How-to: Clean Throttle Position Sensor

For anyone suferring for the infamous TPS problem on an '03-'05 R6, here is your fix.

Signs that you may need to clean your Throttle Position Sensor:

- Bike dies when clutch lever is engaged.
- Erratic idle.
- Bike dies after start up.


*Taken from the "other" forum and edited for correctness.*

Tools:
Electrical Contact Cleaner
No. 4 Allen key
No. 7 Security Torx Key
Flathead screwdriver

1) Before you take anything apart, use the diagnostic mode and view your TPS settings. This will be the first (01 value) screen you see in diag mode. The TPS value should go up as you twist the throttle. Twist the throttle completely and write down the max value, then let go and write down the min value. You will need these later.

*To enter diag mode you need to: First, unplug the two electrical connections to your fuel filter on the underside of your tank. Then, press and hold the two buttons on your display. As you are holding the two buttons, turn the key to the "ON" position and continue holding for 7 secs. Release, then press and hold once again until the screen displays "DIAG".

2) Dismantle your TPS, it is located on the throttle side, under the small matte black cover near where your knee is when riding the bike. You'll need the security Torx bit for the TPS screws. (Note: If you don't want to buy the security torx. you can try to just grip the screw heads with channellocks and then replace them with regular allen head bolts to make the task easier when you have to do it again later.)

3) Remove the small rubber grommet on the underside to the TPS unit. The whole peice looks sealed but don't worry, the small black circular rubber piece is easily removed with your finger.

4) Spray the shit out of the inside of the TPS with contact cleaner. Then proceed to turn the rotor lock to lock multiple times to scrub the contacts clean (pictured). Place the unit face down a paper towel and tap dry.

* I use GT85, a penetrant that drys up gum free, with a layer of teflon to lube the contact. You can find that at cycle shops, best electrical contact lube/cleaner I have used.



5) Reinstall your TPS but leave the screws loose for now.

6) Go back into diag mode (if you are not still in it) and view the TPS settings once again.

7) Here is the tricky part. You need to bring the max/min values back to (or as close as possible) to your stock max/min values. To do this you will need to fiddle with the position of the TPS unit. You can adjust the values by physically tilting the unit (thats why we left the screws loose) and checking the max/min values by twisting the throttle. It take a little time and fiddling with, but it is not too difficult.

8) After you have achieved the right values, tighten everything up and put the cover back on. Enjoy!

good write up

any more problems after the clean-up?

thanks


*note: prior to do this DIY is to make sure that idle speed is 1250-1350 RPM.

If you need the values to reset the position of the TPS;
From 7-9 of the service manual

0 - 125 degrees
Fully closed position (15 - 17)
Fully open position (97 - 100)

My own readings were 17-96

The TPS is located on the right side of the bike, under the black piece of fairing that can be unscrewed then pulled out of the way with a piece of painters tape while you work on the TPS, which is behind several wire plug/jack connections that I disconnected to have more room. The T25 Security Torx tool I bought at Ace hardware for $2.00. Security means there is a hole in the middle of the star socket bit, to fit over the tit in the star on the bolt. The rubber grommet you remove is like an O-ring that fits around the shaft on the engine that the TPS slides over. Once you remove this small o-ring you have a tiny crack now to shoot your contact cleaner into. You cannot see the insides of the TPS and you just have to hope it works. When you put it back on the engine, be sure you line up the grooves in the cylinder on the TPS with the two points sticking out of the shaft on the engine. Don't force it. You don't have to remove the electrical wires from the underside of the tank to do diag mode--I don't know why everyone says that, including the service manual. I have done it several times and no explosions yet. If your TPS is indeed messing up, one common symptom is running very rich--the end of the exhaust pipe will become blackened, and the spark plugs will be blackened with soot. This TPS problem was also common on some Hondas.

Im gonna try taking my TPS off for a cleaning.

Just one question, where is the TPS located on an 07 R6?

In the service manual as well it gives instrustions on adjusting the TPS for the throttle valves and instrustions on adjusting the TPS for throttle cable pulleys. Which one is it?

Anyone have any pics of it?