the wire.

Tackling a check engine light can feel daunting, but code 746 is one you can absolutely handle. By following this guide, you’ve learned how to inspect, test, and replace the components of the EGT circuit. You’ve armed yourself with the knowledge to save money and gain a deeper understanding of your machine.

So grab your tools, be methodical, and be patient. You’ll have that code cleared and be back to kicking up dust on the trails in no time. Ride safe and have fun 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.