[SteveThackery]

I don’t have a spare TPS on hand. Have would I test mycurrent TPS and also the MAP sensor?

Does anyone have the 535 wiring diagram?

[GUNR]

Here you go Steve.

[GUNR]

I’ve just done the test using the MIL connector and got;
66 (CKP)
06 (TP)
33 (EFI)
11 (EOT)

I suppose the next step is check the contacts in the connectors for these sensors.

[GUNR]

… and then…while searching for the CKP connection, I find that my bike  must’ve been assembled on a Friday afternoon as the electrical connector I find is sitting directly under the swing arm.

[GUNR]

After consulting a few learned retired mechanics, it was decided that I should take a look at the fuel filter. Now I’ve learned that it is inside the fuel tank and that the filter is not replaceable. The attached pictures show what I found. The positive wire was so loose that it dropped out. The filter when wet with petrol, was jet black. This picture shows it when it has dried out.

In the morning I’ll crimp that red lead connector and put it all back together to see what happens.

Question time
1. Does that filter look too dirty to pass fuel?
2. Is there a cheaper option than paying the equivalent of $640AUD (plus postage) from our host?
3. Would a carb conversion be a cheaper avenue?

[tooseevee]

The attached pictures show what I found. The filter when wet with petrol, was jet black. This picture shows it when it has dried out.

     Your 2 pictures aren't of the same view. Was the filter part black after drying out? Did you look at it out in the sun with a magnifying glass?

[GUNR]

1st picture is of the dried filter (picture taken at night using a neon light.
2nd picture is of the +ve red lead hanging loose (taken under the same conditions).

[SteveThackery]

Here you go Steve.

Thank you! So, checking the TPS looks simple enough. There'll be pV on one pin, 5V on another, and the third pun should go from approx 0V to approx 5V as you open and close the throttle.

Fuel starvation from a blocked filter is certainly possible, although I've never heard of it happening on our bikes, and it doesn't normally come on suddenly.

[SteveThackery]

I’ve just done the test using the MIL connector and got;
66 (CKP)
06 (TP)
33 (EFI)
11 (EOT)

I've no idea what these numbers mean. Could you explain? And also how you read them?

[GUNR]

Here’s a picture of the relevant pages from the Haynes manual. I used a thin solid core copper wire and earthed the other end by winding it around one of the screws which hold down the rear of the tank and then screwed it in a couple of turns. My ‘Creader 3001’ has just arrived and I’m awaiting the KTM adapter cable which will enable me to connect the code reader to the bike’s wiring harness. Then the codes will show on a screen and I’ll be able to clear them. I can post links to a video and purchasing links if anyone is interested.

[GUNR]

All sorted; the megaphone is snarling like it used to! It was the loose red power lead to the base of the fuel pump that was the cause of the problem. Now she redlines without a hiccup.

I’m glad I emptied the tank, bought a new 10 litre fuel container and filled her up with new juice (potentially crap fuel being one less variable to worry about). Also, the inside of the tank was as clean as a whistle.

Thanks for all the helpful ideas from everyone.

[SteveThackery]

All sorted; the megaphone is snarling like it used to! It was the loose red power lead to the base of the fuel pump that was the cause of the problem. Now she redlines without a hiccup.

I’m glad I emptied the tank, bought a new 10 litre fuel container and filled her up with new juice (potentially crap fuel being one less variable to worry about). Also, the inside of the tank was as clean as a whistle.

Thanks for all the helpful ideas from everyone.

Great news! Thanks for the update - it helps future readers enormously.

[Softlysoftlycatcheemonkey]

I was hoping a more verbose/knowledgable poster might say something but no-go, so I'll mention to GUNR that the fuel strainer is press fit onto the pump and can be replaced. The thread "EFI Fuel Pump Replacement" https://forum.classicmotorworks.com/index.php?topic=26222.0 includes how to handle that in the first post and there are several Indian posted Youtube videos that even in the home language show enough at that step. A quality filter? Hitchcock's. An untried actor? https://www.highflowfuel.com/ Do you feel lucky? Amazon, Ebay, etc.

[GUNR]

I was hoping a more verbose/knowledgable poster might say something but no-go, so I'll mention to GUNR that the fuel strainer is press fit onto the pump and can be replaced. The thread "EFI Fuel Pump Replacement" https://forum.classicmotorworks.com/index.php?topic=26222.0 includes how to handle that.

Thanks for that. It is a well described procedure and I will be sourcing a new filter and O-rings.

I have just returned from a 1,200km trip and the bike performed without a hitch. Once I thought I had a horrible stuttering misfire in 3rd while overtaking a very smokey diesel; but instead it was my first experience of the rev limiter kicking in

[Guaire]

Hi GUNR- That looks like the Air Kit gen 2. You have plenty of air intake.
“ However, from how lean your spark plug looks, I'd suspect the fueling system including the fuel pump module, the fuel strainer and the fuel injector.”
Your fueling might not be keeping up with efficiency of the air intake.
Also, the red lights are either oil pressure or lack of electric charge coming off the alternator. Check the primary voltage off the alternator. Pick any 2 yellow wires. Check the voltage against factory specs. Check the voltage, past the reg/rectifier, that’s coming into your battery. What is it?
What’s your battery? If it’s the stock battery or a lead acid, I would remove it and use it as a shop battery. Or toss it. Get a quality AGM battery in there.
RE coils are a joke. Replace the wiring and the caps. Get an ‘Ignition Kit’ or source locally DynaCoil, quality wiring and caps. NGK is no longer making spark plug caps. Any stock available is NOS.
This is a DynaCoil.
Cheers,
BG
https://www.youtube.com/watch?v=U9fVUEaiB6I