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Old 03-28-2012, 10:18 AM
AKStew's Avatar
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Guide for TPS Adjustment and Testing -- 2010 and Earlier EFI Models

I finally found it again! I used the procedure below when I replaced the TPS on my 700. It can be done without the special Polaris TPS tool; however I did buy the recommended special idle screw tool from KMS because needle nose pliers nearly messed up my screw to the point of being unusable.

The pictures are of a Ranger/RZR with the exact same throttle body as ours but the voltage specs you will have to get out of the proper manual for your machine.

You CANNOT guess or assume other years' specs will work. Make sure you have the right specs for your year AND model or you can cause permanent damage to your engine.

I take no credit for this. You can find the original web page here: Side X Side World :: View topic - Polaris: TPS Adjustment 2010 and older

TPS Adjustment procedure 2005-2010 XPs:
By: commanderjjones aka Jerry
__________________________________________________ ___________

TPS = Throttle Position Sensor:
The TPS is located on the passenger side of the throttle body. It tells the ECU how far open the butterfly in the throttle body is. If the TPS goes bad it can make the machine run erratically, or cause a hesitation at certain rpm’s. The only way to test the TPS is to use the tool Polaris designed to test it, or back-probe the yellow wire at the connector with a multi-meter and watch the voltage as you run up the throttle. It should climb smoothly, not erratically. Its hard to do as the numbers on the multi-meter will run up quickly.
__________________________________________________ ___________

Short Version.....adjusting the idle voltage:

(1) Find the yellow wire leading to the TPS and carefully pierce the insulation with the positive lead of your multi-meter (make sure that you seal that bare spot when finished). If you want to do it "right" and not pierce the wire insulation, you can buy the Polaris TPS adjustment harness ( Polaris part # 2201519-A ), which simply "T's" into the existing harness plug.
(2) Connect the negative lead of your meter to a good ground on the Ranger (the engine will work.....no need to go all the way to the battery).
(3) Set your multi-meter to the lowest setting that you have above .660 volts to get the most accurate reading ( many have a 2 volt setting and that will work great ).
(4) Turn the key on but do not start the engine. You should be seeing the proper volts for your year:

RZR:
08 = .735 +/- .010 vdc
09 = .730 +/- .010 vdc
10 = .690 - .730 vdc

Ranger:
05/07 – (700cc) = .710 vdc
06/08/09 – (700cc) = .660 vdc
10 – (800cc) = .690 - .730 vdc


If the voltage is outside of that range, turn the idle voltage adjustment screw on the left front of the throttle body ( directly above the throttle cable ) until you have the desired voltage.

Although the screw is designed to require a special tool ( Polaris part # PU-47315 ), it can be done with needle nose pliers. You can buy a cheaper version than the Polaris tool here: POLARIS RZR Idle Speed Tool
(5) After the desired setting is achieved, seal and lock the screw with some thread sealant or finger nail polish to prevent it from rattling out of adjustment.

Long Version.....adjusting the base voltage:

Typically this would only be done if the base voltage screw on the TPS has been tampered with, the TPS has been replaced, you have reason to believe this step needs to be done or if you're at the end of your rope and have ruled out everything else.
(1) Remove throttle cable cover on the side of the throttle body and then disconnect the throttle cable. Be careful to not drop the brass barrel on the end of the cable. That part cannot be bought separately from the T/B if you lose it (don't ask how I know ).
(2) Back off the idle set screw (shown in pic' above) until it no longer makes contact with the throttle cable cam. This should allow the butterfly to close completely.
(3) Clean the butterfly inside the T/B with carb cleaner and make sure that it closes completely (that's important for accurate readings).
(4) Check the operation range of the TPS. Using the same probe connections as above, change your meter to the lowest setting that you have above 3.6 volts (this will be 12 volts on most meters). Keep in mind this is a very sensitive sensor and very slight movements will produce large changes. It should go smoothly from 0 volts closed to 3.6 volts at WOT ( wide open throttle ). It should do so very smoothly, without any gaps, peaks, or valleys. If it has an abrupt jump or drop in voltage within a very small movement area, the sensor may be bad and needs to be replaced:

TPS:#2410342

(5) To set the base voltage, verify that the butterfly is completely closed, loosen the torx screw on the TPS

and rotate the sensor until you reach .528 volts. Tighten the screw down and verify the voltage again, making sure that the butterfly is completely closed for that reading. This is a difficult step because the sensor wants to move as you tighten down the set screw.
(6) Reinstall the throttle cable and cover, then adjust the idle voltage to the proper volts as described above.

Doing the adjustments are typically easier if you have a second person to hold the meter probes........unless you're lucky enough to have the type of probe that can hold itself in place while piercing the wire insulation.
__________________
2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips

Last edited by AKStew; 03-28-2012 at 12:17 PM.
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  #2 (permalink)  
Old 08-04-2012, 10:08 AM
primetime1267's Avatar
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Okay, I borrowed the TPS testing tool from my dealer today since my idle is ALL out of WHACK!!

What do you set first, the IDLE voltage screw?
I noticed that when I made changes to the screw I couldnt get my TPS down low enough to the recommended voltage..

I read in the manual that you should back off on the IDLE screw and start from there..

Well, Im still fighting with this, I set mt idle to .70 and then moved over to the TPS and did .528 per the manual.. The stupid would barely run, so I adjusted the IDLE screw by ear until it would run at an acceptable RPM limit.

I understand that when you move the IDLE screw it will in turn change the TPS values also. This is what really gets me tweaked...

Is there something I'm missing.
__________________
2006 Sportsman 700 EFI---29.5 Outlaws, gorilla axles, heelclicker clutch, 2" lift, snorkeled, Rad relocated
2006 Sportsman 500 EFI
-28" Outlaws, Rad relocate, QSC kit, snorkeled, ODI grips, 4 speaker stereo.SOLD
2005 Yamaha Grizzly 686 BBK & Mudbuster cam
-28" Outlaws, Rad relocated, Snorkels, Exhaust snorkel, fan over ride switch, clutch kitSOLD
2009 Polaris RZR LE--27" Mudzillas, snorkelsSOLD
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Old 08-06-2012, 12:42 AM
AKStew's Avatar
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Sounds like you're doing it in reverse order. Back off the idle set screw until its not touching anything. Now adjust your tps sensor to .528 (assuming that's the spec for your machine). It's hard to do because the voltage moves as you tighten the bolt. Be patient. Once the sensor is set, adjust the idle set screw to .700 and put a dab of loctite to hold it. That should do it.

Stew
__________________
2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips
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Old 08-06-2012, 02:07 AM
primetime1267's Avatar
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Stew,
I think ur right, I was doing it backwards. I'm going to try again later today.. thanks Stew!!!

Sent from my ADR6400L using Tapatalk 2
__________________
2006 Sportsman 700 EFI---29.5 Outlaws, gorilla axles, heelclicker clutch, 2" lift, snorkeled, Rad relocated
2006 Sportsman 500 EFI
-28" Outlaws, Rad relocate, QSC kit, snorkeled, ODI grips, 4 speaker stereo.SOLD
2005 Yamaha Grizzly 686 BBK & Mudbuster cam
-28" Outlaws, Rad relocated, Snorkels, Exhaust snorkel, fan over ride switch, clutch kitSOLD
2009 Polaris RZR LE--27" Mudzillas, snorkelsSOLD
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Old 08-09-2012, 03:52 PM
primetime1267's Avatar
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Location: Sarasota, Florida
Posts: 168
Stew, I spent some time today working on it again. Still no luck, when I get done my idle is at 1500-1600rpm.. it makes zero sense as to way it is acting like this.

I called my dealer and I'm going to drag it up there so they can use their laptop to get it dialed in.

When they use the laptop, do they have to adjust the TPS and idle screw or is everything just done electronically?? I'm try to decide if I can put my front plastics back on or not.

Thx again Stew for helping.

Sent from my ADR6400L using Tapatalk 2
__________________
2006 Sportsman 700 EFI---29.5 Outlaws, gorilla axles, heelclicker clutch, 2" lift, snorkeled, Rad relocated
2006 Sportsman 500 EFI
-28" Outlaws, Rad relocate, QSC kit, snorkeled, ODI grips, 4 speaker stereo.SOLD
2005 Yamaha Grizzly 686 BBK & Mudbuster cam
-28" Outlaws, Rad relocated, Snorkels, Exhaust snorkel, fan over ride switch, clutch kitSOLD
2009 Polaris RZR LE--27" Mudzillas, snorkelsSOLD
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Old 08-09-2012, 05:00 PM
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Location: Morgantown, WV
Posts: 1,178
Yea the laptop will not help a bit in adjusting the voltages. Its all done right at the TPS Sensor. Back probe the harness with two thin paper clips and use clamp style leads like found on my Fluke 177E. Adjusted wifes 550 in 10 minutes.

Matt
__________________
Mine:

2011 Sportsman 800
Polaris Front Brush Guard, Polaris Rear Brush Guard, Polaris Rear Rack Extender, Polaris L&R Rear Cargo Box, Warn 2500lb winch, Winch Saver, Ricochet A-Arm Guards (www.TheATVSuperStore.com), 3-High Headlight Mod, 6000k HID kit, Rigid Ind. 2xDually w/ strobe box, UNI Air Filter, 26" GBC Dirt Commanders, 1" Billet Wheel Spacers (Front and Rear) HighLifter HD springs, Dalton Primary Spring O\BL, Realtree Seat custom cover, Polaris Handguards

Wife's

2011 Sportsman 550XP
Polaris Front Brush Guard, Polaris Rear Brush Guards, Polaris Rear Rack Extender, 26" GBC Grim Reapers, Viper Elite 3000lbs Winch w/ wireless, Polaris Handguards, 6000k HID Kit

Fuel It, Flog It, Feel It!
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Old 08-09-2012, 08:55 PM
AKStew's Avatar
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Join Date: May 2010
Location: Layton, Utah
Posts: 919
Even the dealer will have to adjust the idle screw and the sensor by hand. Did you clean out the throttle body real good? It's important that the butterfly be COMPLETELY closed when the set screw is backed off and you're setting the sensor. Just thinking out loud...are you sure you're using the right specs for your make and model? I just threw out .700 & .528 because that's what you said they were. Don't copy another machine's specs just because it has the same size engine. It won't work.

Edit: I just realized you were working on a 2006 700 EFI like mine. .528 is correct and the idle voltage should be .710 according to my manual. Also, are you removing the throttle cable as you should?

BTW, I backprobe with paperclips like Vortecz71wv mentioned. The tool from your dealer should work though.

If you leave the plastics off, maybe the dealer won't charge much. It will only take a few minutes.

Good luck,

Stew
__________________
2011 Sportsman 500 HO Touring: Polaris 3500 lb. Winch, Kimpex Adventure XL Trunk, 7" Passenger Foot Risers, UNI Foam Filter
2006 Sportsman 500 X2 EFI: Superwinch Terra 25 w/Synthetic Rope, Kolpin 4 gal Gas Pack, 3" Passenger Foot Risers, 3-Headlight Mod, K&N Filter

SOLD 2010 Sportsman 300: Polaris 2500 lb. Winch, Kolpin Rear Seat (for the dog), UNI Foam Filter
SOLD 2006 Sportsman 700 Twin EFI: 27" Mud-Lite XTR, Superwinch Terra 35 w/Synthetic Rope, Polaris HD Front Springs, OEM Front Bumper Guard, WES Rear Seat, Kimpex Fender Guards w/Footpegs, 3-Headlight Mod, K&N Filter, Symtec Heated Grips

Last edited by AKStew; 08-09-2012 at 09:05 PM.
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Old 08-10-2012, 12:35 PM
primetime1267's Avatar
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Join Date: Jul 2011
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I cleaned the TB extremely well before I even started. The only thing I have done differently is that I am removing the throttle cable from up top under the lid by the throttle , in that little black box.

I'm using the same specs as you, but still a no go. The idle us waaay off. So I did everything today by ear and throttle response and rpm idle. I have it dialed in to 1180-1240....

I don't get charged my dealer since I am their Amsoil dealer. They have taken care of me for years. I usually buy the guys lunch or something as big thanks!!

I will report back tomorrow when I get back. I wish we had a O2 bung from the factory so it would auto tune itself .. lol

Sent from my ADR6400L using Tapatalk 2
__________________
2006 Sportsman 700 EFI---29.5 Outlaws, gorilla axles, heelclicker clutch, 2" lift, snorkeled, Rad relocated
2006 Sportsman 500 EFI
-28" Outlaws, Rad relocate, QSC kit, snorkeled, ODI grips, 4 speaker stereo.SOLD
2005 Yamaha Grizzly 686 BBK & Mudbuster cam
-28" Outlaws, Rad relocated, Snorkels, Exhaust snorkel, fan over ride switch, clutch kitSOLD
2009 Polaris RZR LE--27" Mudzillas, snorkelsSOLD
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  #9 (permalink)  
Old 08-13-2012, 08:10 PM
primetime1267's Avatar
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Location: Sarasota, Florida
Posts: 168
So I went down to the dealer and plugged in my machine to the laptop... We had a difficult time getting my bike to communicate with the software. Come to find out, the previous owner replaced the ECM before he sold it to me.. Well, he got a Ranger 700 ECM, lol.. It shouldnt really be a difference in specs hopefully..

Needless to say, we still couldnt get the idle 100% correct. I'm going to try another volt meter, I have had this cheap volt meter for years. So it may not be giving me accurate readings for all I know.

Whats your thoughts on a sportsman 700 running a Ranger 700 ECM??
__________________
2006 Sportsman 700 EFI---29.5 Outlaws, gorilla axles, heelclicker clutch, 2" lift, snorkeled, Rad relocated
2006 Sportsman 500 EFI
-28" Outlaws, Rad relocate, QSC kit, snorkeled, ODI grips, 4 speaker stereo.SOLD
2005 Yamaha Grizzly 686 BBK & Mudbuster cam
-28" Outlaws, Rad relocated, Snorkels, Exhaust snorkel, fan over ride switch, clutch kitSOLD
2009 Polaris RZR LE--27" Mudzillas, snorkelsSOLD
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  #10 (permalink)  
Old 08-13-2012, 08:17 PM
vortecz71wv's Avatar
Polaris ATV Junkie!
 
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Join Date: Apr 2011
Location: Morgantown, WV
Posts: 1,178
If you cant even communicate with it, i would be getting a new one put in thats correct for your bike.

Matt
__________________
Mine:

2011 Sportsman 800
Polaris Front Brush Guard, Polaris Rear Brush Guard, Polaris Rear Rack Extender, Polaris L&R Rear Cargo Box, Warn 2500lb winch, Winch Saver, Ricochet A-Arm Guards (www.TheATVSuperStore.com), 3-High Headlight Mod, 6000k HID kit, Rigid Ind. 2xDually w/ strobe box, UNI Air Filter, 26" GBC Dirt Commanders, 1" Billet Wheel Spacers (Front and Rear) HighLifter HD springs, Dalton Primary Spring O\BL, Realtree Seat custom cover, Polaris Handguards

Wife's

2011 Sportsman 550XP
Polaris Front Brush Guard, Polaris Rear Brush Guards, Polaris Rear Rack Extender, 26" GBC Grim Reapers, Viper Elite 3000lbs Winch w/ wireless, Polaris Handguards, 6000k HID Kit

Fuel It, Flog It, Feel It!
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