After, getting a used 2008 KTM 690 Enduro from the dealer her in DaPhilopeens I proceeded to take it on a little 4 week ride around the island of Luzon ridding with the stalling issue. After traveling through rainstorms, mud bogs, portaging the bike across mud slides, and driving thru swollen rivers I think I got it solved(at least on the bike I am riding)
I starting having problems with the bike day one after buying it, we were trying to get of on Manila on a Friday afternoon. It kept stalling on me about every third time I chopped the throttle when pulling in the clutch. I started blipping the throttle when I pulled in the clutch which solved that most of the time, but as we were just about to get on the express way to get out of town the bike starting backfiring and eventually blew the throttle bodies off the head. Once the throttle bodies were reattached it seemed to run ok but I still had the stalling problem and an occasional rough idle.
Long story short, the bike also began to not start well, but when I very gently held the throttle, not giving it gas but putting weight on the throttle just to take the tension out of the cables is started like a charm. One we go for another 4 or 5 days and then we get caught out in a nice little tropical storm 30-40 knot winds and pretty much a downpour. At this point the bike started having the stalling issue but much more pronounced even when letting the throttle out slowly as soon as the bike got to an idle it died, and not only does it die it is almost impossible to start. This happened over and over again and the last time after riding in another down pour I am certain there is a grounding problem somewhere in the electrical system or something else interfering with the current.
Here is what I discovered when putting the bike on the Tune ECU. I downloaded Tune ECU and got a cable and a new TPS (throttle position sensor) sent over from the US. When I put the bike on the computer and tested it, the voltage for the sensor was not in the required range. Then when I took my fingers and moved the wires to the sensor around, the voltage started to change. The voltage should not be changing when you move the wires around only when you use the screws and adjust the sensor.
So here is what I think is and will hope fully solve the problem. The wires from the sensor to the connector are to small and are not allowing enough current through to keep the required voltage. So if the wires are corroded or damaged in any way that will reduce the possible max current into the sensor to achieve the required voltage or short out. The sensor wires on the sensor I took off were crimped excessively and the wires where getting pinched by a zip tie, which also made me think the wires had been damaged.
I got the TPS out and was installing it on the bike today. Is it working without the voltage drop but now the voltage is to high and I need to reset the throttle motor but I can't seem to do that with the Tune ECU software. The Tune ECU software tells me to refer to the
Repair Manuel, which I have, but the repair manual only tells you how to do it using the KTM diagnostic tool. Anyone ever done this before or know how to do it using Tune ECU? I am at the mercy of the dealer here and their KTM diagnostic tool. And my own ignorance of course.
