KTM EXC 2022 TPS Sensor Adjust

The problem

KTM EXC 300 2022 was not running super well from the 0 hour. At certain throttle positions (more than 50%) it was losing power or twitched.

Modifications

From the very beginning I have installed 2 mods:

1. Idle screw

2. TPS Sensor cover

I installed it based on my previous experience with older 2018 model. Idle screw was useful to adjust idles, because adjusting it with air bypass screw was not working perfect. Also I liked how bike feels on low revs with air bypass screw almost all way in.

Another use case of idle screw - is when the crank case seal go bad - your idles go crazy off and you need to adjust it when you wait for deliver/install new seal :)

Refine the problem

I decided to do more tests to identify what exact weird behaviour I have. And found that problem was between 50% to 75% of throttle. It felt like after 50% bike has some restriction and loses power and run with splattering sound.

Resolution try #1

My first guess was one of CCPS (pressure) sensor is bad. So I swapped them - and it give zero result.

I also tried FMF Fatty pipe - it give improvement in all range of throttle, but copied exactly weird behaviour in 50%-75% of throttle.

Final resolution

My last guess was that I have some issues with TPS Sensor position. Proper way to adjust it - check voltage it gives on idle. It should be 0.6 Volts

I decided to go more easy way - check what throttle position ECU reads. TPS Sensor is a 5 Volt sensor, so at 0.6 Volts ECU should read exactly 12% of throttle.

I connected ELM/ODBII/CarScanner app to ECU and found that my throttle position is around 16% which is way off.

I got bolts loosen and try to rotate TPS sensor - the adjustment range was around +/- 1% which is not enough.

So I removed steel rings:

After that I was able to adjust throttle position between 12.5% to 18%

After I set it to 12.5% and make a test run - bike run amazing! how it should!To prove it was not a mistake or placebo I adjusted to 18% and bike was running even worse than before :)

So I put it back to 12.5% and then adjusted idle screw so it show 12%. But I was forced to screw out air bypass screw to 6 turns in order to have 1550 idle RPMs.

And actually I don't like it. My next step would be to find a way to adjust TPS sensor to 12% and keep air bypass screw more in.

Final thoughts

With stock ECU TPS sensor should give 12% of throttle at idle position. And I had 15.5%. This leaded to wrong ECU Map settings at mid range.

I hope I understood it correct :)

Later adjustments

I used dremel to make mounting holes bigger and give more room to adjust TPS sensor. This gave me possibility to screw in air bypass bolt and only keep it 0.75 turn out.