Solved - Diagcode 520194, 520320, 520221

[jung4g]

For the last few weeks, I've been getting various diagcodes on a 2017 Polaris Sportsman 570 SP. Some of the throttle codes I saw: 520194-1, 520194-3, 520194-7 and the others popped up as well. Sometimes without issue, sometimes I'd be kicked into limp mode.

Some of the time, I'd restart (not always easy to do, but that's a different thread and solution), but when I did get it going, they'd be gone and it'd drive fine. Totally intermittent. 

 

Here's the solution I had to all of them, as this machine shouldn't be having so many issues even though it has 800 hard miles of either plowing or cutting trails in Northern MN:

1. Stock battery is tiny and crap. I swapped it out for a slightly larger AGM in the stock location (easy to swap if you crank the wheels out of the way and remove the coolant overflow. I did have to bend the stock battery retainer a bit for the new battery to fit, but that was 10 seconds with a vise and hammer. 

2. I pulled the entire front cover/cowling off to get a clear picture of things, but you could do what I ended up doing with just the wire terminal cover off. The terminal block by the fuse holder has the main power coming in from the battery, and going out to the winch, the starter, etc. I think the most effective thing I did was to remove all of those wires, brush them with a stainless steel brush to remove oxidation, dirt, and corrosion, and then reinstalled those wires good and tight.

Everything has been working better than it has it years since I did that. It seems the weak battery AND some voltage drop through bad connections wasn't supplying the juice needed for all systems and I kept getting codes and limp mode kicking in. 

I hope for you that a new battery for ~$45 off Amazon (way cheaper than my local stores) and maybe 90 minutes of just installing that and then cleaning the main connections up will solve those odd issues. 

 

I will say I checked all of the harness connections on the throttle, checked the throttle itself by removing it, adjust the idle up and down, and put a new air filter, and even tried the zip tie trick in the throttle switch to try to solve this along the journey, but none of those made a lick of difference. It was all the electrical connections.