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2005 800 Sportsman EFI sputters

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  #11  
Old 07-10-2011 | 01:21 AM
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If you do have a t-bap harness problem(big IF), a lot of times NO codes will show on speedo OR even "false" codes may show up.Even hooked up to Digital Wrench, codes don't often show up unless a positive break in wiring! Even have had plenty of codes"21"(loss of synchronization) and "23(bad ECU) show up on the speedo!! One way is to feel the wires and if you find a "soft' spot in the wiring,possibly could be the bad wire. Also you can try the "jiggling' method one Polaris engineer suggested! While running in neutral at higher speeds,jiggle the wires and see if you notice a change in the engine! Sounds squirrely,BUT I did find one t-bap harness problem this way! Plus to reset the codes just disconnect the battery for a few minutes. After all this my best guess is still the t-bap harness since the usual signs are spitting,sputtering and this is what we replaced the most of on the 500,700 and 800 efi machines. OPT
 
  #12  
Old 07-11-2011 | 03:43 PM
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Ok, so last night I took your advice OPT. I felt for weak spots in the harness wires, but I didn't find anything. I wiggled the wires and found that if I held the wires in a certain position it would not bog down when I mashed on the throttle. Am I assume that the wire harness is shot???
 
  #13  
Old 07-11-2011 | 04:05 PM
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Replace with either the oem or after market t-bap harness kit and hopefully will solve your problem. BUT can't guarantee how long the oem one will last!! (not until they address the small wiring on all the sensors and the kits also) OPT
 
  #14  
Old 07-13-2011 | 05:32 PM
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Last night I put a pressure gauge on the fuel rail. It was only pushing 8 psi, is this the result of the tbap? My manual shows it should be pushing 39 psi.
 
  #15  
Old 07-13-2011 | 06:05 PM
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Yes,should be showing 39 psi. May have found the problem! Not from the t-bap,but could be a fuel pump problem. Does it still change when you mess with the wiring also?? Could have a double problem? OPT
 
  #16  
Old 07-14-2011 | 08:02 PM
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No it does not change. It only shows 8 psi no matter what
 
  #17  
Old 07-15-2011 | 03:21 AM
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Are you using a correct fuel pressure gauge hook up? If using just a plain gauge won't show accurately! OPT
 
  #18  
Old 07-15-2011 | 07:57 AM
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Confused by what you mean? I am using a fuel pressure gauge that I use on cars.
 
  #19  
Old 07-15-2011 | 08:37 AM
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As long as its for an auto its fine! Actually have had some people try to use a tire gauge at home!!! OPT
 
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