Several people on this forum helped point me in the right direction this past month so I figured the least I could do is pay it back by helping someone else (I’m not a mechanic, but am mechanically inclined). Below is a list of problems that I encountered, fixes, parts I purchased, part numbers, etc. Most of parts came from Partzilla, but not all of them.
I might have spent $50-$75 that I didn’t have to in the process, but most all of the items (especially coolant fan, instrument cluster, fuel gauge/sending unit, wiring harnesses) were simply shot. Also, the two wiring harnesses (Coolant Temp Sensor and T-BAP/MAP) purchased from OTB Powersports were critical to the repair – I would highly recommend their products (first time purchaser of OTB and not an affiliate or employee).
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2006 Polaris Sportsman 800 EFI
Problem #1: Fuel Gauge/Sending Unit not working
Problem #2: Coolant Fan not working
Problem #3: Blink Codes 41, 42, 45, 46, 52, and 54
Problem #4: Instrument Cluster (significant water/condensation inside; display intermittent; AWD not working; wouldn’t start at all when display went blank)
Problem #5: Rear work lights not functioning
Problem #6: Unit ran poorly overall
Fuel Gauge/Sending Unit:
• Replaced Fuel Tank/Fuel Sending Unit/Fuel Pump Assembly (Polaris: 2204719 / $675 / $47.25 Tax / $722.25); cannot purchase Sending Unit separate on this particular model/year****
Coolant Fan:
• Replaced Cooling/Radiator Fan (Polaris: 2410366 / $218.45 / Shipping $18.36 / $236.81 / No Tax)
• Replaced “Cooling Thermostat Sensor” (Polaris: 4010644 / $38.17 / No Tax)
• Replaced “Coolant Temperature Sensor Harness” (OTB Powersports: OTB-POL-TMP-05-14 / $39.99 / Shipping $2.60 / $42.59 / No Tax)
o Blink Code 42 corrected
o Fan works properly after replacing Sensor Harness
Instrument Cluster:
• Replaced Instrument Cluster (Polaris: 3280431 / $244.79 / No Tax)
o Blink code 52 corrected
o Blink code 54 corrected
o AWD fully functional again
o Unit starts every time now
Rear Work Lights:
• Replaced Work Light Switch to left of Instrument Cluster (Polaris: 4011074 / $23.51 / No Tax)
o Rear work lights now functional again
Unit Ran Poorly Overall:
• Replaced “T-BAP/MAP Sensor” (Polaris: 2411528 / $45.50 / No Tax)
• Replaced “T-BAP/MAP Wiring Harness” (OTB Powersports: OTB-POL-045-05 / $39.99 / No Tax)
T-BAP: Temperature & Barometric Pressure Sensor
o Blink code 41 corrected
o Blink code 45 corrected
o Blink code 46 corrected
o Unit runs much better overall
Miscellaneous:
• Reconnected breather line from air canister to engine (had become disconnected)
o Replaced Reed Gasket Assembly (Polaris: 3021352 / $14.02 / Shipping $18.05 / $32.07 / No Tax)
o Replaced (4) Reed Gasket Screws (Polaris: 7517277 / $7.64 / No Tax)
• Replaced broken Air Breather Box (Polaris: 5433678 / $71.69 / Shipping $11.95 / $83.64 /No Tax)
o Replaced Foil for Air Breather Box (Polaris: 5811650 / $5.68 / No Tax)
o Replaced (2 x $1.56) Screws for Air Breather Box (Polaris: 7515179 / $3.12 / No Tax)
o Replaced (2 x .57) Flat Washers for Air Breather Box (Polaris: 7555859 / $1.14)
• Replaced Fuel Filter (NAPA: 3078 or 533078 / $14.38 / $1.01 Tax / $15.39)
• Replaced Spark Plugs – Gap should be .035″ (Champion: RC7YC3 / $2.27 each / $4.54 / No Tax)
• Replaced all electrical fuses (5, 15, and 20 AMP)
• Wire brushed both ends of the positive and negative cables on the battery, starter solenoid, and frame
• Applied dielectric grease where/as needed
