keith
Expert Class
Posts: 155
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posted November 24, 2003 12:04 PM
tps
Finished rebuilding my 12 with the reprofiled cams, new shells and the bored out throttle bodies. Fired her up, sounded great till we got a bit of heat in the engine then ran like a sack of shit with flames out of the exhaust, wouldn't tick over, showed all the signs of being excessively rich. Checked the ECU fault finder which pointed to the throttle position sensor. The manual says you MUST NOT play with this item which is factory set. Now I purchase a second hand set of throttle bodies which I had bored out. I removed them and fitted the original set and the bike fired up and sounded really good. According to the manual and parts list you cannot buy the throttle pos. sensor from Kawasaki as you MUST NOT play with it. I'm tempted to take the one off the bored out bodies and replace it with the good one. The resistance check showed the dodgy one to be 3.5 kilohms and the manual says 4-6 kilohms. The good one reads 4.5 kilohms. Anyone have any input on this? Going to the dyno next Weds. Keith
  
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MadMike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
Posts: 6579
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posted November 24, 2003 01:32 PM
the TPS is adjustable on the TB, and from what I remember the resistance is adjusted by the movement of the TPS. so what I would do first is adjust the TPS so they are the same ohm's. then give it a try. also do you have a dyno handy. you map probably needs some major tweaking? not 100% but I would bet on it.
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200-MPH CLUB MEMBER!
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VincentHill
Needs a life
Posts: 6520
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posted November 24, 2003 01:37 PM
 Edited By: VincentHill on 24 Nov 2003 13:37
You will need a #25 Tamper Proof Torx bit. The measurement you mentioned , are you in another country? Read the service manual for what wire goes where and heat the engine up (Until the fans come on) for the correct adjustment! (The one in the book!)
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Made History @ Daytona and still one fast old man!!
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catman12
Expert Class
Posts: 169
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posted November 24, 2003 01:53 PM
If someone have a bad TPS, You can buy them as an ZX6R TPS they are the same...
// Mikael
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6.23@126.7mph 1/8mi , 9.44@150.99mph 1/4mi 60" Arm, 1361cc, manual shifting.
http://www.kiruna.se/~mgrape
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted November 24, 2003 08:56 PM
Assuming you have a 2000 model, did you, at that time or at any time previously, mistakenly plug the GREY plug that is meant for the MAP sensor into the TPS instead of the BLACK one, which is the correct plug for the TPS? If you did that, you likely fried the TPS. The result is exactly as described. On a 2000 the plugs are interchangeable. It was idiot proofed on subsequent models.
Doug
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keith
Expert Class
Posts: 155
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posted November 25, 2003 10:38 AM
Thanks for your input guys. Will get back onto it tomorrow. Which ZX6R model tps do you reckon fits Mikael the RR model or the 636 injection. Like I said the second set of bodies I aquired and had bored out came off a breaker so I haven't any history of them but I get your point Doug. Booked intp the dyno next Weds, 250 miles away in London. Keith
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted November 25, 2003 03:13 PM
Yeah, but the bored out one worked OK, right? Could you have switched the plugs back to correct orinetation when you put them on?
Doug
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zxlnt
Needs a job
Kawpuke Extraordinare
Posts: 2853
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posted November 26, 2003 08:01 AM
What are new "shells????
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keith
Expert Class
Posts: 155
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posted November 26, 2003 10:05 AM
Big end and main bearing replacements. Keith
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zxlnt
Needs a job
Kawpuke Extraordinare
Posts: 2853
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posted November 26, 2003 02:46 PM
Ahhh ok. Thought maybe it was kind of new secret speed part 
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