Steady throttle issue/ cutting out

Just down in the Cotsolds visiting the folks. Was out for a blast trying to look an old friend up when the bike started developing a slight miss but only around 3.5-5k if holding throttle in this area. If I spank her she runs fine. I have had an issue with the idle speed running too high 3 times in the last couple of days, runs around 3k but stopping the engine and firing her up again fixed the issue.
The miss got steady worse on the ride home and riding slowly through a village resulted in her cutting out and refusing to idle if started again. Had a FI error 06 come up which is Throttle Sensor but only once. Like an idiot I didn't bring my laptop and TuneECU cable. Should never leave home without it! Going to be a but buggered without it. I've had idle speed controller issues before but that didn't manifest itself like this. Ideas?

May sound strange but disconect the tilt switch,remember mine at cadwell it gave all sorts of false indications of what the problem might have been. Worth a try as it does'nt take long to disconnect

Could be one (or more) of many issues, as you know, but I guess the obvious answer is to start with the TPS and the respective connectors and wiring.

ahh ha ....






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your screwed





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Lol @ Stalker's reply! See Klinck, I told you he was a bastard..

Well its still playing up. One problem I noticed before this started happening is she has been getting very hot. Just allowing her to tick over she will get up to 1 bar from the top. Same in traffic. She doesn't normally do this. Reading the Workshop manual the idle speed is partly controlled by the coolant temp so is this playing a part? When trying to get somewhere with the TPS in TuneECU I got the FI code 6 for Throttle Position Sensor (typical I didn't note for sure which code but I think its the PO122)


Seems you can't buy the TPS from KTM. Instead you have to buy the whole throttle bodies They are speaking to KTM Austria to see if they can source me one. The TPS on the 2nd flies looks the same but the connector is female as opposed to male. I could chop the wires I know but not prepared to go that way just yet. This is all bloody annoying though I have to say. In the end I flattened the battery as the fan running all the time wasn't doing it much good. I did check what the battery was geting with engine running and ti was between 13.5 and 14v no matter what the revs.

I'm going to order one of those Suzuki fan switches that cuts in at a lower temp. Am a bit concerned why she is hitting 111+c at tick over or at least thats the temp TuneECU is giving me. Seems way to hot to me even if the engine is idling way too high.

viewtopic.php?f=5&t=19394&p=229928&hilit=+tps#p229928

You can order this one separately but do not know whether this, or any another, is the same as that for the SD/SDR - would be worth checking the reference numbers (not the KTM part numbers) marked on the parts themselves.

Cheers for that. There really is nothing that is beyond Bert's reach Gear4 couldn't find it, they spoke to parts guy from KTM UK and he couldn't find a part. If he wasn't a algorithm I'd be buying him a pint.

Not sure if Bert's second link is actually for an SD as other SD/SDR fiches only list the complete throttle body and not individual parts - interested to know if you find out otherwise.

Well I returned to the pits this evening with a fully charged battery. Set the TPS at 3.8v. I think there is an issue with the TPS as on occasion if I tried to wiggle it in and out or flicked it with my finger nail the volts would drop off to 0.02 from the .70 with a closed throttle and I'd get the error code P0122 TPS - Output signal too low (interruption) I couldn't make it do it every time but got it to happen 6 times.

Anyway I press on and fire her up. She runs ok, stalls a couple of times but much better than last night. I decide to check the volts across the battery one more time once she's warmed up. tickover is 13.5 which is normal. I rev it to 5 k and hey presto the volts jump and vary between 15 and 17.8v So at 48k miles plus change, the rectifier regulator finally gives up the ghost.I can't blame the TPS error on it though as it was giving errors with the engine off. All those volts probably weren't doing it any good mind. Oh well another £80, it could be worse.

Shingenden Mosfet?

viewtopic.php?f=5&t=19875&p=238668#p238668
and
http://www.regulatorrectifier.com/catal ... -Rectifier

Oh nice one.

We really need to put together a list of non OEM parts for the SD and put it in the Must Read Threads thread.

Your wish is our command

viewtopic.php?f=5&t=19922&p=239189#p239189


I changed the rectifier today. Volts now back to normal. Tried the TPS at .6v closed and although she would tick over ok and rev and back to tick over without stalling, as soon as I rode it and put the engine under load she would stall with as soon as I pulled the clutch in with a closed throttle. Tried it at .65 volts and bingo she ticks over perfectly and I can ride her and no stalling. I did still get the volts dropping to .002 a couple of times when I was fiddling with it and the error code flash up. She behaved perfectly on a 25 min ride though and no error code. Hmm going to have to keep an eye on this one.

Thanks, now go make me a cup of coffee. no sugar.

More reading material, that's good!

And keep us updated with your problem and solution.
I'm having something similar too, which makes want to paint the mother****er blue and sink it at the ocean.
No FI or codes though, just unsteady ride at under 5000 RPM and jerkiness at urban rides, the latter increasing when the bike's very hot.

While riding the highways around up too about 5000 RPM, the bike would feel as if it's slowing down, like when an engine dies because of running out of fuel. It makes me ride on and off the throttle or just a gear or two lower so RPM is higher.

When giving it the spanking - none of this occurs. Weird shit.
I too had an electrical problem with my clocks going on and off all the time. People here advised me it's the REG\REC unit. At some point it became so bad and the FI would flicker, the bike would not rev and then died. Managed to get it back home.
When I came to check the battery I found the positive wire disconnected!
The bolt apparently came loose and the wire would not sit tight. At some point it fell, and the wire was only touching the battery because of the preasure the batt box would put on it.

Since then - no more clocks going on and off but... that annoying un-smooth ride thing.
I love this bike, but I'm not happy with it. It's like having a latina girlfriend.

Well my idle issue isn't cured yet. She was being good but then she stalled at some traffic lights. Had to kill ignition to get her to run properly again. One min she is fine, then stalls when clutch pulled in or idiles at 3k+. Ronin has posted me his TPS off his SDR. I would imagine they are the same part. Hopefully that will fix it as I'm at Cadwell on tuesday.

Are you sure that it's not a faulty clutch switch?

I have the clutch switch bypassed. Could that make her tick over at 3+k though?

Not sure what you mean by bypassed - the clutch switch signal is used to boost tickover and prevent stalling - maybe what you've done is confusing the ECU?

Dodgy bypass plug? Try reconnecting the clutch switch?

Swapped TPS for the one Ronin sent me and after an hour of riding around London I'm feeling confident enough to say problem solved Kinda makes sense as the FI error I kept getting was for the TPS. Fingers, toes and bollocks crossed its solved.