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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 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:

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

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:


(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.
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