Polaris Engine Code 65590: Causes & Fixes

As a Polaris owner, few things are worse than seeing your ride grind to a halt in the middle of a ride due to engine trouble. Those dreaded check engine lights and error codes can signal anything from a quick fix to a major repair.

One of the more common diagnostic trouble codes (DTCs) reported on Polaris ATVs and other models is code 65590. This simple code can halt your ride and ruin your plans for epic trail adventures or getting work done around the property.

When your Polaris flashes 65590, it’s signaling a problem with the throttle position sensor (TPS). Essentially, this important sensor is reporting inconsistent values back to the engine control unit (ECU). This triggers the check engine light and 65590 code.

In this detailed post, we’ll cover everything you need to know about Polaris 65590 codes, including:

• What are the most common causes of 65590 errors?
• How can you accurately diagnose the problem?
• What potential fixes and repairs resolve 65590 codes?
• Steps to prevent future throttle position sensor issues.

By understanding what triggers code 65590, how to pinpoint the problem, and potential fixes, you can get your Polaris up and running again quickly. Let’s start by taking a closer look at the origins of the 65590 error.

What Does Polaris Code 65590 Mean?

The 65590 code is quite literal in what it’s reporting – an issue with the throttle position sensor on the vehicle. Let’s break it down:

• 65 indicates it’s an engine system error
• 590 specifically points to a fault with the throttle position sensor circuit

On Polaris models, this code can appear on any vehicle that uses an electronic throttle control system. Most modern ATVs, UTVs, snowmobiles, and side-by-sides are equipped with electronic throttle technology vs old-school carbureted systems.

The throttle position sensor is a key component of the electronic throttle control system. This sensor monitors the position and movement of the throttle mechanism. It provides constant feedback to the engine control unit about how far open the throttle is at any given moment.

This data allows the ECU to precisely control fuel injection, ignition timing, transmission shifting, and other systems based on throttle position and user input.

When this vital sensor isn’t providing accurate, consistent data back to the ECU, it triggers a 65590 code to alert the owner of a malfunction.

What Causes Polaris 65590 Codes?

Polaris throttle position sensors are durable but they can eventually fail. There are a few common issues that can trigger the dreaded 65590 error:

1. Faulty Throttle Position Sensor

By far, the most common cause of 65590 codes is a throttle position sensor that has failed or is malfunctioning. These electro-mechanical sensors are constantly exposed to environmental contaminants like mud, dust, and moisture. Over time, this can lead to corrosion and component failure.

The potentiometer inside the TPS is especially vulnerable. This measures the position of the throttle butterfly valve by changing resistance values. Contamination and wear cause the potentiometer “track” to develop faults. This leads to incorrect resistance readings and 65590 errors.

Even though OEM sensors are high-quality, they don’t last forever. The average TPS lifespan is around 60,000 to 100,000 miles. On machines used heavily in demanding conditions, expect closer to about 50,000 miles.

Catching a failing TPS early and replacing it promptly can help avoid being stranded out on the trails.

2. Damaged Throttle Position Sensor Wiring

The TPS relies on a 5-wire harness to transmit data to the ECU. Over time, this delicate wiring can become damaged. Fraying wires, cracked insulation, and corrosion in the connectors can cause connection issues.

Once the harness has any breaks in continuity, it prevents stable communication between the sensor and ECU. Irregular voltage signals and incorrect sensor data triggers 65590 errors.

Carefully inspecting the condition of the sensor wiring and connectors is part of diagnosing Polaris 65590 problems. Repairing any wiring damage can often resolve these error codes.

3. Loose Throttle Position Sensor Connections

Along with wiring damage, loose TPS connections are another easily missed cause of intermittent 65590 codes.

Vibration, dirt buildup, and worn connector pins all allow the connections to lose contact intermittently. Once connections get loose, the data signal tends to cut in and out, leading to erratic throttle position readings.

Loose connections are most noticeable at higher speeds and harsher riding conditions when more vibration is present.

Reseating all TPS connections and cleaning any corrosion should be one of the first steps when diagnosing Polaris 65590 issues.

4. Weak Battery

On older machines, a weak battery struggling to output sufficient amperage can actually end up triggering 65590 codes occasionally.

As the battery voltage dips below optimal levels around 12-volts, it can cause the ECU and other electronics to get wonky readings from sensors, including the TPS. Strange sensor values then lead to sporadic 65590 errors.

Checking battery voltage is wise anytime you have to track down electrical gremlins. Recharging or replacing the battery if needed can resolve some intermittent 65590 codes.

5. Defective ECU

In rare cases, the issue may stem from a malfunctioning engine control unit rather than the sensor itself. ECUs can fail due to power surges, voltage spikes, electrical issues, and normal wear over extremely high mileage.

If the throttle position sensor tests fine during diagnosis, along with the wiring, chances are the ECU may be defective and triggering incorrect codes. Substituting in a known good ECU to test is the best way to rule this out.

Now that we’ve covered the typical causes of Polaris 65590 codes, let’s go over how to accurately diagnose these throttle position sensor issues.

Diagnosing Polaris 65590 Codes

When your Polaris flashes a 65590 code, how do you pinpoint whether the issue is a failed TPS, wiring problem, or something else? Here is a step-by-step process for diagnosing the error:

Step 1 – Scan Error Codes

The first step is using an OBD-II diagnostic scanner to pull the engine error codes. This will confirm the 65590 code is present along with any other related trouble codes that can provide clues.

Writing down the full code identifiers is important for accuracy. You want to be sure it’s 65590 and not a similar code related to another sensor.

Step 2 – Check Battery Voltage

Using a digital multimeter, test the battery voltage with the vehicle off. Turn the key to “on” and test again. Healthy voltage ranges are:

• Off: 12.4 to 12.7 volts
• On: 13.5 to 14.5 volts

If voltage readings are outside these values, charge or replace the battery as needed. A weak battery can mimic or contribute to sensor problems.

Step 3 – Inspect Wiring Condition

Next, inspect the visible condition of the throttle position sensor wiring and connectors.

Look for any chafed or cut wires, damaged insulation, loose plugs, moisture buildup, corrosion, etc. Verify the connector pins are straight and intact. Any wiring faults will need repairing.

Step 4 – Check Resistance Values

Now use the multimeter to test the TPS resistance values. With the key off, backprobe the sensor connector while operating the throttle.

Compare your measurements at closed, half, and full throttle to the factory specification range:

• Closed: 900 to 1100 ohms
• Half-throttle: 1600 to 1800 ohms
• Full throttle: 3800 to 4100 ohms

Notice how resistance decreases as the throttle opens further. Irregular patterns point to a faulty sensor that isn’t accurately reporting position.

Step 5 – Check for Loose Connections

After testing the sensor output, now verify all the TPS connections are tight and corrosion-free.

Loose connections that intermittently drop the signal can mimic a failed sensor. Reseating connectors often resolves erratic electrical gremlins.

Step 6 – Perform a TPS Sweep Test

Finally, using your scanner’s live data function, observe the TPS readings while slowly sweeping the throttle through its full range of motion.

You should see a smooth linear increase in the sensor voltage, with no weird jumps or dropouts in the reading. Any erratic readings indicate a faulty TPS or wiring issue is present.

By methodically following these diagnosis steps, you should be able to confirm whether the issue stems from a failed throttle position sensor itself, wiring faults, loose connections, or even battery voltage concerns.

Now let’s explore the typical solutions and repairs to resolve Polaris 65590 error codes.

How To Fix Polaris 65590 Errors?

Once you’ve accurately diagnosed the root cause of the 65590 code, here are the most common fixes to get your Polaris up and running again:

Replace the Faulty Throttle Position Sensor

If testing shows the TPS is intermittently giving irregular readings or out of specification resistance values, replacing it is the definitive repair.

You want to use a high quality, OEM-equivalent sensor from reputable brands like Electrosport, Mikuni, Hitachi, Walker, OE+, and Edelbrock sensors. Avoid cheap knockoff sensors that often fail prematurely.

Polaris machines tend to use 2 common TPS sensor designs:

• 2-pin with 3 wires
• 3-pin with 5 wires

Make sure to get the properly matched replacement.

Swap the new throttle position sensor in and make sure the connections are fully seated. Clear any residual error codes using your scanner tool. Test ride to verify normal operation before hitting the trails.

Repair Damaged Sensor Wiring

If your diagnosis uncovered wiring damage as the culprit, properly repair any degraded wires or connectors.

For minor insulation damage, wrapping the wire in protective electrical tape is sufficient. For more severely damaged spots, splice in a section of new wire.

Replace any corroded or damaged pins or connections with new OEM connectors and terminals. Solder and seal all splices for reliable, water-resistant repairs.

Reconnect Loose Throttle Position Sensor Plugs

Another simple fix is to double check any seemingly loose sensor connectors.

Unplug them, visually inspect for bent or spread pins, clean out any dirt or corrosion, then firmly re-seat each connector. Use a high quality electrical grease inside the plugs to improve conductivity and prevent moisture contamination.

Often this quick fix resolves the common “loose connection” issues that randomly plague sensors.

Recharge or Replace Weak Battery

If you found the battery was consistently under 12-volts, especially when the vehicle is running, addressing this issue can potentially fix some electrical gremlins.

Fully recharge the battery to 12.7+ volts and load test to verify it holds a charge. If it’s more than a few years old, replacement may be the smarter option for reliable starting and electronics operation.

Replace ECU if Needed

In the rare event all other components test good, but the 65590 error persists, chances are the engine control unit may be defective.

Substitute a known good, working ECU to isolate whether yours is malfunctioning. If the code clears up, it points to a bad stock ECU as the issue. Install a replacement ECU programmed for your vehicle to get back on the road.

By following the strategic troubleshooting steps and making the necessary repairs, most 65590 issues can be resolved fairly quickly. Let’s wrap up with some tips to help prevent future sensor problems.

Preventing Future Polaris 65590 Issues

To help avoid those dreaded 65590 codes popping up again down the road, here are some important maintenance tips:

• Use dielectric grease – Apply some dielectric grease to the TPS electrical connections and pins during installation. This prevents corrosion from dirt, moisture, and chemicals.
• Check battery health – Periodically load test your battery to ensure it’s maintaining proper voltage, especially if issues are intermittent.
• Consider a throttle position sensor cover – Adding a sealed cover protects the delicate sensor from mud, dirt, water intrusion.
• Replace at first sign of trouble – Swap the TPS at the first sign of issues to avoid being stranded trailside later on. Don’t wait for complete failure.
• Follow factory maintenance schedules – Sticking to the recommended service intervals helps identify worn parts before major issues arise.

Given the importance of the throttle position sensor for proper engine operation, taking steps to protect this fragile component from unnecessary contamination and wear will help ensure the 65590 codes stay away.

Conclusion

Dealing with Polaris 65590 check engine codes can certainly be frustrating when all you want is a fun day on the trails. But armed with the right troubleshooting knowledge, these throttle position sensor issues don’t have to kill your ride time.

Now that you understand what causes code 65590, how to accurately diagnose problems, potential fixes, and tips for prevention, you can be confident tackling these issues.

The most common fix is replacing a worn throttle position sensor that’s sending inconsistent readings. But don’t overlook damaged wiring connectors or loose plugs either.

With some patient diagnosis and inexpensive repairs, you can clear that pesky 65590 error code and get back to enjoying your Polaris again. Ride on!