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.*
Electrical Contact Cleaner
No. 4 Allen key
No. 7 Security Torx Key
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!