TPS error with rain?

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Connection doesn't look healthy
 

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endodoc said:
So the ground wire in that mess is shared. It is a solder-less crimp inside the wire loom. It is not very well done. I would investigate there. I have seen this ground junction where a ground wire is literally holding on by a single strand. Or just go the easy route and get another airbox harness. Time is $$
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The solder on the connector that plugs on the TPS? I see is kind of sealed, any recommendations to seal it back in case I open it to check the connector solder?
 
Yep that’s a .... show right there. As mentioned, contact cleaner and maybe a toothbrush. Give that a shot then check the meter again.
 
Yeah clearly the problem with the socket connection for sure. Have to remove the round clips on inside of airbox with small cutters/needle pliers. They are not needed toss them and once connector is locked on its sealed can't go nowhere.
 
Everything is super helpful guys! Cleaned the pins om both sides with some fancy battery terminal cleaner foam, resistance is now 0 on all pins regardless the position of the cable, will test tomorrow! Thanks!
 

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Good work man, great to see people taking the initiative and fixing their own situation instead of getting penetrated at the service center.
 
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Maybe,
you should (pinout the connector and) clean the contact cleaned contacts with a contact cleaner cleaner.
depends on how aggressive the first one is (on the long run)
or put at least some petrol jelly inside.
 
Both the harness side and the airbox are sealed assembles (at least they were when they were built)at the shell. How’s he going to get the pins out? Thomasmryan, have you actually done this procedure on either the harness or the air box side?
 
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I've rewired a few electronic throttles off Mercs from the early 90's with sealed multi-pin connectors but not on bikes. Yes, it sucked but new units where 1500 or so. Ze Germans used some vegetable sheathing on the harnesses to make them recyclable which was a fail.

As Neil would say, corrosion never sleeps. If you don't get it all, it will just come back. From the picture, at least three pins where still crusty at the base.
 
As I thought. For this application, cleaning the contacts as well as possible to ensure proper electrical integrity (which he checked)
And maybe periodically rechecking is the most economical and sound solution.
 
If the connector at the airbox looks like that what do the others look like?

Gear position crank position map etc

Biodegradable electrical tape smoked
 
Mick1976 said:
The mill spec airbox harness runs about $225 so if you end up finding issues with your harness I can set you up with a mill spec or can send you a oem stock airbox harness that is new no issues for like $40
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Do you still have a new OEM harness you can sell?
 
Thanks! PM sent, so just as update, no errors on the bike so far, however idle still likes to die after a long compression on down hill to a stop. I'm thinking on getting spark plugs also, might still be using the factory ones as the bike is almost 15k.
 
Awesome man so you're all set so yeah if you have the bike apart enough to get both plugs out by all means drop new ones in. Another thing is when you drop my harness in check to make sure there is no gunk in the ports of all 4 injectors. I use the Motion Pro injector tool to clean them internally.


nesmsm said:
Thanks! PM sent, so just as update, no errors on the bike so far, however idle still likes to die after a long compression on down hill to a stop. I'm thinking on getting spark plugs also, might still be using the factory ones as the bike is almost 15k.
Click to expand...
 
So I installed the new harness, and maybe due to moving cables around I made something worst. Here is what is happening:

Each time I connect the top V injector, the TPS associated with it will not start, it will now throw the error right away, and will not operate, I connected the Vertical cables to the Horizontal Throttle body and this will not start, so it looks like is not an issue with an specific TPS. If I disconnect the top V injector and turn the key to on, the tps associated will start and operate normally.

Important to mention that the issue is when I connect the top v injector cable, regardless of which actual injector I connect, so is not the injector. Also injector ports look very clean.

So can't ride anymore, tried rolling back to the old harness, same issue. Any ideas where to check next?

I really appreciate your help!
 
Hey man did you have your throttle apart or add spacers recently? I would be looking at the throttle housing next. The 99's reset TPS when ignition is on each time. If the throttle is not going to close all the way or is sticking it will cause TPS errors and won't start.


nesmsm said:
So I installed the new harness, and maybe due to moving cables around I made something worst. Here is what is happening:

Each time I connect the top V injector, the TPS associated with it will not start, it will now throw the error right away, and will not operate, I connected the Vertical cables to the Horizontal Throttle body and this will not start, so it looks like is not an issue with an specific TPS. If I disconnect the top V injector and turn the key to on, the tps associated will start and operate normally.

Important to mention that the issue is when I connect the top v injector cable, regardless of which actual injector I connect, so is not the injector. Also injector ports look very clean.

So can't ride anymore, tried rolling back to the old harness, same issue. Any ideas where to check next?

I really appreciate your help!
Click to expand...
 
Mick1976 said:
Hey man did you have your throttle apart or add spacers recently? I would be looking at the throttle housing next. The 99's reset TPS when ignition is on each time. If the throttle is not going to close all the way or is sticking it will cause TPS errors and won't start.
Click to expand...
Haven't touched the throttle or add spacers, I also tested it with melcodiag to check it operates smoothly from 0 to 100 on all points and looks fine, stays at 0 as well with untouched.

I put the new harness back again, and started to behave normally, was able to start it for about 5 minutes with no issues, felt pretty good. then I assembled just the necessary to test it on the street, put my helmet, sit on the bike, turned the key on, and ENGINE error.. again, same H TPS error as usual. I also notice that each time this happens, when I turn the key off, the H TPS opens and closes, the V TPS doesn't, and then the V TPS will continue to produce sound, like if it is still getting some voltage when the bike is on, for about 1 minute. When the bike is fine this doesn't happens, everything will just shut off after both TPSs do the opening and closing when the key is turned off. Also it's curious that the error shows it is the H TPS, when it's actually the vertical that doesn't work sometimes, however I believe melcodiag reads them backwards.

Does all this sound like a possible bad ECU? or what else could it be? is there any complication on swapping ECUs on these bikes?
 

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