The three most hated letters T P S !!!!

[unfazed]

Remember, the TPS is a datum and shouldn't be moved before checking the settings of No4 carb.   

You need to check butterfly operation, throttle cable and linkage freedom/movement, air screw condition/setting, idle speed and that's pulling the correct level of Hg (230 - 250) at the correct idle.  If it's not there's a problem that you need to sort out on the carb. 

No 4 carb is non adjustable when carrying out balancing it's the datum.  The biggest mistake and what leads to many TPS failures is owners and stealers adjusting them before checking the settings above.  In theory unless strip/take the carbs the TPS should rarely if ever need adjusting, that's why from the factory the screws are covered in paint. 

My own Fazer 99, still has it's OE TPS, all those I work on for owners still have theirs.  All of the TPS's I've had to adjust over the years are because one of the above mentioned have moved it, due to incorrect balancing, sticking throttles and/or people messing about with them. 

I've only replaced 3 OE TPS's due to failure and these where 80k plus mileage, obviously this is likely to increase as bikes age, some Fazer are knocking on 27yrs old now.

Not 100% correct, I bought my 600 new and the TPS  failed at 35000n miles and it had never been touched. It now has 102000miles  and still on the TPS I replaced at 35000miles

The one on my Fzs1000 failed recently at 68000km and it had not been touched either.
Adjusting them does not cause the failure, as you are only moving the start point of the TPS. 
Yes they should be checked after the carburettors are synched and idle speed set. 
They are mechanical and anything mechanical is prone to wear regardless. 
I know of bikes with over 80000 miles and still have the original TPS, it is like most things mechanical some wear quicker than others.
 All all Fazer carburettor are set to number 3 which is the reference/base carburettor as it has the throttle cables attached which is why you should really set 3 & 4 first then 1 & 2 and finally the screw between 1 & 2 to £ & 4is set. 
Some came from the factory set incorrectly. Many 05 model FZS1000 had the Carbs and the TPS set incorrectly from the factory.
Wear and tear on the engine like Valves going out of adjustments effect the carb synch and when synchronised it can throw off the idles setting. 
Adjusting the idle setting can throw off the TPs setting which is why it should be checked everytime you resynch the carbs
On my recent failure on the FZS1000 it tested perfectly on the tacho 0,  5000 and 10000 revs, but knowing I had a surging and vibration issue, I tested it with a meter and it was going open circuit around 2.7Kohm about half way through its rotation. No reason for it to fail at that point, but it did. I have a video of the test in MP$ format, but for some reason it will not allow me upload it.

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Remember, the TPS is a datum and shouldn't be moved before checking the settings of No4 carb.   

You need to check butterfly operation, throttle cable and linkage freedom/movement, air screw condition/setting, idle speed and that's pulling the correct level of Hg (230 - 250) at the correct idle.  If it's not there's a problem that you need to sort out on the carb. 

No 4 carb is non adjustable when carrying out balancing it's the datum.  The biggest mistake and what leads to many TPS failures is owners and stealers adjusting them before checking the settings above.  In theory unless strip/take the carbs the TPS should rarely if ever need adjusting, that's why from the factory the screws are covered in paint. 

My own Fazer 99, still has it's OE TPS, all those I work on for owners still have theirs.  All of the TPS's I've had to adjust over the years are because one of the above mentioned have moved it, due to incorrect balancing, sticking throttles and/or people messing about with them. 

I've only replaced 3 OE TPS's due to failure and these where 80k plus mileage, obviously this is likely to increase as bikes age, some Fazer are knocking on 27yrs old now.

Hi Gnasher,thanks for the indepth reply ,my TPS problem was down to the fact that there was no readings at all ,this gave a reading of 10000 that was not adjustable using the turning method,I've just received and tested the new mikuni one with a multi meter and have a standing reading of just under 5,this is when using the pins at either end and if you use one end and the middle pin the reading increases as it should,I took a photo of the old TPS position before removing and put the new one in the exact same place and got the wonderful 5000,that'll do for me .
Coeurdelion

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Morning,hope everyone is well,I got my 2000 yamaha fazer 600 very wet whilst out and the day after whilst riding I noticed the revs dropping from 5000 to 0 then back up to 5000,i replaced a dodgy double headlight conversion wiring with a proper plug thinking thatveas the cause but no luck,I did the unplug and plug in tps technique and it went to 10000 and will not adjust down to the usual 5000,the bike is fine on tickover and runs normal with no surging or flat spots,with the ignition on and the tps unplugged the revs jump 0 to 3000 then 0 and 3000 repeating  ,I bought a new tps and it had the bike still had same symptoms ,I bench  tested the new tps with a meter ,no reading between the outside two pins but either one of the outside and the center pin I got a reading of 5.9 but this didn't alter when I turned the tps as if it was the throttle twisting ,my old tps had no readings at all,basically was the new tps dodgy or am I looking at another problem that isn't tps related?,apologies for the long thread 
Cheers coeurdelion

Hi ,thanks to all the members for their help and advice  quick update,received the new mikuni TPS for the fazer 600 year 2000,tested it with multimeter before fitting ,got a standing reading of 5ohms using the top and bottom pins ,when using the end pin and the center pin it gave a reading which increased when the center was turned ,like the butterfly flap opening,fitted and tested and got the 5000 OK, the new part has A3 on it whereas the original had A1 ,it came from a reputable  motorcycle shop here in france not a dodgy chinese knock off ,should have just paid the €129 the day it packed in and saved the stress and constant testing,haven't had a test run yet so will post after,one thing I did notice is that it came with a small rubber ring ,impossible to fit with this on,my original didn't have one so I've fitted the new one without,maybe it's for a newer model as mine is the first edition FZS600 I don't know ,maybe someone can shed a bit of light on this 
One thing I did notice is that the new TPS when in the setting mode (unplugged then plugged in )creates a slight humm whereas the original had no sound whatsoever, might be helpful to someone testing there's ?
Coeurdelion

Just a newer upgraded version, usually referred to by yamaha as Superceded.