I have made the 5 volt regulated power supply for testing the TPS, Question do I have to un plug the TPS wire and test right to the TPS itself ? OR can I t-tap the wires to the TPS and leave it pluged in while I apply the 5 volts and read the meter? Will the meter read anything other than the TPS if it is still pluged into the rest of the harness. If the latter works I will post a TPS Sensor you can make real easy for under $15.
Thanks

the plug has to be unpluged and test right on the sensor.the more precise you are the more you gain.

Thats what I thought, Problem is I am having trouble finding the mating connector the the TPS. and I was trying to either make the tester to be able to plug right on to the TPS (need the mating connector ) or cut into the wire harness just before the TPS and put in a male /female 3 conductor connector in line then use the same for the tester and break it at the new connectors and plug in the tester there to be direct to the TPS.
Any help on finding a supplier for the mating connector to the TPS, or brand of the TPS would be greatly appreciated.
Thanks

Can you put up a pic of the connector - both female and male part so I can go rummaging thru the brain and parts suppliers.

Yes Give me the a day or two, I will also post pics of the tester

No time like the present, Here are pics of the connector, and the Tester. The tester is reading 5.2 volts because ther is no load ie: the TPS sensor pluged in to it. If I can find the mating connector you can build this VERY inexpensively.

Up loaded more pics with the above but ??????????? will try again tonight

Can you post some additionl information? i.e. What leads go to what terminals on the TPS? What should it read? Thanks.

What you do not see in these pics is a 3 wire cable that comes out of the black box, That is what will go to the TPS (thats the connector I am looking for) But on the TPS there are three terminals one +5volt , one -, the center is the terminal that the variable voltage comes off of and that is what the meter is reading, From what I have read on the posts here it should be .93 volts at idle and 5 volts at WOT. Red/white is 5v + Black is neg-,
blue is the variable voltage lead.
Check out this link it is very informative.
http://www.snowest.com/fusetalk/messagevie...mp;keyword1=tps

Yes, the repair manual states .920-.940 ...So .930 is a good target.

Also, according to service manual:

5 volt: R/W
Output: Light Blue
Ground: Black

Connector not needed but would be convienient. Just use small allegator clips one for the voltage to and the other two for the digital meter to read. Make sure you have a torx security socket to adjust the TPS. Bosch makes a small set which I purchased at Lowe's 5yrs ago, don't know if they still have them. Manhattan Supply should also.

This is the unit I built a few years ago for my 02 XC800.
They work great and are cheap to build!

Click to view attachment

Just finished the tester and tested the TPS. Found at WOT was below the 4.2 so I adjusted the slack from the cable under the handle bar cover. at idle it was .92 any one interested in making a tester like this I would be happy to help. Thanks to all on here who shared their knowledge!
Having problems posting the pics. will try later
thanks