I have a 2006 Polaris Sportsman 800 that I’m working on (important to note that I’m not a mechanic, but am mechanically inclined). Aside from the fuel gauge not working (needs new sending/float unit), I encountered error codes 41 (Intake Air Temp Sensor), 45 (Baro Pressure), and 46 (Baro Pressure).

I took the seat and side panels off and noticed that the intake from the air box to the block assembly had become disconnected at the block, and that the 2 screws, along with Reed Assembly/Gasket were missing. Replaced with Polaris OEM P/N 3021352.

I also read that the Thermister Sensor (4010644) could be bad so I replaced it as well. Also threw in a new set of plugs while I had it all apart.

After starting and letting the machine idle for a few minutes, it smoothed out considerably.

Took it for a quick spin and ran the diagnostics and now I’m getting an error code 52, and the coolant fan (OEM; brand new as well) will not run unless I disconnect the Thermister Sensor plug-in.

I read somewhere this morning about a T-BAP Sensor but I can’t afford to keep throwing money and parts as it’s adding up quickly.

Lastly, I noticed that even if the unit is off and the key is out of the ignition, a light stays on in upper right hand corner of Instrument Cluster on handle bars, so I disconnect the battery every night, but it keeps coming back on.

Any help/ideas/suggestions given are greatly appreciated.

Thank you,

Kelly