My guess would be a broken TPS Harness wire. I am currently getting the rough idle when cold and 22 TPS code. Have not had time to check my harness, but I am betting it has a broken wire in the harness. I have already replaced the TBAP Sensor wire harness over a year ago for a similar issue. Common problem on the Rangers XP's

 

I have went through the TPS setting procedure. When I set it to spec and started it, low idle was much too high. I adjusted the idle screw and got the idle back down. I put new spark plugs in and the old ones came out pretty black, I think pretty rich. I cannot find any damage to the TPS wiring. I have been reading about the TBAP sensor and wonder if this would be causing a rich/poor starting problem? I'm just about ready to take this to the dealer, but am afraid that will be a lot of lost $$$ and time. Will the TBAP sensor throw a code? I can't find one for it on the list in my owners manual.

It still sometimes throws a 22 code, but now I don't know if its because the idle screw is set lower then spec voltage wise. Can I get one of you guys that has worked on these a lot to give me a call, or let me call you? I just need more info about how the system works. I've been wrenching for living on heavy/ag equipment since 1995, I'm no rookie. Just need some guidance.

FYI it has amost 5000 miles and nearly 500 hrs on it as it sits. Its been pretty trouble free until this last cold snap, and it won't start at 10*F. It will crank forever but not start. Let it set in the shop overnight and it will start, but stumble a few times before running normal. Thanks guys.

 

The TBAP issue won't always show a code.....especially if it's only an intermittent issue. If you're confident that the TPS is set correctly, functioning properly, and has no broken wires, then the problem is most likely the TBAP wires. I don't recall ever seeing the actual sensor go bad, but they can get dirty if it was ever ran without a filter or there was an airbox sealing issue, so try cleaning the sensor with MAP sensor cleaner.

I'll shoot you a PM with my phone number.

 

I have checked fuel pressure, 39 psi. I have taken and went back through the setting of the TPS insuring the throttle is completly closed. This time is seemed to idle at a tolerable engine speed. Seemed to miss a little at idle, but ran ok. I checked voltage of the TPS at the engine module and checked out good. My 22 code seems to be gone now. I let the machine set outside all night, and at about 20*F this morning it would crank and crank, after three times of cranking it started and died. With a little nursing of the throttle it would start and run.

What should I do next? I'm getting tired of fighting this thing, but want to wait another 6-8 months before trading to a 900.

Michael

 

Does the starting issue seem to be temp' related (colder it is, the harder it is to start)?

 

I would say so. It starts normally 60 degree shop. Outside overnight With temps in the 20s or lower it cranks forever and may not fire. It used to start the same cool or warm Ambient temps. Once i get it started, it seems to start and run the rest of the day.

 

You might have a broken TBAP wire.........a pretty common issue with these machines. The wires are VERY thin and will often they will break internally and leave the insulation intact, making it nearly impossible to find the problem. OTB Powersports makes an upgraded repair harness (thicker wiring) and I recommend installing it if you can't find any other issues. Unfortunately, that's often an intermittent issue that will not show a code, making it even more difficult to diagnose.

 

I thought I would bring this to the top one more time and let everyone know what I found, or didn't find with my machine. I replaced the TBAP harness end and looked everything over. I parked it outside and again it would not start. I put a full bottle of fuel additive thinking maybe moisture in the fuel, and still no help. I eventually got it to fire and I parked it in the barn and used my pickup for my day to day chores and let the Ranger sit all of January, Feburary and part of March. I would occassionally try and start it, and it was very hit or miss. Warmer ambient temp and after 3 times of cranking the starter it would start and die, start then and run. Last week we had temps in the 60's and it started very poorly(cranks very well, just doesn't want to fire). I used it for chores and the 3rd day of warm temps it went back to starting normally. One turn of the key and maybe one second of cranking and it was running. I've been using it every day again, and temps have been back to the teens and even colder wind chills and it starts like a dream.

What fixed it? I really don't know for sure. I suspect that I had moisture in the gas and the cold temps would cause it to freeze......however I will not know for sure. Thanks for reading and all the help. I hope this helps someone in the future. I like the machine, however I did make the mistake of driving a new 900 in January. When finances look a litle better, I believe I will be trading.

Michael

 

......I suspect that I had moisture in the gas and the cold temps would cause it to freeze......

That's my suspicion. I've seen it happen before. The fuel additive was probably the solution.