2005 sportsman 700efi wont run

[hydnseek]

I have replaced the fuel filter, replaced the plug (it was black a bit), checked the ETC and cleaned the throttle body out. Voltage is 12.5 v
Connections at battery and coil are good. Cleaned air filter and box. Fuel pump is running for a few seconds when I turn key on.

It is still doing the same thing. If i hit the gas right after I start it, it will stall right away, and not start for about 1/2 hour. If I start it and just let it idle it will run and I can give it a bit of gas, but if I hit throttle too hard, it will stall. If i open throttle slowly, it rev up but even at higher revs, if I give it too much gas it will miss.

One other thing.
When I first was having problems, I ran the error code check and it gave me nothing. Now it gives me a 45 and 41 error.


I have done a bit of searching, and am led to believe that I am probably looking at the T-bap wiring harness or T-map sensor on the air intake.
Does anyone know how to test either of these, as I dont wanna start replacing 100$ sensors if it isnt the problem.

I have read of some others having problems with the T-bap harness and broken wires, on this model and year, and Polaris has a kit to fix it, but it isnt extra cheap either.....

Anyone have any experience with this, or know how to test either?

Thanks for the help


Anything else I should be looking at?

[fruth04]

i dont know crap about efi's but make sure all ground wires are tight

[cd]

My service manuals are at the shop, I'll try to do some research on your codes tomorrow if I can get a minute, I initially was thinking tps sensor but let me do some looking, unless someone beats me to the punch. I love how the self-diagnostic stuff is coming along, the crotchrockets are shweet to diagnose.

[boatman]

I don't know anything about how it works but sounds like the Throttle postion sensor ( If that is the proper name on a four wheeler) is bad. I know on a car that when a TPS goes bad it will cause that type of problem. A guy I know had a problem with his wires on the throttle body not making a good connection. I think the dealer had to replace the plug on the throttle body. This was on a 2007 model 500 efi.

[cd]

Code 41 Air Temp Sensor: Short to Ground
Code 45 Barometric Pressure Sensor: Circuit Low Input

and I quote:

Temperature and Barometric Air Pressure Sensor Test
The temperature and barometric air pressure sensor (T-BAP) is a non-serviceable item. If it is faulty, it must be replaced. This sensor requires a 5 Vdc input to operate yada yada must us Polaris Diagnostic Software to diagnose.

Long story short you can either replace that sensor in hopes its the problem, or have your dealer plug into the computer. I think atleast you could let it hooked up and pierce the wires with a multimeter to see if it has the 5V. Thats one of the only sensors that do not give a test procedure outside of using a laptop.

If you have to get the harness kit could you please get me the part number for it.

[hydnseek]

The part number is 2875542. I looked it up on bike bandit, I dont know the polaris part #

[mud monkey 7-4-80]

It really don't sound like the t-bap sensor. Mine has been bad a while and it is not doing that. Have you checked the relay's by the ecm? They could have some crude in them or they could just be going bad. Just my .02

[cd]

right, it may not be the sensor, however without plugging it in you will have to do some serious checking things out.

[SweetSportsman]

did you ever find out what the problem was mines doing the same thing

[mud monkey 7-4-80]

Have you checked the relays by the ecm? They run the efi system. That could very well be the problem. Mud and trash can get in between the relay and plug and cause a problem also.

[bullet1014]

is your speedometer working properly? i had a bunch of moisture in mine i could start it and it would idle fine but once i hit the throttle it would die so i unpluged my speedometer and poof it work just no 4x4 so i drilled a hole in the speedometer face to let the moisture out and put some dielectric grease in the plug on the back of the speedometer and everything works fine now

[hydnseek]

Still havent figured it out, so I gotta break down and take it to the dealer, its going in on thursday. :(

[crimbshaw188]

sounds sorta like the sommon problem of your t-bap sensor wireing harness gettiing rubbed though.......either try and check all the wires from the t-bap to the computer or buy another sensor

[hydnseek]

The wires looked good (even though they COULD be broken inside) and I have replaced the sensor.....going to the dealer today grrr

[Dirtbmw20]

The wires looked good (even though they COULD be broken inside) and I have replaced the sensor.....going to the dealer today grrr


I have read on several different occasions where that was the case. The wire had actually broke on the INSIDE and the insulation was perfectly intact, no cuts, scrapes, or tears in the insulation around the wire but the wire was still cut or broke in half inside the insulation.

[hydnseek]

Yes I have read people saying this also. That being said...I know my skills and weaknesses, and wiring isnt one of my skills....im pretty much an electrical idiot. Mechanically I checked everything I could think of, so it was time to let the dealer look at it.

I will post back, when I hear what the problem was

[hydnseek]

Well I got it back from the dealer....it was the ETC. Apparently I didnt know how to check it very well, but they said everything inside the cap was loose and out of adjustment.

At least it wasnt an expensive fix

[SweetSportsman]

what is the etc? mine is doing this again and i just replaced the wiring harness

[hydnseek]

Electronic Throttle Control.

Mine is still occasionally hesitating like it was though....
Im gonna sell this thing. Every ride it has been on the last 6 times something has gone wrong or broke down. My 2001 Magnum 500 has been bulletproof, but not this one.

[Atomic]

wiring around the T-bap sensor...Its a known problem with the 05 700's

D/L manual here http://www.execulink.com/~jesten/pol...800Service.pdf

Common problem on 04-05 700 efi. there is a pink wire that plugs into the t-bap sensor and it breaks right where it plugs in.

Here is a fix I found on another forum....

Okay, so here’s your bulletproof fix. You’re going to need to buy a common automotive trailer connector, or four-terminal “flat plug.” You need to get both sides, the one that goes on the vehicle and the one that goes on the trailer. There are four wires going to the T-Bap. You need to manually connect one side of the flat plug to the T-Bap and the other side to the wiring loom that goes to it. This is going to require some soldering so if you can’t do that don’t even try, or enlist the help of someone who can.

Unscrew the T-Bap and draw yourself a diagram or “map” for which colored wires go to which terminals on the sensor. The sensor has numbers on the plastic that correspond to the terminals. Unplug the connector. You’ll see there are four flat spade terminals on the sensor down inside a protective plastic sheath that the connector plugs into. You’re going to have to cut this sheath off to work on the spade terminals. It’s only about 1/16” plastic. You can use a knife or hacksaw to carefully cut through it all the way around without damaging the terminals. Once the sheath is removed to expose the terminals drill a 1/16” hole in each terminal and tin them with solder.

The flat plug wire colors aren’t the same as the wiring loom so you have to decide which color replaces which (white becomes pink, etc). Amend your drawn diagram so there’s no confusion as to which colors go to which terminals, making sure that the original wires get connected to the correct terminals on the sensor after they go through the flat plug. Slip a piece of heat shrink tubing over the wire on the plug, solder it to the proper spade terminal at the hole you drilled, slide the shrink tube down and heat it up to seal the connection. Do the same for the other three wires. Now you have a T-Bap that has a built-in connector. I brushed a couple layers of Plasti-Dip around my connections on the sensor just to be on the safe side.

Cut the original connector off the wiring loom. Allowing more length than Polaris did, cut the wiring on the other half of your flat plug so you’ll be working with a finished length. Slip shrink tube over each of the wires and solder them to the flat plug wires using your diagram to match up the right colors. Seal your connections with the shrink tube, reinstall your T-Bap, put some dielectric grease on the flat plug terminals, connect the plugs together and ride

[SweetSportsman]

yeah the wiring harness isn't the problem. I just replaced that and I'm still geting those erroe codes 45 41
but very good info thow