How do I test the t-bap itself? I traced the t-bap and tps harnesses... both look good.

I did replace that grommet, no change in how it runs other than no longer sucking air at the sensor. Is it possible a backfire took out the sensor?

 

Manual doesn't show any good way to test the tbap sensor itself(I can't remember when I ever had to replace one),but does show on the tps sensor.You really need the tester harness,9 volt battery and regulator to see if the tps is working ok and set right. This might be one of the times when hooked up to Digital Wrench could be your best and cheapest option.It should be able to pin point the problem whether it's in the tbap or tps sensor or their wiring harness.

 

that's kinda what I was thinking - time for a ride to the dealer. :/

 

Got myself a voltage regulator and made a tps tool.

I am a bit confused about the readings I am getting. If I connect the dmm to ground and sensor output, I was getting 1.12 volts. If I connect to sensor output and to the 5 volt ref, I get 4V. The manual says sensor to ground is .7-.99, and sensor to 5v should be 1.1-1.14.
How can the initial setting be so far off?

 

With a home made tester there's no way I can tell you which way to go. There are several different posts on different forums on home made testers and some using paper clips,etc and all of them seem to differ in what they come up with.They've come out with 40 buck tester harness on the 700/800 atvs (1/4 the price of the Polaris tester harness) but haven't found one for the 500. POLARIS RZR TPS Adjustment Tool (3 pin triangle)

 

did some more digging - apparently that .7-9V section in the manual is just a reference drawing.

Off to the dealer she goes!

 

Had one more hunch and went back to probing. On tbap, getting 5v on one pin, 2.6 on the other
​other. (Pins 1&3). Pin 2 = ground. If I probe pins 1&3 I get 2.6V - tbap shorted internally?

 

All the manual shows is that it has to have 5 volts input. Any further checking would require Digital Wrench testing as the manual says.

 

Ok. Thanks again!

 

Went to the dealer.. they found a partially broken wire on the TPS harness. Code cleared. Start her up, flick the throttle and it still backfires (through TB) and dies. No new codes yet.

Looks like I have mechanical demons to chase now. :/