Are you positive it looses spark?
I was thinking check the TPS with an ohm meter.

 

Are you positive it looses spark?
I was thinking check the TPS with an ohm meter.

Yes, I put an in line spark checker and it drops all spark as soon as you touch the throttle.. I ohmed the tps and it seemed within spec

 

Does it immediately die? or does it sputter and fade out?

I'm not an 800 expert by any means, but I know there's an oil pressure check/relief that gets stuck and will cause low oil pressure so the lifters won't have oil pressure and the valves won't open all the way, or even at all, I've read of it causing all sorts of goofy problems...don't know that it's your problem, but as a known issue, might be worth looking into, at the very least verify the oil level

Very odd problem tho... have you checked voltage while the machine is idling and as it dies? perhaps something screwy going on with the charging system or a loose ground, could be in the ECU too...

 

duplicate

 

It does immediately when the throttle is pressed. But idles perfectly.
I haven't checked charging voltage as of yet

 

Good idea, seems if the voltage was so low it killed spark it wouldn't even crank.
look into the gas pedal switch thing, I don't know much about it but sounds like it could be your culprit. It sounds like it is some kind of safety feature and switched off idle......Everything I've read on it seamed vague.

 

I had a snowmobile that did that. Drove me nuts! Finally found it was the kill switch wire grounding out when the throttle cable moved it ever so slightly. I would check your wiring.

 

im with this guy ?
and also adding,
did the new fuel pump come with a new pressure regulator??
tossing parts at it can get costly as you found out.

 

I've unplugged the tmap with no change. My fuel pressure at idle is 38 psi. The fuel pump I put in was an All Balls racing complete module. My service manual says 35 +-3 on pressure so I think I'm good there.

 

mine manual says 36-42. One would think that is enough but man it's just not right, it's low. Did you try it with some throttle?(start it with the pedal pushed, pump it even), if it sputters, tries to run anywhere off idle I would go with pump. I've seen weak pumps do that same thing. Do it with the gauge on it if you have the inline type to see whats up.
Also check the voltage to the pump to make sure it's close to battery voltage, at least 11 or more cranking and 12 or more running.