Very weird throttle body/TPS issues??

Guys I've run into a weird problem with my bike. Around the time I got her dyno'd the idle started playing up again. Went to a day at Snetterton which started wet but dried out and it got worse as the day went on. Had to hold throttle open some of the time to get her to tick over. Switching her off and on would temp fix it but then it felt like it was hunting. She went off to John at Track Electronics, ran when she arrived but 2 days later refused to start. The GinReaper swapped my throttle bodies for Ronin's spare ones and she started up. Still had problems idling but John tweaked on Dyno and she appeared ok. Raced her and as the day went on she started missing again and developed idle problems. I sent my injectors off to be cleaned and have just refitted them. Plugged into TuneECU and the TPS is 60%. No matter how far I adjust it it won't drop below 40%. This TPS is less than a year old. Swapped Ronin's TPS on to the bike and that reads correct values but gives 6 flashes PO122 Throttle Position Sensor - Output too low. Bike runs though. Won't run with my TPS in. So plugged Ronin's throttle bodies in and I get exactly the same errors/reading off these with the 2 TPS. Have to say this scares me a bit as its maybe pointing to a wiring loom problem. Can't be same problem with both throttle bodies and both TPS playing up at the same time? Any ideas?? Am I missing something obvious?

Craig - suggest you start with the loom side connector to the TPS and then the BGC - moisture/poor TPS connection here will affect running and give you false readings.

Ok so I've got rid of the error with Ronin's TPS by WD40'ing the fook out of the BGC. Mine is still reading 40% as lowest value so I guess that's fooked. Setting it is such a bitch though. Manual says 0.6v at idle and operating temp. Mine never seems happy here. If anyone with a 05-06 (all years may be the same?) bike would mind plugging there's in to see what the volts are at
1. Engine off and cold
2. Engine running, up to temp and idle.
3. Engine off and throttle wide open

Cheers

Just went out in the garage and checked thru TuneECU. 2005....
Cold, not running: .77-.78 Right on edge.
WOT, cold. 3.75-3.76 Right on the edge there too.

If I remember correctly mine idles .68 hot.

Good luck!

Hey Klink, think you are headed down th right path thinking loom but I would suspect the connectors on the loom in lieu of the conductors themselves.

Are you using dilectric grease in the connectors? Been a while since I've been into a halford's but they should have some sort of dilectric grease in a tube.

Here is some info I posted on the other SD forum explaining how moisture gets into the backshell of the BGC and how dilectric grease prevents it from shorting out the conductors. I would assume some of the other connectors (including the connector that attaches directly to the ECU) would be similar. I would check and grease every single connector on the bike first. If it's not connector related then I fear you could be correct about the loom....that'll take some time to troubleshoot. Good luck.

"Moisture gets into the connector from the backshell, the area where the individual wires enter the connector through the little rubber grommets. These are supposed to seal around the wires but they do not do a very good job.

You have to get all of the moisture out of this backshell. Blow it out for several minutes with compressed air...from a compressor...not a can of air for your computer keyboard. Special focus on the half with the female contacts.

Once the moisture is out, pack the shit of the female contacts with dilectric grease...force it down through the contacts so that it will enter the backshell from the front. This will prevent the moisture from making contact with the pins where they're crimped onto the individual conductors (wires) in the backshell. You cannot use too much dilectric grease...again, pack the shit out of it. Use dilectric grease that comes in a tube with the small pointed tip. Allows you to get the grease down in there. Do the same to the male portion of the connector to the extent possible.

Your problems will be resolved if you do this properly. Like I've mentioned in previous posts, I was having all of the problems associated with this issue...high idle (3-4K), stalling, hunting, etc. Started happening 6 months after I purchased the bike. Chased my tail for over 6 months trying to figure out what the issue was. Dealers were absolutely useless.

Once I dicovered the issue and applied this fix I've had 4 trouble free years...not one of the previously mentioned running issues.

I've had freinds have their throttle bodies replaced under warranty to try and sort the issue only to have it return. Once fixed with the dilectric grease no more issues. This is THE fix.

I'll be in London in January if for some reason you don't get it sorted by then.

Good luck.

Yeah I'm going to take apart every connector and dry them out and repack with dyalectric grease. Never done ECU so will do that as well.

Thanks for the volts info as well jgaches

Jgaches cheers for those figures m8. Bike is running perfectly again

No worries. Glad it worked out!