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Voltages in this video (0,39V, 0,5V idle, 0,65V coldstart) are for the KTM 125SX / Husqvarna TC125 / GasGas MC125 TBI models!
Intro
Welcome everybody to VHM special Racing Products. Today we're going to walk you through the steps of setting up the TPS sensor on the TBI models from KTM. We're going to do this with our brand new designed tool to setting up the throttle position sensor (TPS).
Why check and correct the TPS?
If the sensor is not set up correctly, the engine control unit will give the wrong mixture into the engine causing the engine to run poor and give less performance.
What's needed?
VHM TPS setting tool, dummy stick (that came with the bike), 25 Torx screwdriver & #4 Allen key.
Step 1 ECU in sleeping mode
Setting up the sensor with our tool is only possible when the ECU or engine control unit is in sleeping mode. You can check this on the hour meter when it's off, just as the default indicator light. When there's nothing visible, it's sure that the ECU is in sleeping mode.
Step 2 Connect VHM tool
The TPS sensor is located on the left side of the throttle body behind the plastic cover. Remove the two hex screws with an allen key to remove the cover. You will see the sensor behind it. You can take the blue connector off easily with a small clip. Push it in and take it off. Now you can mount our VHM tool in between. There's no voltage viewed on the display yet in this step. This all happens with the ECU in sleeping mode. If you do this when the ECU is not in sleeping mode, you will have default indicator light, lighting up and you have to visit the KTM dealer!
Step 3 Use dummy plug
When the seat taken off, you will notice on the right side of the ECU the red diagnostic connector. Put the dummy stick in to get the ECU out of sleeping mode. When you put the dummy stick in, you notice that the VHM tool and ECU are getting out of their sleeping modes. This is correct. You now see the voltage viewed on the VHM tool display. If you put it on number one, you will see the sensor voltage and if I turn the throttle you will see it change a little bit. And on two it should be 5 volts. That's the supply voltage from the ECU. If it's not 5 volt then there's something wrong. Put the VHM tool on one for the sensor voltage.
Step 4 Close the valve
Now turn the red knob out of the throttle body, until you feel no resistance from the spring. It's located on top side and you can twist it out very easily with two fingers until there's no resistance anymore. That means that the valve is completely closed. Next step is to adjust the sensor on the other side of the engine.
Step 5 Adjust sensor to 0.39V
Ue use a torque screwdriver, torx 25, to loosen up the bolts of the sensor. Adjust it to 0.39V, you have to maintain that, and tighten up the bolts again. 0.39V is for the 125cc TBI models!
Step 6 Idle: sensor 0.5V
The next step is to turn the red knob back in until your voltage is 0.5 volts. When you start turning you will see the voltage change. This is idle. So normally when you put the dummy stick in you will see 0.5 volts. That means that the idle voltage is correctly adjusted. Adjusted if necessary to exactly 0.5V. 0.5V is for the 125cc TBI models!
Step 7 Clicking in coldstart
When idle voltage is adjusted you adjust the cold start voltage. Adjust it by clicking in the cold start button. It's the yellow button on the underside of the throttle body. You can reach it easily underneath the exhaust. Click it in and you hear a click. Now the voltage on the volt meter should be changed to 0.65 volts. If it's not, you need to adjust it.
Step 8 Coldstart: sensor 0.65V
If the voltage is off you need to adjust this. Turn the coldstart button and go to 0.65V. We now click it back and you do that with the throttle. Turn it in the opposite direction and then you hear a click. Then it's back again on the idle voltage. 0.65V is for the 125cc TBI models!
Use throttle to click coldstart back in position
Step 9 Remove dummy plug
So now the three levels of the sensor voltages are adjusted. It's not possible to disconnect our tool when the ECU is on. So we need to get the ECU back in sleep mode again and it's easily done by getting dummy stick out. And then wait a few seconds before it goes in sleeping mode. You can see that the tool is switched off. Just as the hour meter.
Step 10 Disconnect VHM TPS tool
Now you can disconnect the VHM tool from the wire loom. And get the sensor connected back on the wire loom. The ECU is in sleeping mode. You can see the tool is switched off. So we disconnect it from the loom and get the sensor back on the loom. Until you hear a click. And then put the plastic cover back.
We now successfully set up the TPS sensor on this bike.
