2002 Yamaha 115 4 Stroke Issue

[jcbruni]

I have a 2002 Yamaha 115 4 stroke. I bought it used. Ran good a couple of times and then it would stall out randomly and then crank up fine. Then it died when in idle. Now it’s a no start condition. At first, I thought it was a fuel issue so I checked all the fuel lines, LP and HP pumps, VST, etc. Checked sparks. Then I bypassed the neutral and opened up the throttle and it started up. So I then concluded it was an IAC issue. Replaced the IAC and still didn’t start. However, if I take out the IAC completely the bypass air will make it start normally. So then I checked the TPS. The ground wire shows 0ohms. Reference wire is near 5V. The signal wire was .47V at idle and 1.6V at WOT. So I bought a new Yamaha TPS and nothing changed. When I manually turn the bottom of the TPS, it will go to 4.5V so I know it’s not the ECU or TPS. Sounds to be mechanical. Another thing I noticed was the throttle plates are maybe 10-15% away from opening up all the way. The plate rest on the idle air control screw. I haven’t messed around with that screw or the throttle sync screw. When disconnecting the throttle cable from the engine, the throttle lever/ linkage is pretty tough to pull back and only gets the TPS signal wire to 1.6V. Is this a mechanical issue?? Please help!! Thank you!