I will replace the tmap connector since I ordered one of those as well. as an interesting note the throttle release switch on the handlebars is supposed to read 6.7 ohms at normal throttle and 2.15 at idle.... mine reads 4 and 1.7 respectively. thanks for all the tips.... hopefully this stuck throttle error will go away after today.

 

Ohm resistance values are + or - 20% so you have some wiggle room on these readings.

 

all put back together, seems to run good. drove a couple miles and no errors so far. we will see the next time I take a real ride. thanks again for the assistance.

 

Fired up the machine sunday morning.....soon as I got it out of the enclosed trailer and put it in high....bam 520194-7. I am thoroughly frustrated. My day job I am a cnc machine tech....all day I work on machines worth millions and this ATV is a basket case. I will try any and all suggestions.

 

Only thing I can tell you is to find a good dealer that can hook it up to Digital Wrench as you sound like you've done all you can do at home.

 

Well, it's at a Polaris dealer. They are confident the issue is somewhere in the wire harness, I am inclined to agree due to the results of my testing. thank you OPT for all the assistance. I will be posting the results.... hopefully someone will find it useful in the future.

 

90% of our time was spent tracking down wiring problems on the efi machines that came in.Hopefully it's something simple.

 

Hey Diesel73, they ever figure out the issue? I can't get correct voltage out of my tps and get the same readings out of a brand new one. Can't get to the .67 per the manual. Only .35 - .50. I'm starting to think it is a wiring issue also.

 

Very seldom did we ever have to change a tps,tbap,idle air control sensor,etc at the shop. A few tps sensors yes that people had messed with and messed up the internal spring mainly. Voltage problem generally are because of the thin harness wiring or the cheap connectors.As mentioned these thin wires can chafe and have bare spots or can even break internally. Feel for any soft feeling wires from the connector down to the main harness if you cant find any bare spots,plus look for any wires that may have pulled out of the connectors just a bit. Look at the "sticky" post above this section on efi wiring problems and it will explain a lot. It also leads to an option on heavy duty repair kits instead of the cheap Polaris kits we used that continued failing.Only The Best

 

Just went and relooked at this and my tps is running 3.4 to 5 volts vs. the .67 volts it is supposed to have. Thanks for the reply OPT but this is the 2013 and not sure the tbap affect the tps reading. I did look however and wires look good on it. I will try and test wires out in the morning.