TL1000S TPS Adjustment

INTRODUCTION

This supplement contains additional information about TL1000SV running characteristics which was not available during 1997 New Model Update Seminar presentations. The information in this supplement is intended to familiarize your staff with the TL1000S engine performance characteristics and provide additional low RPM tuning information.

The TL1000S has a high performance V-Twin engine. This high revving engine is designed to produce optimum mid-to-high RPM power. The engine is equipped with an aggressive camshaft profile, large valves and large throttle bodies.

The TL1000S will have different running characteristics than four cylinder motorcycles, especially at lower engine speeds. When riding the TL1000S, the operator can feel the power pulses the engine produces from idle to 4000 RPM.

Break-In

We recommend to put some miles, (approximately 20 miles), on a TL1000S motorcycle before performing any adjustments and delivering the motorcycle to the customer. With at least 1000 or more miles of operation the piston rings will begin to seat which will improve the effectiveness of throttle body synchronization.

Recommended Engine Speed During Break-In
Initial 500 miles	Below 5000 RPM
Up to 1000 Miles	Below 7500 RPM
Over 1000 Miles	Below 10500 RPM

Throttle Body Synchronization

Careful throttle body synchronization and throttle position sensor adjustment improve low and mid-speed throttle response and smoothness.

Follow these instructions carefully for effective throttle body synchronization, throttle position sensor adjustment, and fast idle adjustment.

TPS Adjustment & Fast Idle Adjustment

Throttle body synchronization also effects the setting of the throttle position sensor, (TPS). During synchronization the throttle valves relationship to one another changes. The TPS setting changes because the TPS is mounted on a throttle valve shaft.

To obtain the best idle and low RPM performance it is important these settings be checked and adjusted in the following sequence using the proper special tools and procedures.

1. Required Special Tools

• Carburettor Synchronization Gauge Set: PN 09913-13121
• Adapter Hoses, (QTY.2): PN 13682-02F00
• Air Jets, (QTY.2): PN 09493-20015
• Lead Wire Coupler: PN 09930-82710
• # T-25 Tamper Proof Torx Bit

2. Inspect Before Throttle Body Synchronization

• Fuel type
• Proper engine oil type & level
• Spark plug condition
• Engine idle speed
• FI malfunction warnings
• Throttle position sensor adjustment
• Air cleaner element condition

3. Fuel Recommendations

Use only unleaded gasoline of at least 87 pump octane (R+M/2) method.

The fuel should be alcohol free whenever possible.

Blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) can be used. Blended gasoline/alcohol fuel can be used, provided the fuel does not contain more than 10% ethanol. Gasoline/alcohol with up to 5% methanol can be used if co-solvents and corrosion inhibitors are present in the fuel.

If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline.

4. Oil Recommendations

SUZUKI Performance 4 motor oil should be used. The recommended viscosity is SAE 10W/40.

Other oils may be used if they are rated SF or SG under the API,(American Petroleum Institute), service classification. Synthetic oils and friction modifier additives are not recommended, especially during the critical break in period.

If a 10W/40 oil is not available, select an alternative using the chart below.

5. Oil Level

When checking oil level, hold the motorcycle upright on level ground. Do not use a service stand. Wait one minute after shutting off the engine to check the level.

Check the oil level using the inspection window on the right engine cover. The level should be in the _middle_ of the window between the upper "F" and lower "L" marks.

Add or drain oil to set the level.

CAUTION - Do not over fill the oil level or the air cleaner element may get contaminated during sustained high RPM operation.

NOTE: When replacing the oil filter, be sure to use the proper one PN 16510-34E00 Oil Filter

This filter looks similar to the filter used on GSX-R, Katana and VS models. However, it is constructed different internally with a different oil bypass pressure valve.

Please remind your service and parts department staff of this difference so customers will receive the correct filter.

6. Pull Fairing Panels away from Frame

• The panels must be loosened to disconnect air inlet ducts from air cleaner.
• Remove the left panel to allow access to throttle body and TPS adjustments.
• Remove the two fairing Allen bolts located below the headlamp.
• Remove the Allen bolt on the left panel, under the windscreen.
• Remove the Allen bolts which secure the fairing panels to the radiator.
• CAUTION-Use care to not damage the radiator while removing bolts.
• Remove the Allen bolts located on the panel upper edge, below the handlebars.
• Pull the lower edge of the fairing panels outward, releasing ducts from the air cleaner.
• Remove the left mirror and the three left hand side windscreen screws.
• Carefully pull the left panel outward, exposing the turn signal connector.
• To release the connector and the panel, pull up on the connector's tab.
• Set the removed fairing panel in a safe location.

7. Remove Seats

• The seat lock is located on the lower edge of the left frame cover.
• Use the ignition key to unlatch the seats.
• Turning the key clockwise will release the forward seat.
• Counter clockwise will release the rear seat, (or cowl).

8. Access Fuel Tank Prop Stand

• The prop stand is held to the right side of the sub frame by two plastic clips.
• Pull up on the rod to free it from the clips.
• Remove the rubber plugs from the ends of the prop stand.
• CAUTION-Do not misplace the rubber caps. These caps are used to seal fuel nipples if the fuel tank is removed.

9. Raise Fuel Tank

• Remove the two Allen screws at the front edge of the fuel tank.
• Leave the collars and rubber grommets in the tank's mounting tabs.
• Insert the "S" bend portion of the prop stand into the hole in the steering stem.
• Lift up on the front of the tank, the rear will pivot on its hinge.
• Set one of the front tank tabs onto the prop stand.
• Do not disconnect any fuel lines or hoses.

10. Accessing Spark Plugs

• Both spark plugs are located in the centre of each cylinder's valve cover.
• With the fuel tank lifted the rear spark plug cap is easily accessible.
• Pull up on the cap to remove it from the spark plug.
• CAUTION-Do not pull on the coil wire leading into the cap. This could cause a open electrical connection and affect engine operation.
• To access the front spark plug the radiator must be moved forward.
• Remove the 6mm radiator mount bolt on the front cylinder valve cover.
• The bottom of the radiator swings forward to allow spark plug access.
• Remove the spark plug using the same procedures as the rear cylinder.
• CAUTION-Do not damage the radiator when removing the front spark plug. The aluminium cooling fins can be damaged if pushed on.

11. Spark Plugs

Standard spark plug application depends on the VIN number of the motorcycle as shown below:

The plugs must be resistor type, which prevents radio noise that may affect the ignition system operation.

Check for carbon deposits on the plugs. Clean the spark plugs if the deposits are not severe. It is recommended to replace the spark plugs if heavy deposits are present.

Replace the spark plugs if the electrodes are worn or burnt. Replace the spark plugs if they have broken insulators or damaged threads.

Measure the plug gap with a thickness gauge. If out of specification, adjust it to the following gap.

Spark Plug Gap: 0.6 - 0.7mm (0.024 - 0.028in)
Thickness Gauge: PN 09900-20803

12. Idle Adjustment

The proper idle speed is 1200 RPM.

Adjust the idle using the throttle lever stop screw. The screw is a black plastic knob mounted to the frame above the left engine cover.

Set the idle speed once the engine has warmed to operating temperature. This is 160' to 190'. The LCD on the tachometer will display the temperatures.

Incorrect idle speed may make the engine run improperly, as throttle position sensor settings may be affected. Turning the idle stop screw will open the throttle valve the position sensor is connected to, thus altering the sensor's adjustment.

13. FI System Self-Diagnosis

In the rare occurrence that a malfunction exists, the system will detect the problem.

A "FI" symbol on the LCD tachometer display indicates a problem. A continuously lit or flashing red LED in the tachometer face accompanies the "FI" symbol.

The engine may run in "Relief Mode", with a malfunction present. However, throttle body synchronization and TPS adjustment may not be accurate if performed while the engine is in "Relief Mode".

Use the instructions in the TL1000S service manual, section 4, to troubleshoot and resolve any problem before attempting throttle body synchronization.

14. Throttle Position Sensor(TPS)

The Throttle Position Sensor  (TPS), provides the Electronic Control Unit (ECU), critical throttle information that is used for ignition and fuel injection operation. The TPS is located on the left side of the rear throttle body.

A function of the FI system aids in TPS adjustment. An LCD on the tachometer displays FI malfunction codes and sensor adjustment bars. The bars are visible to the left of the malfunction code. Only one bar is visible at a time.

The "c00" code is visible when no malfunction is detected. If a code other than "c00" appears, follow the troubleshooting procedure in the TL1000S service manual, section 4. When the throttle position sensor is correctly adjusted, only the centre bar is visible.

The Mode Selector Switch is used to display TPS alignment bars on the LCD dash.

The connector for the switch is located under the passenger seat, along the right side of the storage compartment tray. A rubber cap covers the white connector, (W/R,B/W wires).

Take the rubber cap off the connector and plug in the mode selector switch.

The screw holding the TPS to the throttle body are a tamper proof T-25 Torx style. This type of tool is needed if the TPS requires adjustment.

Use a floor mount cooling fan directed at the radiator and the engine during TPS and Throttle Body Synchronization.

When running the engine, maintain the coolant temperature between 160 to 190.

If the low fuel lamp on the dash is illuminated, lower the tank and add fuel.

To verify TPS adjustment turn the mode selector switch to "on" and use the procedure below.

• Without the engine running the lower or middle bar may be visible.
• Start the engine, allow it to idle.
• At 1200 RPM the centre adjustment bar should be visible.
• If the centre bar is not visible, the TPS must be adjusted.
• Use the Torx tool to loosen the TPS screws.
• Rotate the TPS until the upper bar is visible.
• Expect a delay of about one second as the bar display changes.
• Slowly rotate the TPS in the other direction until the centre bar becomes visible.
• Use light pressure, as a small amount of movement on the TPS will result in a large change on the display.
• After adjusting the TPS, tighten the screws.
• Check to make sure the centre bar is still visible.
• Rev the engine slightly and allow it to idle.
• Adjust the TPS again if the centre bar is not visible.
• TPS adjustment above idle must be checked.
• As the throttle opens _just past idle_ the bar should become visible in the top position.
• Closing the throttle and allowing the engine to idle should return the bar to centre.
• Another way to verify above idle adjustment is to use the fast idle, (choke), lever.
• Open the lever so the engine speed rises to 1400 RPM.
• The top adjustment bar should be visible at 1400 RPM.
• If the top bar does not become visible off idle, further adjustment of the TPS is needed.
• Adjust the TPS so the centre bar is visible at idle, but the top bar is visible at 1400 RPM.
• Rev the engine and allow it to return to idle several times to make sure the settings are correct.
• Always check the adjustment bar display after tightening throttle position screws.

15. Air Cleaner Element

A dirty or contaminated air cleaner element can keep the motorcycle from running properly. Follow the steps below to inspect and service the air cleaner and element.

• Raise the fuel tank. Remove the four Phillips screws holding the lid of the air cleaner. The lid holds the screws so they will not fall into the air cleaner.
• With the lid removed, the element can be removed. Use caution to not allow debris to fall into the throttle bodies or the flapper valve in the bottom of the air cleaner. Wipe clean the inside of the air cleaner.
• Inspect the element. If it is gas or oil stained, replace the element. Carefully use an air hose to blow dust from the element. Spray the air from the outside of the element. Do not spray air from the inside as this will force dirt into the pores of the element.
• There is a drain cap on the lower front edge of the air cleaner. It is located just above the front cylinder. Use a rag to catch any fluid and pull the cap off. Clean the cap and reinstall.
• There is another drain and a capped drain hose on the left side of the air cleaner. The cap and hose end is located just below the air duct coming from the left fairing panel. Use a rag to catch fluid, remove the caps. Clean the caps and reinstall them.

16. Disconnect Intake Air Temperature Sensor

• The sensor is located on rear, right underside of air cleaner.
• Plugs into a green electrical connector, (G/R,B/Br wires)
• Press tab in to release connector from sensor.

17. Disconnect Intake Air Pressure Sensor

• Sensor is a small square component located at rear edge of air cleaner.
• The sensor has a vacuum hose and a black electrical connector, (B/Br, Dbr, R wires)
• Carefully pull hose off the sensor.
• Press tab in to release connector from sensor.

18. Disconnect Vacuum Control Solenoid Valve

• The control valve is located on the left, rear side of the air cleaner.
• Two hoses and a black electrical connector, (O/W, Lg wires), connect to the valve.
• One hose routes to the Intake Air Valve Actuator on the bottom of the air cleaner.
• DO NOT disconnect the hose to the air valve actuator.
• The other hose routes to the vacuum transition valve.
• Press the tab in to release the connector from the control valve.

19. Remove Air Cleaner Assembly

• Loosen both throttle body clamp screws with a Phillips screwdriver.
• Remove the mount screws which hold the air cleaner to the frame near the steering head.
• Un-clamp the fluid drain tube from the frame on the left side of the air cleaner.
• Slip the clamp down, and remove the crankcase breather hose from the left, lower edge of the air cleaner.
• Lift the air cleaner up and off the throttle bodies.
• Move the air cleaner rearward to allow the front fluid drain to clear the frame.
• Lift up and pull the air cleaner out to one side from under the fuel tank.
• CAUTION-The throttle bodies are now exposed, don't allow objects to fall into the open intakes.

20. Reconnect Sensors to Wiring Harness

• The air temperature and intake pressure sensors must be reconnected before throttle body synchronization can be attempted.
• Without sensor input the fuel injection system will operate in a _"relief mode"_ and the synchronization may not be accurate.
• Use a wrench to remove the air temperature from the air cleaner.
• Do not lose the thin plastic insulating washer.
• Reconnect the sensor into its green wiring harness connector.
• Hold the sensor in place with the wiring clamp located just to the right of the rear throttle body.
• Do not allow the sensor to touch the frame, this might affect sensor readings.
• Using a Phillips screwdriver, remove the intake air pressure sensor from the air cleaner.
• Reconnect the vacuum hose from the throttle body to the sensor.
• Reconnect the black electrical connector and allow the sensor to hang free behind the throttle body.

21. Un-Cap Vacuum Nipples on Throttle Bodies

• The vacuum nipple on the front throttle body is located near the intake manifold, facing rearward.
• No hoses connect to this nipple. It is only used for synchronization.
• Remove the rubber cap and spring clip from the nipple.
• There are two vacuum nipples on the left side of the rear throttle body.
• These nipples are made of black plastic.
• One is capped, the other has a hose that routes to the vacuum transition valve and vacuum damper canister.
• Remove the hose.

22. Balancer Adapter Hoses

• Adaptor hoses with reduction jets are required to attach the synchronization gauge to the throttle bodies because different sized vacuum nipples are on each throttle body.
• A 1mm air reduction jet must be placed in each adaptor hose so the gauge draws the same amount of vacuum from each throttle body.
• Use an in-line hose joint to connect the synchronization gauge to the throttle bodies.
• Install the adapter hoses on each throttle body vacuum nipple.
• Use the cap removed from the front throttle body vacuum nipple and cap one of the balancer hose joints. IMPORTANT-The adapter hoses and jets must be used. Another type of hose may not be the correct size to fit snugly on the vacuum nipples. This could affect synchronization and result in improper engine operation.

24. Throttle Body Air Screws

• Air screws are located on left side of throttle bodies under black rubber caps.
• These screws are preset at the factory.
• The screws normally do not require adjustment.
• If the screws have been tampered with, they will need to be reset.
• The screws appear and turn in a similar fashion to a carburettor pilot air screw.
• The screws control an air bypass circuit that can affect low RPM synchronization, (discussed later in the procedure).
• Before beginning synchronization any screws that have been tampered with must be reset.
• Remove the rubber caps to access the screws.
• Set the screws to 1 1/2 turns out from lightly seated.
• The front air screw can be accessed with a long standard screwdriver through a hole in the left frame rail.

25. Connect the Balancer Gauge

• Connect the calibrated balancer gauge to the adapter hoses.
• Hang or hold the gauge so it can be seen clearly.
• Start the engine and let it idle.

26. Throttle Valve Synchronization

• The Throttle Valve Balance Adjusting Screw is located on the right side of the front throttle body.
• Turning this Phillips screw will change the balance between the throttle bodies.
• With the engine idling, turn the screw so the height on the balancing gauge matches.
• After each adjustment, rev the engine slightly and allow the idle to settle.
• Wait a moment, as this allows the throttle valves to settle and the readings on the gauge to be more accurate.
• Once the height is matched, increase the engine speed to about 2000 RPM.
• The fast idle, (choke lever), is useful for doing this.
• If the synchronization is not even at 2000 RPM, use the balance adjusting screw to align the balance gauge.
• Reduce the engine speed to idle.
• If the balance is now different at idle, use the Air Screws on each throttle body to match the reading on the gauge.
• IMPORTANT-Matching the synchronization precisely is critical in allowing the engine to run properly at low RPM, light throttle operation.
• Once the synchronization is set, adjust the idle speed to 1200 RPM.
• Watch the coolant temperature display, don't allow the engine to get too hot.
• If the cooling fan turns on, allow the engine to cool for a few minutes before proceeding with more adjustments.
• Turn off the engine.
• Remove the balancer gauge.
• Remove the adapter hoses.
• Replace the cap and spring clamp on the front throttle body vacuum nipple.
• Reattach the hose from the vacuum transition valve on the rear throttle body vacuum nipple.

27. Throttle Lever Gap Adjustment

• The throttle lever gap must be adjusted following synchronization.
• The adjustment is done on the right side of the rear throttle body.
• Without adjustment, the throttle valves may have stiction in the throttle body when the throttle is closed. This could cause improper running or poor throttle operation.
• The gap is measured between the throttle lever and the stop screw.
• The adjustment gap is 0.25mm with the throttle closed.
• Set the gap by loosening the lock nut and turning the screw.
• Once set, tighten the lock nut.
• Recheck gap after the lock nut has been tightened.

28. Install The Air Cleaner

• Check the air cleaner element condition. Clean or replace as necessary.
• Disconnect the air temperature sensor from the wiring harness.
• Reinstall the air temperature sensor, with it's insulating washer, into the air cleaner.
• Disconnect the intake air pressure sensor from the vacuum hose and the wiring harness.
• Reattach the air pressure sensor to the air cleaner.
• The vacuum nipple on the sensor should face downward.
• Lower the air cleaner down onto the throttle bodies.
• Reconnect the crankcase breather hose and clamp.
• Route and secure the fluid drain hose on the left side of the air cleaner and frame.
• Make sure the air cleaner is set onto the throttle bodies correctly and tighten the clamps.
• Install and tighten the mounting screws to the front tabs and the frame.
• Restart the engine and set the idle speed to 1200 rpm.
• It may change when the air cleaner was reinstalled.
• Stop the engine.

29. Fast Idle Adjustment

• The fast idle allows faster engine warm-up after cold starting.
• A lever on the left handlebar operates like a choke lever.
• The fast idle adjustment screw is located on the right side of the front throttle body.
• Adjustment is made using a standard blade screwdriver.
• Correct fast idle speed is 2000 RPM.
• Start and warm engine, (176F to 194F or 80C to 90C).
• Pull the lever down fully.
• Adjust the engine speed using the adjusting screw until it reaches 2000 RPM.
• Return the engine speed to idle and stop the engine.

30. Re-Check TPS Adjustment

• Turn mode selector switch to "on".
• Verify the centre bar is visible at idle, 1200 RPM.
• Verify the upper bar becomes visible at just above idle, 1400 RPM.
• Readjust the TPS if the bars are not in the proper locations.
• Follow the TPS adjustment instructions on pages 8, 9, and 10.

31. Remove Mode Selector Switch

• Before disconnecting switch, check the LCD display.
• It should read "c00", indicating all the sensors have been reconnected correctly.
• If there is a code other than "c00" use the Service Manual, section 4, to locate and correct the problem.
• Disconnect it from the wiring harness.
• Place the connector back by the right side of the storage tray.

32. Verify Air Valve Operation

• The Air Valve aids with throttle response by not allowing too much air to enter the throttle bodies at low engine speeds.
• With the engine not running, the Air Valve will be in the closed position.
• The Air Valve will open at 4000 RPM.
• Start engine and allow it to idle.
• Look in the left air inlet duct on the bottom of the air cleaner.
• Verify the Air Valve is closed by the Actuator Rod being in the down position.
• Rev the engine to 4500 RPM.
• At 4000 RPM the rod should move upward, opening the Air Valve.
• Allow the engine to idle, the valve should close again.
• If the valve does not work properly, check vacuum hose routing and connections.
• Follow the troubleshooting procedures in the Service Manual, section 4, if needed.
• Turn off engine.

33. Lowering Fuel Tank

• Lift the front of the tank up off the prop rod.
• Make sure the fuel line under the right side of the tank is routed correctly.
• Watch to make sure the fuel filler overflow hose does not get pinched as the tank is lowered.
• Slowly lower the tank back down to the frame.
• Do not allow the tank to drop, this may damage it.
• Reinstall the Allen bolts in the mounting tabs.
• Replace the rubber caps on the prop stand.
• Put the prop stand back on the clips along the right sub-frame.
• Place the notch in the prop stand into the front clip.
• This helps the prop stand not rub or pinch any wires.
• Verify the prop stand does not rub on or pinch any wires.

34. Secure Fairing Panels

• Press fairing panels inward and push air ducts back into the air cleaner inlets.
• Install the Allen screws under the headlamp.
• Install the Allen screws under the handlebars.
• Install the Allen screw that secure the panels to the radiator.
• CAUTION-The aluminium radiator threads can be damaged if care is not taken installing the bolts.

35. Install seats

• Install the rider's and passenger's seats, (or cowl).
• Make sure no wires, hoses or cables are pinched.

36. Test Ride Motorcycle

• Ride the motorcycle a few miles, at different road and engine speeds.
• Make sure the chassis components and all controls are working properly.
• Listen to the engine sounds, does the engine note sound even?
• Do not hesitate to perform the throttle body and TPS adjust procedure or reset air screws that have been tampered with, again if needed.
• Once all service is complete and quality checked, return the motorcycle to the customer

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