Hesitation at 2000 RPM (with Tune ECU questions)

[warp9.9]

Relaxed is shut ther

at this point if it was mine i would turn ignition on let it do its thing and ign still on with (tunecu on) i would remove sec tps and work tps with screw driver.
(don't carve this in stone) i think that relaxed it should be around 4+ volts and when loaded u should get around .6 volts. now if that works u can compare with sec shaft to figure out what to do

It is always just about shut until you put it in a specific gear, then it follows the program/tune settings. So unless you're in gear and you let off the clutch, the butterfly should be almost shut or closer to .6 volts. 4 volts is closer to wide open IMO

 

[TURBO200R4]

It is always just about shut until you put it in a specific gear, then it follows the program/tune settings. So unless you're in gear and you let off the clutch, the butterfly should be almost shut or closer to .6 volts. 4 volts is closer to wide open IMO

i agree

i was referring to the tps sensor removed from the throttle body in its relaxed position (not spring loaded) i believe that it should read 4+ volts. and when u spring load it it should read about .6 volts
this is what i think because when u install the sec tps u open secs plates put on the sec tps then u close the throttle plates to get the .6 volts

 

[Jabo75]

at this point if it was mine i would turn ignition on let it do its thing and ign still on with (tunecu on) i would remove sec tps and work tps with screw driver.
(don't carve this in stone) i think that relaxed it should be around 4+ volts and when loaded u should get around .6 volts. now if that works u can compare with sec shaft to figure out what to do

Well, I took the TPS off while the bike was in the "on" position, with TuneECU connected. The TPS did in fact move through the voltage range as I rotated the hub with a screwdriver. It actually went from 0 volts (counter clockwise at stop-full tension) all the way up to almost 5 volts - no tension. At this point, I am wondering if maybe something inside the TPS may not be grabbing the tang sticking out of the throttle correctly. Regardless, I am supposed to pick up a new TPS sensor on Wednesday, so hopefully it will solve the issue.

 

[TURBO200R4]

that sounds pretty bad.
even if the sec tps goes through the volt range it is still possible to be bad.however i think that your trouble is in the secondary shaft or secondary motor.
at this point i would try to find out if the three plates and tps part is all connected by gently push one one of the plates while watching the others including the tps tang
question what operates the secondary tps? blade,mill flat, shear pin ect

 

[Jabo75]

that sounds pretty bad.
even if the sec tps goes through the volt range it is still possible to be bad.however i think that your trouble is in the secondary shaft or secondary motor.
at this point i would try to find out if the three plates and tps part is all connected by gently push one one of the plates while watching the others including the tps tang
question what operates the secondary tps? blade,mill flat, shear pin ect

I have looked extensively at all of the parts mentioned above.

• All of the plates move in unison.
• The TPS tang moves when the plates move.
• The motor will always close the plates if they are left open.
• The secondary plates open when I rev the bike.
• After my last few rides, I can confirm that the motor is definitely opening the secondary throttle when necessary while riding. Interestingly, this was not happening when I first had this issue. I had very little/sporadic secondary throttle response.

At this point I am going to blame it on the hub in the TPS not properly engaging the throttle tang. It appears that the stepper motor wants to move the throttle past the closed position because it is not sensing the voltage drop that should occur as the TPS rotates. I am betting that a piece of the plastic hub on the TPS may be missing. Hopefully....

 

[TURBO200R4]

make sure tps turns the correct way
u might check to see if tps tang is long enough to work tps.(may be broken off or in to far to reach) also may be clocked wrong.
good luck we have r fingers crossed.

 

[Jabo75]

.....
At this point I am going to blame it on the hub in the TPS not properly engaging the throttle tang. It appears that the stepper motor wants to move the throttle past the closed position because it is not sensing the voltage drop that should occur as the TPS rotates. I am betting that a piece of the plastic hub on the TPS may be missing. Hopefully....

Well gentlemen, I am happy to report, I installed the new secondary TPS, and all is good with the world. When comparing the old TPS, I could immediately tell that the old unit (on the left) had one of the splines slightly rounded off. So in fact it wasn't engaging the throttle tang. As soon as I put the new unit in, I cleared the code, made sure the butterfly was closed and set the voltage to .6 volts. Cycled on and off several times and FINALLY no more error.

Thanks to all that have helped, especially Warp and Turbo!!

Any time you guys are in Pittsburgh, the Mickey's Big Mouths are on me!!

About to road test it this evening. Then on to loading a tune to take advantage of the triple K&N's I just installed.....

 

[warp9.9]

Well gentlemen, I am happy to report, I installed the new secondary TPS, and all is good with the world. When comparing the old TPS, I could immediately tell that the old unit (on the left) had one of the splines slightly rounded off. So in fact it wasn't engaging the throttle tang. As soon as I put the new unit in, I cleared the code, made sure the butterfly was closed and set the voltage to .6 volts. Cycled on and off several times and FINALLY no more error.

Thanks to all that have helped, especially Warp and Turbo!!

Any time you guys are in Pittsburgh, the Mickey's Big Mouths are on me!!

About to road test it this evening. Then on to loading a tune to take advantage of the triple K&N's I just installed.....

Glad it worked out. After you give her a good thrashing so she knows how much she upset you. Do not be afraid to check the throttle body balance and then do a ISCV check. I say check because if nothing changed you're just clicking thru. If something did it's probably from settling in. Enjoy rubber side down

 

[TURBO200R4]

thanks for the pictures
on my 07 i have been waiting for the primary tps to go bad because it is original and i wonder how they fail. looking at yours i can see why it would hesitate t 2000 rpm.
the way it is broken it probably won't move till about 2000 rpm.
i believe if u were checking it with tunecu that u could tell by watching the voltage.
thank u for taking the time and for the posts i have learned a lot from your problems.

 

[Jabo75]

Thank you my friend.

Remember though, this is my secondary TPS. I will go back now and look at my primary TPS. Once I replaced the primary TPS, my hesitation went away, so I am curios (and would it be really coincidental) if the same thing was causing the hesitation at 2K RPM?

I will report back if I can observe anything.

Also, Rode about 20 miles today, everything seems to be fine. No longer feels like I am riding a Harley....

On to the tune to take advantage of the triple K&N's....