Homemade Polaris CFI TPS Setting Tool

[diamonddave]

TPS Adjustment Tool

+5V to "Vc"
-5V to "E2" and to the (-) into your digital voltmeter
"Vta" is the output to the (+) on your voltmeter

Also, Remember this is not a TESTER....it is a tool for setting the TPS... you could have a "Bad spot" in the TPS and not have it show up on the meter..

To "TEST" the TPS, you need a good old fashioned analog volt/ohm meter, the kind with a needle and scale.

You hook the probes up to the Vc and Vta terminals and slowly squeeze the throttle lever... look for smooth movement of the needle on the meter without any jumping or dropping off the scale.

I had one TPS that "set well" but it had a dead-spot in it.

Also, The 5 volt regulators from Radioshack come as bad as well... Test for 4.99 to 5.01 volts, with a fresh 9 volt battery before you solder it together... I had 3 out of 5 test low for voltage from the ones I bought at radio shack.


courtesy Mountainhorse

TPS Homemade Tool Parts List

TPS

These are Radio Shack Parts numbers to assemble a homebuilt Polaris TPS Adjutment Tool.

2761770 - $1.49 +5VDC voltage regulator 1amp
2700324 - $1.99 9 volt battery connectors (they only come in a pkg. of 5)
2701545 - $2.99 Insulated Alligator Clips(come in a pkg. of 6 pairs)
2701802 - $2.29 Project Box
2300875 - $2.69 9 volt Battery

Total price for regulator, 1 battery connector, 1 pair alligator clips,
project box and battery was $7.36.

TPS RESET PROCEDURE

Quote:
TPS BASELINE RE--SETTING PROCEDURE
The TPS comes set from the factory and should not need any adjustments. If replacing a TPS or resetting the TPS, Polaris has developed a TPS test kit for aid in setting the Throttle Position Sensor to specification.

1. Assemble your TPS sensor tool (PN 2201519) as per the instructions that came with the tool.
2. Make sure your 9 volt battery is in good condition by inserting the black voltmeter probe from your Fluketmeter in the black
terminal and the red probe into the pink terminal. Voltage should read 4.99 to 5.01 volts. If not, try a new 9 volt battery.
3. Insert the red voltmeter lead into the terminal above the pink wire, and the black meter lead to the terminal above the black
wire. Slowly open throttle and check for smooth voltage change.
NOTE: The Fluke meter will change scales and show O.L. momentarily when throttle is opening.
4. Remove the throttle cable in order to take the slack out of the cable.
5. Back off the idle lock nut counterclockwise and then back out the idle adjuster (A) counterclockwise until the screw tip (B)
separates from the adjusted lever tab.
6. Turn the synchronization screw (C) counterclockwise until the synchronization lever is touching the synchronization screw
hole (D) tab.
7. Remove the connector from the TPS on the throttle body and install TPS sensor tool on to the TPS.
8. Place a shop towel under the throttle body incase you loose grip on the spring or thread a small wire around it if it should fall.
9. Remove the synchronization lever tab spring (E) and gently open and then close the throttle plateswith the throttle, allowing
the plate to close gently. Note the voltage at this point.
10. Insert the synchronization lever tab spring and screw.
11. Turn the synchronization screw clockwise until the volt meter reads the voltage level that you noted in step #8.
12. Loosen screws on the TPS sensor (F).
13. Adjust the TPS sensor until the voltage on the volt meter reads .705 -- .715 volts.
14. Tighten the TPS retaining screws, making sure that the voltage continues to read .705 -- .715 volts.
15. Turn the idle set screw clockwise until the voltage reads .930 volts.
16. Voltage at the yellow terminal should be .920 -- .940 volts at idle. Once the TPS voltage is verified and set, remove the sensor
tool and re--install the TPS harness

#17 12-15-2008, 11:24 AM
mountainhorse




The baseline calibration IS with the throttle plates closed. This is an independent adjustment of both TB's.

THEN you adjust the TPS to the closed throttle plates at :
900/755 CFi .705 - .715 volts (I shoot for the middle at .710)
600/700/800 CFi 0.70 +/- 0.01 Vdc.

After the baseline is done... THEN you open the throttle plates with the Idle screw to:
755/800/900 CFi .930 volts
600/700 CFi .950 volts
Both +/- .01 volts
... lock it down (I like to use low strength wick-n-lock locktite on this screw after it is locked down.

If you have a little patience, the factory tester (or the homade one) and a multimeter, this is one of the least inimidating processes on the sled... Just follow the video that I posted up.

ALSO as a side note... I had to go thru a couple of regulators at radio shack until I found a good 5.00 vdc regualtor... most were out of spec.

I made another tester for a friend and found that my local computer parts house had better quality reguators that were spot on.

I helped a guy locally last year that was having a real hard time with his new Dragon 700... The TPS sensor had some internal problems that would not show up in the baseline calibration it was more mid range... I put an old school analog meter on the output and found it had a dead spot internally that was causing the problem...this is hard to spot with a digital meter. I first do an idle to WOT (slowly) with an analog meter to verify that the TPS itself is good and shows a smooth voltage increase.. then I do the full baseline calibration... I had a spare TPS with me and got him up and running in the parking lot.

The TPS setting method for the CFi's is NOT the same as the carbed sleds and should not be used with the CFi motors.

Thank you to Mountainhorse for this info

[diamonddave]

Courtesy of Mountainhorse

Baseline voltage on CFi SMALL BLOCKS (600/700/800):

the voltage is 0.70 +/- 0.01 Vdc.



Idle speed adjustment AFTER baseline is set:


Slowly turn the idle speed adjustment screw (A) clockwise
until the voltage displayed on the multi meter reads 0.95 +/
- 0.1 Vdc (.93 +/- 0.1 Vdc for 755/800/900 CFI engines).

[HUNDO]

Thanks for bringing this over Dave. I've been meaning to build one and now I don't have to look

[smwizzz]

Good to see this here. I built one some time ago. Thing works great.

[Ghostwhite]

Wish I had a radioshack to get stuff from!

[HUNDO]

Originally Posted by Ghostwhite

Wish I had a radioshack to get stuff from!

Send me your address and and I'll buy 2 sets of everything

[mtbarr64]

Originally Posted by Ghostwhite

Wish I had a radioshack to get stuff from!

www.radioshack.com

[Ghostwhite]

Originally Posted by mtbarr64

www.radioshack.com

but with everyone saying that the parts may be out of speck I would be leary and wouldn't wanna send stuff back.

Originally Posted by HUNDO

Send me your address and and I'll buy 2 sets of everything

Thanks for the offer but I have been cut short on my riding/wrenching time so I am having the dealer do it today. Next season I will definately hit you up about it.

[diamonddave]

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[BIGGDAWG]

thanks dave i was going to bring this one over too. now i don't have to