Hesitation at 2000 RPM (with Tune ECU questions)

[Jabo75]

Update: Now I am getting an error (P0223- 2nd throttle position sensor, high voltage (Short circuit to sensor supply)). Sometimes I can clear the code and it stays cleared, sometimes I can't. Once I start the bike, the engine light comes on and the error comes back. That said, the bike seems to be running fine except for this **** hesitation. I am getting ready to just make a dealer appointment and see if they can sort it out.

 

[Jabo75]

Ok since you had the tps units swapped I would ask if when you went and put the old sevondary tps back in did you open the secondaries fully before inserting the secondary tps ?

How do I go about opening the secondaries fully?

 

[warp9.9]

Manually its really easy if you have the secondaries installed. Otherwise reach down in the throttle body grab the shaft and rotate it open. It will have spring loaded tension on it. After you rotate the shaft fully the you insert the secondary tps. The shaft is spring loaded so after you insert the tps hold it while you release the secondary shaft. You can also start the screw before releasing the secondary shaft.

 

[Jabo75]

Update: Just rode about 75 miles. My primary throttle hesitation is gone! WooHoo. Thanks everyone! Apparently I didn't ride it enough after putting the new primary TPS in it to get the bike adjusted. There is absolutely no low rpm hesitation now.

Now the bad part. I can't get rid of the P0223 (high voltage- short) code for the secondary throttle TPS. The bike runs like crap (I feel like I am on a Harley--shudder) when I twist the throttle. I held the secondaries open and inserted the TPS per the instructions, but I cannot get the code to permanently clear. Any suggestions?

 

[Jabo75]

Have you checked the little metal tongue that engages the TPS to make sure it is solidly moving in unison with the throttle shaft ?

Rocket Scientist, the metal tongue on the secondary throttle is not moving when I open the throttle. I resisted the urge to grab it with a pair of needle nose pliers (with a cloth to prevent marking it) and jiggling it to see if it will come loose. Any thoughts on how to get it to move?

 

[warp9.9]

I believe

Rocket Scientist, the metal tongue on the secondary throttle is not moving when I open the throttle. I resisted the urge to grab it with a pair of needle nose pliers (with a cloth to prevent marking it) and jiggling it to see if it will come loose. Any thoughts on how to get it to move?

Rocket scientist if refering to the primary which you have solved.

I am not sure if you have the manual to referr to

So first we must mske sure you installed it right. Not saying you did just establishing base line and what might have happened. You'll note above the dotted line this is the position you should be installing the secondary tps while you manually with you finger opend the secondary all the way. The shaft is spring loaded and the only way for you to open it is manually. The throttle cables, grip, and lower throttle plates are not in play here. After you force the secondaries open insert tps dotted line position.then rotate it to the solid line position so you can insert the screw. If this is the way you did it the only thing I think it could be is the rotation tabs inside the tps are out of sync possible from when I asked you about this a while ago so you would not throw the code. So you might have to rotate the inside of the potentiometer say with a screw driver. But first I would check and install like the manual because you aught to be able to look at the orientation of the secondary tab verses the slot on the tps in the dotted install position.

 

[Jabo75]

I do have the shop manual.
OK, so now I am showing my lack ok knowledge here. I thought If i used tape and opened the throttle all the way, then taped it to the brake to keep it open, it would make the job a bit easier. By you telling me that the throttle cable doesn't come into play here, I realize that this may be part of the problem.

1) I have been looking at the diagram, but ****ed if I can figure out what exactly I am supposed to push open with my finger.
2) As far as pushing the butterflies closed, does that mean I have to remove the air intake? is there a way to do it without removing the intake?

 

[TURBO200R4]

it seems u r having a little prob understanding what the guys have been telling u (which has been good info)
the primary set up lower shaft. tps at rear works with throttle cables one to open and one to close.
the secondary set up upper shaft. tps at front operates with an electric motor (between the 1st and 2nd throttle bodies) it is controlled by the ecu. when the ign is first turned on the ecu makes the secondary shaft butterfly sweep 100% and the ecu checks that. if it is off then u get a code.
i just looked at mine it is all covered so the only way is to remove the stuff to hold the butterflies with your finger or something that will keep them open while u install the tps.
i have been told if u have original air plumbing that it is a bear to get back in.
i have been helping a guy on his trans so someone may have already posted the answer.

 

[warp9.9]

Ok I don't have any secondaries or I would post a picture of them. But it's really simple; each throttle body has two plates. The bottom one is primary and where the primary TPS attaches to the shaft on #3 throttle body. The top plates which if you have them are the first thing you see when you look down the hole. And on the shaft that they bolt to is the secondary tps in front up on top of the throttle body right in line with the secondary shaft. if you stick you finger down the throttle bodies probably number 2 is the best you can manually open them provided you can figure out which side of the flap you need to push on. Once it's open fully then we insert the secondary tps in the position shown in the manual. Sorry I think this sounds rough maybe I need another sixer.

 

[TURBO200R4]

just reading the thread i think i need one myself.