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2013 Scrambler 850xp TPS wiring screw up


JacobSlabach

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Hey just picked up another scrambler 850 was told the tps was bad.  This atv has been beet to hell.  Wiring has been tinkered with the crankcase has been replaced recently and the motor rebuilt (can see horizontal scores thru spark plug hole where it’s just been honed out and rebuilt)

my guess is it was ragged out till the motor blew a rod and rebuilt but the clown that did it couldn’t get it to run again and sold it.  When I bought it it would pulse and smoke black at idle and die with throttle.

New tps installed and it won’t run period.  I went to celebrate it and I’m getting 5 volts on 2 of the 3 wires running to the tps.  Is this normal and if so how should I celebrate it?

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  • 2 weeks later...
  • 4 months later...

update on this bike, found a wiring diagram, checked wiring, and its all good.  swapped ECUs with my other scrambler and the ECU is good.  took the bike to my local polaris dealer to dial in the tps and they charged me $100 to say the diagnostic tool said the new tps was toast.  so back to the drawing board.  ive heard of the timing gear on the cam jumping time on these machines so that may be an issue.. will check that also.

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  • 2 months later...

alright will do, also found that theres no spark either.  so no spark and no fuel.  it has compression and the timing is good.  could the TPS being out of adjustment make it not get spark or fuel?  it was pulse-running when i bought it (pulsed at idle and i couldnt give it more then 1/4 throttle without it dying)

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8 minutes ago, MarkinAR said:

It won't fire if it doesn't detect fuel. My guess is a bare spot on the harness rubbing against the frame. It takes a direct short to pop a 20A fuse. 

alright makes sense.  ive been through the whole wiring harness and nothing seems worn or bare.  traced all the wires and the ground wires from the injectors run directly to the ecu.  positives run to the efi relay which i switched with another relay to make sure its good and no change there.  theres a black box in the wiring harness that has wires chopped and reconnected to it im curious what that is.

...or if it has anything to do with my issue.. and i swapped the ecu to my other scrambler LE and it ran just fine, used and tried averything i could think of and it checked out

Edited by JacobSlabach
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I hate chasing electrical gremlins.  Still leaning towards it being a direct short to ground. Could it be the reg/rect pumping out too much voltage and causing a problem?  Without it running that's probably difficult to troubleshoot.

I'd really dig into that area where wires were chopped and reconnected and then go from there.  You might loosen the harness from the frame and pull it away the best you can to put space between the harness and the frame and then see if that helps.  May not, but worth a shot maybe.

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19 hours ago, MarkinAR said:

I hate chasing electrical gremlins.  Still leaning towards it being a direct short to ground. Could it be the reg/rect pumping out too much voltage and causing a problem?  Without it running that's probably difficult to troubleshoot.

I'd really dig into that area where wires were chopped and reconnected and then go from there.  You might loosen the harness from the frame and pull it away the best you can to put space between the harness and the frame and then see if that helps.  May not, but worth a shot maybe.

alright theres also one more thing ive seen on all the polaris bikes but not sure what it is ill take a picture of it and post it.  i traced the wires from the little black box (pretty sure its a relay) and wires run out of it to the left handlebar and the the other wires run to the headlights so i thin its just the headlight low beam/high beam relay and the headlights work as they should.  im with you on the wiring if id have known it wasnt just a faulty TPS on this bike i wouldnt have bought it lol

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update:  went to show a buddy what the scramblers issue was and it fired up.  it idles rough still and only runs on one cylinder but at least its running.  i guess the ecu just had to have a while to reset itself?  i also think i blew the fuse when i installed the last TPS incorrectly (reversed two of the wires).  also the code 520 194-7 (manual says stuck throttle) is the only code on the bike now, the two for the injectors are cleared

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