throttle position sensor faulty - Page 3 - Kawasaki Forum :: KawasakiWorld.com
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post #31 of 52 Old 10-02-2018, 10:40 AM
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Ninjayorkie you goin to be selling the test leads once you've made them?
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post #32 of 52 Old 10-02-2018, 10:42 AM
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dastardly

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Apr 20, 2015*∑ #21

Do you have a manual for your bike it's not a big job to check it out and che I the Ecu aswell it could be another problem not the tps it could be an earth problem or power supply When you use your manual it tells you what to do and where to do it my manual is for earlier mods sorry but good luck I hate electrickery problems Craig

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2 days ago*∑ #22

Hi guys noobie on here and looking for some help. My 2000 a1 zx12 has developed a really horrible coughing/ spluttering/bucking between 3500-4000 revs it's rite at motorway speeds. [email protected]#[email protected]@in nitemare to ride. At first I thought it was dodgy fuel. I have had the injectors and rail cleaned, new fuel pump fitted and I disconnected pc5 just to eliminate it. It is even worse now. Could it be the tps? I have no idea how to test it or where I can get another. Cheers guys

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1 day ago*∑ #23

Changed your spark plugs?

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1 day ago*∑ #24

Hi yes when the bike started this I had plugs oil and filter done. It was about due so I thot I would start there. No change. Then put some fuel system cleaner in the tank for the next 4 or 5 fill ups. No difference. Disconnected pc 5. No change. Got the injectors and rail back during the week. The guy said there wasn't enuf gunge in them to cos the problem. Fitted them at weekend. Even worse???

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1 day ago*∑ #25

As this is a common problem here is some information. The zx-12r A to B2 use the same TPS (throttle position sensor) where as the ZX-12R B3 onwards use different ones and the plugs are smaller so you can't use the patch in test lead.
While I have found the patch in plugs to make up test leads for the zx-12r A to B2, (hopefully I'll make 5 patch in test leads this week) Kawasaki part number 57001-1521 Though the one I bought look like a bodge job. I've not found the smaller plugs yet to make test leads for the B3 onwards.
How to set one up can be found here. The Kawasaki ZX-12R under modifications
ZX-12 A to B2 Sensor TPS £ 141.56 € 152.88 $ 181.20
Assemblies where 21176-1083 is used 1998 NINJA ZX-6R (ZX600-G1) - Carburetor 1999 NINJA ZX-6R (ZX600-G2) - Carburetor 2000 NINJA ZX-12R (ZX1200-A1) - Throttle 2000 NINJA ZX-6R (ZX600-J1) - Carburetor 2001 NINJA ZX-12R (ZX1200-A2) - Throttle 2001 NINJA ZX-6R (ZX600-J2) - Carburetor 2002 NINJA ZX-12R (ZX1200-B1) - Throttle(B1/B2) 2002 NINJA ZX-6R (ZX600-J3) - Carburetor 2003 NINJA ZX-12R (ZX1200-B2) - Throttle(B1/B2) 2005 ZZR600 (ZX600-J4) - Carburetor 2006 ZZR600 (ZX600J6F) - Carburetor 2007 ZZR600 (ZX600J7F) - Carburetor 2008 ZZR600 (ZX600J8F) - Carburetor
ZX-12R B3/4 TPS 21176-0002 SENSOR,TPS £ 149.44 € 161.40 $ 191.28 Assemblies where 21176-0002 is used
2003 NINJA ZX-6R (ZX636-B1) - Throttle 2003 NINJA ZX-6RR (ZX600-K1) - Throttle 2003 Z1000 (ZR1000-A1) - Throttle(A1) 2004 NINJA ZX-12R (ZX1200-B3) - Throttle(B3/B4) 2004 NINJA ZX-6R (ZX636-B2) - Throttle 2004 NINJA ZX-6RR (ZX600-M1) - Throttle 2004 Z1000 (ZR1000-A2) - Throttle(A2/A3) 2005 NINJA ZX-12R (ZX1200-B4) - Throttle(B3/B4) 2005 NINJA ZX-6R (ZX636-C1) - Throttle 2005 NINJA ZX-6RR (ZX600-N1) - Throttle 2005 Z1000 (ZR1000-A3) - Throttle(A2/A3) 2005 Z750S (ZR750-K1) - Throttle 2006 NINJA ZX-6R (ZX636C6F) - Throttle 2006 NINJA ZX-6R (ZX636D6F) - Throttle 2006 NINJA ZX-6RR (ZX600N6F) - Throttle 2006 Z1000 (ZR1000A6F) - Throttle 2006 Z750S (ZR750K6F) - Throttle

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Last edited by*ninjayorkie*-*about 10 hours ago

dastardly

Senior MemberJoin:*Aug 2014Mentions:*4Posts:*1003australia

1 day ago*∑ #26

im pretty sure the TPS from an early Yamaha R1 also fit, I think the 1998 R1 was a direct swap for my 2002 12, I just happen to have a spare from my R1 lying around when i needed one not that this helps Craig

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about 22 hours ago*∑ #27

Ninjayorkie thanx for that info. You have given me more info in one message that the kawasaki dealer I emailed. I'll get a new one and hopefully thatl cure it. Is there any particular way to set it up once I have put new tps on?

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about 22 hours ago*∑ #28

Iv also heard that Suzuki have used the same tps on a few models don't know what ones tho??

SteveW

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about 17 hours ago*∑ #29

Kawamadgaz said:

Original Post

Ninjayorkie thanx for that info. You have given me more info in one message that the kawasaki dealer I emailed. I'll get a new one and hopefully thatl cure it. Is there any particular way to set it up once I have put new tps on?


Stevew I haven't gone deep into the pc5 so didn't know you can set up tps using the laptop. I'll have a look into it. Can't be to difficult.
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post #33 of 52 Old 10-02-2018, 02:05 PM
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Originally Posted by Kawamadgaz View Post
Ninjayorkie you going to be selling the test leads once you've made them?
Yes, I believe I will. Probably have 3 available.
Do you want one and are you in the UK?
I'll have to price up postage, parts, and 2 pints of Guinness for building, to work out the total cost.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #34 of 52 Old 10-03-2018, 12:59 AM
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Yes, I believe I will. Probably have 3 available.
Do you want one and are you in the UK?
I'll have to price up postage, parts, and 2 pints of Guinness for building, to work out the total cost. Ninjayorkie yes I'm up in Glasgow I'm sure the guineas(extra cold) will taste even btr free!!!
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post #35 of 52 Old 10-03-2018, 02:28 AM
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It comes to about £6 parts and postage, £7 for the Guinness. So £13 each.
Where 2 x pints of Guinness drinking time can vary between 10 minutes to an hour, the build of these takes about 40 minutes as I don't rush the build and they are crimped and soldered.

Don't forget you will need a security / tamper-proof T25 Torx to loosen the TPS and a digital Multimeter to measure the voltage, or do resistance checks on it.
Also, a charged up battery that's been off the charger for 10 minutes just to make sure you don't get false readings due to a battery voltage not settling down after being disconnected form the charger.

PM me your address.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.

Last edited by ninjayorkie; 10-03-2018 at 02:32 AM.
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post #36 of 52 Old 10-14-2018, 02:37 PM
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Hi guys firstly a BIIIG THANK YOU to ninjayorkie for sending me the lead to make testing the tos easier. I tested tps today engine off. Ign on multi meter showed 1.063v. Full throttle engine off ign on 4.14v adjusted sensor to 1.085v engine off ign on. Started bike up (had warmed it up before adjusting sensor) held bike at 3500revs(where stuttering started) and it still stuttered and backfired. Am I best to get a new tps? Or could it be something else. The engine wasnt under load just held revs at 3500 in the driveway? Any ideas??
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post #37 of 52 Old 10-15-2018, 02:39 AM
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Plug the test lead in but leave it disconnected from the loom, then do a resistance check while opening the throttle and watch for a fairly smooth increase in resistance.
If the meter starts jumping about its probably an indication the internal contacts of the TPS are worn and a new one is needed.

The meter reading will jump around a little in the .0* Ohms area. But not in the Tenths by more than 1 or 2.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #38 of 52 Old 10-16-2018, 09:54 AM
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Just for interest, I made a test lead for the zx-12r b3 onwards, smaller plugs. Pictures bottom of page 2. I'm waiting for more parts to make more of them.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #39 of 52 Old 10-16-2018, 05:02 PM
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Quote:
Originally Posted by ninjayorkie View Post
Just for interest, I made a test lead for the zx-12r b3 onwards, smaller plugs. Pictures bottom of page 2. I'm waiting for more parts to make more of them.
I'm interested in one!

2006 ZX-12R B6F
Ohlins / TRAXXION Dynamics / NISSIN / HEL / Power Commander / Bear Racing / Akrapovic / BMC / Muzzy / Healtech / ERMAX / Helibars / GSG / R&G / NUI Racing
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post #40 of 52 Old 10-17-2018, 03:13 AM
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I just tested the B3+ one out on my B4 bike, 5 minutes, worked a great resistances checks and voltage checks ok.
TPS plug was a little tight to get back off but all in all a nice bit of kit to have, even if your hardly ever going to use it.
Im waiting for bullet connectors to build the rest, but Iíll let you know when there made steve.
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For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.

Last edited by ninjayorkie; 10-17-2018 at 05:55 AM.
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post #41 of 52 Old 10-21-2018, 04:18 AM
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Added B3+ testing pictures to the bottom of page 2.
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For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #42 of 52 Old 10-21-2018, 09:00 AM
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Excellent!!!

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post #43 of 52 Old 10-21-2018, 09:55 AM
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Finished making the rest of the ones for the B3 onwards. A little harder to do these ones, taking over an hour each.

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.
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post #44 of 52 Old 10-21-2018, 01:55 PM
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Finished making the rest of the ones for the B3 onwards. A little harder to do these ones, taking over an hour each.

How much $$$ are you saving by making your own versus buying the Kawasaki part? I have not priced the Kawi part or have any idea what its costing you to make them is why I am asking, Thanks!
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post #45 of 52 Old 10-22-2018, 02:47 AM
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How much $$$ are you saving by making your own versus buying the Kawasaki part? I have not priced the Kawi part or have any idea what it's costing you to make them is why I am asking, Thanks!
Kawasaki doesn't make them any more or at least list them as no longer available here in the UK. Saying that there may still be some available somewhere.

You could try https://www.partzilla.com/product/kawasaki register to see if they have any. There may be other places too,

Kawasaki Special Tool: Throttle Sensor Harness Adaptor.
ZX-12R A to B2, 57001-1521 NO LONGER AVAILABLE UK Price: £16.22
ZX-12R B3 to 6, 57001-1538 NO LONGER AVAILABLE UK Price: £12.78

After tracking down what plugs you need (which I'll probably list later) and if you can order a single one, which may cost up to £7 you then need to order lengths of wire colors £9 or use whatever you have available if you don't mind the colors being different. Then you will need a crimping tool to attach the pins, £15. I suppose you could solder them and file any excess out so the pins fit in the plugs, knowing that if you've only bought one plug and you knacker it while fitting a pin you need to get another one. Plus you will need the bullet sockets for attaching probe leads, these will come to £6 in packs of 20 and you only need one half. Then the time to make one about an hour each. If all goes well you could make one for less than £10.

I had the crimping tool after making some for the zx-9r. When I found the plugs for the zx-12r minimum order was 5 plug set, so that's why I made 5 sets, I then found out the zx-12r B3 onwards uses smaller plugs so had to find and order 5 sets of those. This is the only reason I made so many sets, I only planned on making one for my B4.

For and against.
For, it makes doing the job piss easy.
Against, you only need it for 5 minutes checking or adjusting.

If you're going to make your own TPS test leads to a good standard, you'll need:-
Search ebay for, "3.9mm Brass Bullet Female/Male Connector DJ211-4A DJ221-4A Insulation Sleeves" for the patch in test leads to fit.
Search ebay for, "3m 1mm≤ 16.5A 12v cable wire wiring loom" then select or look for, Yellow/white, Blue/white, Brown/black. Same colors need for all zx-12r's.
Search ebay for, "Professional Ratchet Terminal Wire Crimping Pliers Tool Kit 4 Dies" or whichever takes your fancy. As well as crimping I also soldered.

ZX-12R A - B2.
Plugs for making test leads for zx-12r A to B2, x5.
https://www.aliexpress.com/item/5-se...001566526.html
Toyota-Denso-3-way-female-and-male-waterproof-fuel-injector-connector-plug

ZX-12R B3/4/6.
Plugs for making test leads for zx-12r B3 to B6, x5.
https://www.aliexpress.com/item/5-Se...724084704.html
3-Pin-Yazaki-7283-8730-30-7182-8730-30-Wire-Connectors-EVO-Mivec-Cam

Now you have all the information I have sourced, you can decide for your self if you want to make your own.

Just a thought, do you think I'm charging too much for the extra ones I made?

Found this on ebay which should work on the B3 onwards, search for "KTM Husqvarna Throttle Position Sensor TPS Diagnostic Harness Test Tool"

For Tech Questions Bike Model letters and Country are more useful than saying the year, for UK owners anyway, as registration year is not always the year of manufacturer model.

Last edited by ninjayorkie; 10-26-2018 at 02:33 AM.
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