Here it is guys, I come to you with hat in hand.
I have never had a butt kicking like this before in my life.
A buddy buys and brings his 2008 sportsman 500 over to the house.
Says it wont idle, I am thinking "typical slack adjustment on the cable"
OMG was I ever wrong. 6 or 7 new parts later " new wire harness, stator, map sensor , throttle body, injector tp sensor etc etc, I still have fault codes 22 , 41, 42, 51, 55, . and it still wont idle.
machine has 186 miles on it , I cant believe the poor condition of the wire harness.
I am at the end of my rope with this thing.
I have been working on bikes, atvs , jetskis since the late 80"s and nothing makes sense with this thing,
AND YES I HAVE THE REPAIR MANUAL AND HAVE WORN IT OUT, LOL.
If anybody knows any secrets about these bikes please let me know .
thanks

 

Problems on efi machines is 80 % wiring so the manuals say and not the sensors and I tend to agree for the most part. 41,42 is air temp(could be bogus),22 is tps voltage high or low,51 is injector high or low voltage. Tps code may be correct as it and the tbap wiring harness or connector may be the problem.Replaced a bunch of sensor harness kits that failed time and again. Same thin wires in the Polaris repair kits. Read the sticky post above the expert section on 700/800 efi problems. Most of the time the tbap wiring was the worst offender. Idle problems,popping back,but ran ok off an idle were some of the symptoms.The sticky post led to better repair kits from this place.https://otbpowersports.com/products/

 

Thanks OPT. I will look through the sticky posts.