I have a 2007 Sportsman 500 EFI that will not idle after it warms up. It idles fine at startup and while the engine is warming up. Once warm, it will idle either really rough or not at all. However, if I open the throttle it will run fine. I can take the free play out of the cable and get it to idle just fine, but this method just opens the throttle enough to make the engine run at an idle speed. It doesn’t fix the problem. Also, I have checked the switch on the ETC and it is working like it should.

I have a manual and I’ve read the fuel injection section and tested the components that can be tested with a meter. Everything up to this point has tested good. If the throttle is open at all, even the smallest amount, the engine runs fine. It seems like when the throttle hits the hardstop in the throttle body, which would also be the reference for the TPS, it will not idle. This leads me to believe that my problem may be that the TPS is slightly out of adjustment due to mechanical wear at the hardstop or a problem with the TPS itself.

This seems like something that is likely a common problem with an easy solution. I have tried searching and basically found that most people aren’t fixing it, just using the freeplay adjustment to prop the throttle open. Has anybody experienced this a fixed it for sure? Seems many take it for dealers, get it back, and the problem comes back. Others reflash the ECM and are good to go.

Error codes were 22 41 47.

 

Probably the map sensor wiring harness has damage wires or the wires may have pulled back from the connector. Kits are available to repair this,but click on the expert section above on the "sticky" about the harness wires being fragile. Posts are about the 700 but applies to all efi machines. Aftermarket kits are supposed to be available with stronger wiring. This was a common problem on idle. Some only did when warm,some right off,others just backfired,etc. Adjusting the throttle slack just covers up the problem and can be dangerous if not enough slack in the cable. OPT

 

Thanks for the info. I haven't had a chance to check that since you replied because I work a weekend shift, but I'm going up to my dad's today (that is where my shop and wheelers are at) and I will be checking for loose or elastic insulation according to the sticky. I'll let you know what I find out. Thanks again.