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02-04-2012, 04:15 PM
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ATV Enthusiast
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Member #22639
Join Date: Jan 2012
Posts: 99
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HELP!! Throttle Position Sensor (TPS) Wiring Harness - Wires Broke
In the process of pulling my engine out of my 2007 Sportsman 500 HO EFI, I pulled several wires from the Throttle Position Sensor (TPS) Wiring Harness out.. This is the female end that connects to the engine. Does anyone know if I can just buy the TPS wiring harness or do I need to buy the entire main wiring harness. Please advise.
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02-04-2012, 06:52 PM
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Polaris ATV Legend
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Member #3687
Join Date: Mar 2010
Location: east arkansas
Posts: 2,301
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You might could find a pigtail for an automotive TPS and use it. Go to smpcorp.com and look at bottom right and select standard brand catalog. Then you will need to select the wc(wire & cable) catalog. Pigtails begin on page 152. Once you find the part # you can get it crossed over and a parts store. If it sounds like to much trouble you can always take the TPS off and have a pigtail matched to it. If you want to post a pic I will try and help you find a replacement pigtail part #.
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02-05-2012, 04:28 AM
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ATV Enthusiast
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Member #22639
Join Date: Jan 2012
Posts: 99
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Quote:
Originally Posted by tt425
You might could find a pigtail for an automotive TPS and use it. Go to smpcorp.com and look at bottom right and select standard brand catalog. Then you will need to select the wc(wire & cable) catalog. Pigtails begin on page 152. Once you find the part # you can get it crossed over and a parts store. If it sounds like to much trouble you can always take the TPS off and have a pigtail matched to it. If you want to post a pic I will try and help you find a replacement pigtail part #.
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I will post a picture of the pigtail today..I was trying to determine if Polaris sells the pigtail separately or would I need to buy the entire main wiring harness.
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02-05-2012, 04:33 AM
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Polaris ATV Legend
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Member #11982
Join Date: Feb 2011
Location: Douglas Wyo
Posts: 1,943
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yes they sell a pig tail with about a foot of wire with it
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02-05-2012, 05:23 AM
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ATV Enthusiast
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Member #22639
Join Date: Jan 2012
Posts: 99
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Quote:
Originally Posted by Russ C
yes they sell a pig tail with about a foot of wire with it
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Do you know the Polaris part number? Additionally would I just splice into old wire to connect the new pigtail. What would be the best thing to use to connect the wires so that connection is protected against water and won't come loose.
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02-05-2012, 01:16 PM
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ATV Enthusiast
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Member #22639
Join Date: Jan 2012
Posts: 99
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Attached is a photo showing the back of the TPS wiring harness with one of wires broken off at the pigtail.. I have circled the TPS pigtail in red. As you can see, the engine has been removed. I am rebuilding the engine....
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02-05-2012, 05:34 PM
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Polaris ATV Legend
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Member #3687
Join Date: Mar 2010
Location: east arkansas
Posts: 2,301
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I haven't seen a pigtail like that in a parts book. I could be wrong thou. I would use some heat shrink butt connectors with solder in them to connect it or just solder the wires and use heat shrink.
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02-05-2012, 09:34 PM
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ATV Enthusiast
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Member #22639
Join Date: Jan 2012
Posts: 99
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Quote:
Originally Posted by tt425
I haven't seen a pigtail like that in a parts book. I could be wrong thou. I would use some heat shrink butt connectors with solder in them to connect it or just solder the wires and use heat shrink.
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This is the pigtail that connects into the TPS sensor located on the throttle body. The photo shows the back of the pigtail where the wires connect into. It looks like the Polaris part # for the just the TPS wiring harness is 2878498. Cost maybe around $30. Can you provide me a link to the heat shrink butt connectors with solder or the heat shrink tubing....
Last edited by pglover19; 02-05-2012 at 09:46 PM.
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02-05-2012, 09:42 PM
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Junior Member
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Member #22822
Join Date: Jan 2012
Posts: 10
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this may not be the most ideal or proper way to do it, but i would try stripping about 1/2 inch of the wire off, sliding a 1 inch or more heatshrink on the wire and then shoving the wire into the plug and try to get a solder gun and solder down into the plug around the wire, in hopes of getting the 2 wires to solder together, then do the heatshrink. i would just try and do that before dropping a pretty penny on a whole harness. hope it helps
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02-05-2012, 09:47 PM
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ATV Enthusiast
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Member #22639
Join Date: Jan 2012
Posts: 99
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Quote:
Originally Posted by joeyrossmiller12
this may not be the most ideal or proper way to do it, but i would try stripping about 1/2 inch of the wire off, sliding a 1 inch or more heatshrink on the wire and then shoving the wire into the plug and try to get a solder gun and solder down into the plug around the wire, in hopes of getting the 2 wires to solder together, then do the heatshrink. i would just try and do that before dropping a pretty penny on a whole harness. hope it helps
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It looks like just the TPS wiring harness is available for around $30.00
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