http://www.advrider.com/forums/showthread.php?p=16102728
Simptoms:
1. Bike stalls after startup when cold. U need to fire it up every 10 or 30 sec. U can hear it idle iregular and u can even know when its going to stall just by listening to the engine...
2. Bike does not stall during idle but when u try to apply small amount of throttle for 1st gear take off. During idle try to open throttle by very small amounts Very slowly and u can hear engine running irregular or even stall.
Cause of the problem is in two throttle sensors on each side of keihein throttlebotdy. For ECU to know how much throttle is opened, its sensors needs to be in voltage ballpark (so to speak). If sensors are not aligned ECU will think it has throttle opening of 3% while actual opening would be 5% or more, it can also go other way around. Also if sensors are not aligned ECU will not pickup small thottle openings that u apply around idle.
To fix this: one needs TuneECU software, connecting cable, Service manual and some tools. To be able to unscrew throttle sensors one needs torx t20 that has hole in middle.
Procedure on how to adjust these 2 sensors can also be found in Repair manual from pages 165-169. I also advise to read it twice. In manual this procedure is explained using ktm diagnostic tool. U dont need the tool to adjust anything u just need it to read voltages.
Try to read all of the TuneECU guides to get familiar on how to use this software before u start to adjust sensors.
Procedure:
Do this while engine is as cold as possible. Always consult manual first before doing any of this. I am not explaining how to turn every bold around and I am using nuts and connector names and numbers as in repair manual.
Take off seat, body fairing and air box (dont forget to unplug air temp sensor before u remove air box), then unplug motor drive connector thats under keihein throttle body on the left side of the bike (connector DR1 from manual). There are 2 connectors and DR1 is one that has more then 3 wires! U will know if u unplug wrong one by hearing drive motor working when u use your finger to fully close throttle valve (see repair manual on how to close it with your finger). Now connect TuneECU to the bike and go to diagnostic menu. When its comunicating with the bikes ECU u will see most of bikes sensors values appear in Diagnostic menu, here is how it looks like when its not communicating
What u need is to be able to see 2 voltage values under the "Throttle" menu in software ("Throttle" is under "Ignition" and above "Idle" menu on left side of the TuneECU Diagnostic window). Both upper and lower voltage should be round 0.70-0.74 V, and when u use your finger to close throttle valve u should see that the upper voltage value from those 2 drop to 0.50-0.54V. Now if ANY of these voltages is only 0.1V off from what it should be u need to adjust all 3 readings.
So upper voltage reading in TuneECU should be 0.70-0.74V normaly and 0.50-0.54V when u press throttle valve to closed position with finger. While bottom voltage reading value in TuneECU should be 0.70-0.74V.
U always need to adjust all 3 voltages values if any of them is now within spec.
1st u need to adjust voltage reading when u press throttle valve to closed position with your finger. See manual on how to do this! So u need torx t20 key with hole in it (when u see bolt u will know what iam talking about) to losen up sensor that is on left side of the bike its on same side where u unplug motor drive connector. Now adjust sensor by rotating in both directions untill u get 0.50-0.54V reading in TuneECU while pressing throttle valve to closed position. TuneECU reading has lag so dont expect voltages to drop instantly. Make sure that voltage reading stays adjusted AFTER u screw sensor bolts tight.
2nd u need to adjust upper voltage reading to be within 0.70-0.74V when u r NOT pressing throttle valve to closed position. See manual on how to do that! U need to unscrew the cap (fuse cover is called in manual) then u need to loosen the nut no.5 from manual and adjust voltage with screw no.6 from manual. I found manual guide not working for me since top fuse cap was glued on to screw no.6 and nut no.5 was glued so hard to screw no.6 that i need to take it out completly and use some mechanism to hold screw no.6 while i turn nut no.5. I cant give u any advice on how to do that u will just need to figure out yourself, just make sure u dont fuck up the threads on the screw no.6. Once u get this top voltage reading to 0.70-0.74V u can go to 3rd step. Sorry for not being more help full here but I am not sure if u will find this screws glued or not (mine ware glued in not very logical way!).
3rd u need to adjust throttle position sensor on the right side of the bike so that bottom voltage from TuneECU reads 0.70-0.74V. Its same procedure as in 1st step only by using sensor or right hand side of the throttle body (opposite side from 1st step). Adjustment is done after u open throttle fully and close it 10 times and voltage is within specification every time!
4th u need to turn off and back on ignition on the bike, then w8 till it connects to TuneECU and check AGAIN if all 3 voltages are in specification range. If they are in spec range then u are done. Dont forget to do this after any sensors adjustment!
