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TPS (Throttle Position Sensor) 101 (2002-2007)

22K views 27 replies 7 participants last post by  Samurai_Warrior1  
#1 ·
The closed throttle adjustment of the TPS is linear and as such the numbers presented in the Yamaha Warrior Factory Service Manual {Max resistance x (0.13~0.15)} are percentages. The mean percentage being 14% (0.14) throttle closed!

  • Late TPS 3P6-85885-00-00 = 2.38~2.4k Ohms (2380-2400)
  • Earlier TPS = 4~6k Ohms (4000-6000)
Using mathematical masturbation and the Fact that the TPS input voltage is approx 5vdc from the isolated power supply that feeds all sensors from the ECU we can calculate the output voltage @ Idle to be 14% of 5vdc (0.14 x 5 = 0.700 approx)
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Take note of the early and late TPS voltage @ Idle from manual shown below

  • Early = 0.605-0.755 = 12.10-15.10%
  • Late = 0.63-0.73 = 12.60-14.60%
IMHO Yamaha tightened up the tolerance is all .... and setting up the TPS using output voltage will be more challenging for most members :)

So for those of you trying to match the magic 0.630vdc based on Ivan's specs, you're still in the Ball Park but just barely ... i think it was also stated that the bike burns less fuel or is more economical at the low end of the adjustment scale at idle but please don't quote me ;)
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I HOPE THIS CLARIFIES SOME OF THE RECENT QUESTIONS REGARDING SET-UP OF THE EARLY & LATE TPS
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Various Threads of Interest w/supporting documentation:


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#6 ·
Duane.. how about some Show & Tell for the members and this writer of your technique and instrument/probe you used to back probe the water tight TPS connector to achieve the 0.630vdc closed throttle adjustment ... thanks in advance :)
 
#3 ·
^^^
Duane ... no i'm not.
My TPS set-up is listed in one of the earlier prior links using ohms as the Benchmark @ 14%
 
#10 ·
Alternate TPS Closed Throttle Adjustment using DC Volts

Engine Off - Ignition Key-ON to perform this adjustment.
0-20vdc Scale is fine or Equiv, automotive back probe pins are handy with a couple of alligator clips to hold in place

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#13 · (Edited)
Okay well I put the meter on the bike and I'm getting .74 on the volts did not do an ohms test. I will do it although it's not going to make a difference I can't change it for I'm set to Ivan specs hovering between .629 and .632 had a couple of hesitations while riding yesterday this is starting to piss me off. If I lean it out it starts to hesitate if I go rich and it backfires heavily can't seem to find the middle.

I,m at co1-2 co2-5 and its hesitating on the settings backfires still but they're small I guess I'm just going to have to run it richer and live with it backfires cant find any vacuum leaks anywhere everything is solid. It idles perfectly never dies and I don't even have to use the throttle to start it when its warmed up just push that button and it starts right up with no LCV.

If anyone has any thoughts on this I would really appreciate it. Thanks

Duane out
 
#15 ·
.........
If anyone has any thoughts on this I would really appreciate it. Thanks

Duane out
I suggest you set-up the TPS per the Yamaha Factory service manual as has others and not thru the FM software.
Then make the closed throttle idle adjustment per the FM instructions and see what your results are!
 
#14 ·
My TPS ohmed out with 784 being the middle of the road on the ohm reading. My idle is at 800rpm's. When i checked the TPS reading on my PCV, it was lower than the 0.630. If i had idled the bike up to Ivan's test bikes idle ,975, it would more than likely been very close to the 0.630 setting. My bike starts right up, idles smooth, very good throttle response. The bike runs great with Ivan's map, very fast, no hesitations or backfiring what so ever, and i am running Mortons Executioners with no baffles. My ECU CO numbers were Co1=2 Co2=3, i changed them to Co1=2 Co2=2 because of adding Bills power pipe, i don't know if it makes any difference making them the same or not but it just seemed like it should work being the rear cylinder was breathing as good as the front cylinder. The flashed ECU makes the bike better, no doubt. Happy with the results.
 
#20 ·
ok new settings
so it was in spec at .63 and having problems ohms were 324

So I'm trying a little more within the range of .63v .73v with .68v ohms 342. I hit the freeway for a 25mi ride and all I can say it's got more throttle response off the line, but it still has the "hesitations" or back fire through the throttle bodies, and almost always the front. it still has the backfire out the pipe but not as bad.

2 plugs look good, nice and even light brown, but I need to do longer ride to get a better read.

I don't think this is a TPS problem anymore :confused:

so what's left to check?

I did do a leak down test and compression test cylinder 1 and 2 even on compression and the leak down test pass.:)

All the problems happen low end of power curve the backfires through the throttle body's happen on downshift, and it backfires as soon as I close the throttle, about 50% of the time.

thank you for your time ;) duane out :cool:
 

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#28 · (Edited)
ok new settings
so it was in spec at .63 and having problems ohms were 324

So I'm trying a little more within the range of .63v .73v with .68v ohms 342. I hit the freeway for a 25mi ride and all I can say it's got more throttle response off the line, but it still has the "hesitations" or back fire through the throttle bodies, and almost always the front. it still has the backfire out the pipe but not as bad.

2 plugs look good, nice and even light brown, but I need to do longer ride to get a better read.

I don't think this is a TPS problem anymore :confused:

so what's left to check?

I did do a leak down test and compression test cylinder 1 and 2 even on compression and the leak down test pass.:)

All the problems happen low end of power curve the backfires through the throttle body's happen on downshift, and it backfires as soon as I close the throttle, about 50% of the time.

thank you for your time ;) duane out :cool:
insaneduane, Did you ever resolve your issues? I am having similar problems and was curious what your solution was. I was hoping to hear that all your problems went away when your replaced the exhaust gasket.
 
#21 ·
Make sure you do not have any exhaust or intake leaks. I believe that coughing through the throttle bodies is a lean condition when giving throttle. Maybe bump your ECU numbers up a tad and see if that fixes the coughing from the throttle bodies or add some fuel in the 0 column on your pciii or pcv if you have one. Just a suggestion to try.
 
#22 ·
Nothing about the plugs says lean, I check the exhaust and intake for leaks months ago when I started this project. If I add fuel it backfires heavily but will still hesitate. This is why I'm having such a difficult time and thinking that it could be TBS. Could the Dayna coils be causing this problem?
 
#24 ·
well the exhaust is coming off when the brake lines and new belt go on and I have the gaskets for that. the intake I checked a month ago and the boots were in good shape I did not take them off did not think it was need.

I'm 99% sure of no vacuum leaks I even sprayed starting fluid
around the throttle body's when it was idling and it did not produce a surge

Anyways bike runs good for now so I'm going to do the brake lines and belt before the weekend got a big ride Sunday. I will get back to this later

duane out :)
 
#25 ·
So I think I found out why I'm getting so much hesitation and why the rear cylinder has been giving me so much trouble, after doing my middle drive pulling the rear exhaust I found a very burned up exhaust gasket. I knew there was something going on just a matter of taking things apart to figure it out sure run smooth now no popping no hesitation everything's great. :)
 

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#27 ·
Yes quite frankly I was praying for an exhaust leak because if it wasn't an exhaust leak then I had some real trouble inside the cylinders or in the valves. I think when Yamaha put this pipe on for the previous owner I don't think he tighten it down quite enough, so it's going to get a real good ride today should be nice temperatures are in the high 50's nice and comfortable think I'll wear my extra heavy leather.

Duane out :)