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Discussion Starter · #1 ·
Getting code 45 (Barometric Pressure Sensor: Circuit Low Input) on my 09 sportsman 500x2 what does it mean?
 

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Here is the lowdown on Polaris Sportsman 700-800 T-Bap wiring:

Symptoms of broken Temp/Baro sensor wires:
1. The ATV will run very erratic at idle.
2. The "CHECK ENGINE" will sometimes come on.
3. Diagnostic codes 41 and or 45 will be present.
4. Fuel mileage will be poor.
5. Exhaust will smell really rich. Sometimes even black smoke can be seen from it running so rich.

How to test if the Temp/Baro sensor wiring is broken:
1. Turn the key switch on and off 3 times leaving it on the 3rd time. This puts the ECU into diagnostic mode. If codes are present their numbers will be displayed on the instrument cluster. When all codes have been displayed "End" will appear on the cluster.
2. Remove the seat and locate the sensor on the air intake tube. Unplug the wiring to the sensor by pressing down on the tab on the top of the connector. DON'T PULL THE CONNECTOR BY IT'S WIRES!!! Pull back the vinyl tubing that covers the 4 wires going to the connector. Gently pull on each wire with your fingers. The wire should have no stretch and feel solid. All the wires should feel the same. If one or two of them feel weak and stretchy chances are you have a broken wire. Is what happens is the wire breaks inside the insulation so it appears to still be connected.

Why do the Temp/Baro sensor wires break in the first place?
1.The problem with the current Polaris wiring is too short and Polaris used 7/32 stranded 22AWG wire. This wire has a very low strand count and should not be used in applications where vibration occurs.
2.The next problem is the mounting location of the sensor it is in a vibration prone spot on top the air intake tube going from the air box to the throttle body. Next time you're bored take the seat off and rev it up in neutral. That intake boot and sensor vibrate to the point where it looks blurry. The combination of these engineering flaws causes the cable to break in a big hurry.

The Polaris repair kits keep breaking. Why?
1. The replacement kits from Polaris use the same 7/32 strand wire that can't withstand vibration.
 

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Discussion Starter · #6 ·
took a look at it the orange wire from the MAP plug came out, who ever designed this was not to bright, pushed wire back in and applied goop, CEL now gone off, hope the goop holds.
 

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Discussion Starter · #7 ·
goop stuck it in place, used tiewrap to resecure it now got to wait and see if it holds
 

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This forum helped me a lot recently and I wanted to add something to this that I discovered. So I was getting the check engine light with the same codes. I started looking to replace the sensor but instead checked the wiring harness after reading this forum. As you can see in the cut off wiring harness the wires are showing through the rubber insulation and it finally gave out. I believe this was caused by the sharp aluminum wrap that was rubbing up against it in the other picture. I bought a Xislet 4 pin T-Bap Temp/Baro sensor wire replacement harness for polaris ranger and sportsman 700 750 and 800 EFI's from Amazon. I cut the end off the old one and replaced it with the new one giving it a lot of extra length. It worked and the codes went away and the check engine light went off. $35 repair and I didn't have to take it to a shop.

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This forum helped me a lot recently and I wanted to add something to this that I discovered. So I was getting the check engine light with the same codes. I started looking to replace the sensor but instead checked the wiring harness after reading this forum. As you can see in the cut off wiring harness the wires are showing through the rubber insulation and it finally gave out. I believe this was caused by the sharp aluminum wrap that was rubbing up against it in the other picture. I bought a Xislet 4 pin T-Bap Temp/Baro sensor wire replacement harness for polaris ranger and sportsman 700 750 and 800 EFI's from Amazon. I cut the end off the old one and replaced it with the new one giving it a lot of extra length. It worked and the codes went away and the check engine light went off. $35 repair and I didn't have to take it to a shop.

View attachment 137276 View attachment 137275
How did you know what wire from the new harness matched existing wiring? How did you match the wires?
 
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