HOW TO MAKE YOUR OWN TPS TOOL KTM is a registered trademark of KTM North America Not associated with, or even acknowledged in any way by KTM NA or any other KTM entity. Not related to KTMTALK.com in any way.

FOREWARD: THIS IS A GUIDE TO MAKE YOUR OWN TPS TOOL. I USE SOLDER, HEAT SHRINK AND FLUX. I HAVE THEM AVAILABLE TO ME. YOU WILL HAVE TO MAKE YOUR TOOL HOW YOU LIKE IT. I USE CERTAIN COLORED WIRES THAT I CAN REFERENCE BY MYSELF. YOUR COLORS CAN VARY. I DID THIS BECAUSE THE OTHER INSTRUCTIONS I SAW WERE CONFUSING. I DID THIS FOR KTMTALK MEMBERS. KTM TALK HAS BEEN A GREAT SOURCE OF INFO SO I WANT TO ADD TO IT.

YOU NEED: 5V REGULATOR (2396 SHOWN) WIRING: (CHOOSE YOUR FLAVOR) I USE RED,BLACK,YELLOW, AND GREEN. ON/OFF SWITCH 9V CONNECTOR LED LIGHT (IF YOU WANT IT) FEMALE DISCONNECT FITTINGS (IF YOU WANT IT. I HAVE USED A VARIABLE VOLTAGE REGULATOR IN A OTHER TOOL I HAD MADE. AS LONG IT REGULATES TO 5V YOU WILL BE FINE. ALSO YOU WILL HAVE TO FIGURE OUT HOW YOU WILL CONNECT YOUR TOOL TO THE TPS. COVERED LATER.

IF YOU USE A 2396 REGULATOR YOU WILL HAVE 4 PRONGS IF YOU USE A 2396 REGULATOR YOU WILL HAVE 4 PRONGS. FROM LEFT TO RIGHT: IN-OUT-GROUND-CLIP OFF THE FOURTH AS SHOWN. YOU CAN BEND THE FOURTH RIGHT OFF AND IT WILL BE CLEAN. REMOVE IT AND DON’T WORRY ABOUT WHAT ITS FOR. YOU DON’T NEED IT.

YELLOW WIRE: VOLTAGE OUT CONNECT YOUR YELLOW WIRE TO CENTER PIN YELLOW WIRE: VOLTAGE OUT CONNECT YOUR YELLOW WIRE TO CENTER PIN. THIS IS YOUR REGULATED POWER OUT (5V) AGAIN: YOU MAY USE ANY COLOR WIRE YOU, I USE YELLOW BECAUSE I KNOW IT IS USED AS A REGULATED POWER WIRE.

CONNECT YOUR RED (+) WIRE FROM YOUR 9V CONNECTOR TO THE LEFT PIN (IN) I LIKE TO “TIN” THE TIP OF MY WIRE AND PUT ALITTLE FLUX ON THE PIN SO IT WILL SOLDER FASTER.

TAKE YOUR BLACK (-) SIDE WIRE FROM YOUR 9V CONNECTOR AND TWIST YOUR BLACK WIRE TO MAKE ONE WIRE. THIS FREE RUNNING END WILL BE EXPLAINED LATER. CONNECT THE END YOU JUST TWISTED TO THE RIGHT SIDE PIN. YOU SHOULD LOOK LIKE THE PICTURE ON THE RIGHT. YOU SHOULD HAVE 1 WIRE COMING FROM THE FIRST AND SECOND PIN, AND TWO COMING FROM THIRD PIN. IF YOU LOOK, YOU WILL SEE THE 9V CONNECTOR PROVIDES THE POWER INTO THE REGULATOR. THE YELLOW AND OTHER BLACK WIRE WILL PROVIDE THE REGULATED 5V POWER OUT. PUT YOUR 9V CONNECTOR OUT OF THE WAY. YOU ARE DOWN WITH IT.

SNIP THE YELLOW AND BLACK WIRES. GET YOUR LED LIGHT(OPTIONAL) SNIP THE YELLOW AND BLACK WIRES. GET YOUR LED LIGHT(OPTIONAL) **THE FLAT SIDE ON THE LED LIGHT IS THE NEGATIVE SIDE. ROUND SIDE IS POSITIVE SIDE. I LIKE TO SNIP THE NEGATIVE SIDE SHORT SO I CAN TELL EASIER. CHECK YOUR LED LIGHT SIDES. ALSO CERTAIN LED’S CAN’T HANDLE MUCH VOLTAGE. MAKE SURE YOU GET ON THAT CAN HANDLE AT LEAST 9 VOLTS TO BE ON THE SAFE SIDE. YOU CAN BYPASS THIS STEP IF YOU DON’T WANT A LIGHT.

CONNECT THE YELLOW WIRE (SHORT ONE YOU JUST CLIPPED) FROM YOUR REGULATOR TO ONE OF THE PINS ON YOUR ON/OFF SWITCH (RED ARROW). TAKE YOUR LOOSE YELLOW WIRE AND SNIP OFF A PIECE THEN TWIST TOGETHER (BLUE ARROW). THEN CONNECT THAT END TO THE OTHER POST ON THE SWITCH (GREEN ARROW). I RECOMMEND USING A SWITCH. YOU DON’T HAVE TO, BUT MAKE SURE YOU REMEMBER TO DISCONNECT YOUR BATTERY EVERYTIME YOU USE IT.

TAKE THE SHORT BLACK WIRE COMING FROM YOUR REGULATOR AND A LOOSE PIECE OF WIRE AND TWIST TOGETHER JUST THE YELLOW WIRE YOU JUST DID. TAKE THAT END AND CONNECT TO THE NEGATIVE (FLAT) SIDE OF THE LED LIGHT. CUT THE (+) POSITIVE SIDE LEG SHORT ON THE LED JUST LIKE THE (-) NEGATIVE SIDE YOU DID EARLIER. CONNECT YELLOW WIRE TO (+) POSITIVE SIDE OF LED.

WHAT IT SHOULD LOOK LIKE SO FAR. SO NOW FOLLOW HOW YOUR SET UP SO FAR. 9V CONNECTOR IS SUPPLYING 9 VOLTS INTO THE VOLTAGE REGULATOR. (RED/BLACK WIRES) YELLOW WIRE IS SUPPLYING YOUR SWITCH WITH REGULATED 5 VOLT POWER, WHICH WHEN TURNED ON WILL SUPPLY THE LED WITH 5 VOLT POWER. THERE IS ALSO A FREE RUNNING YELLOW LEAD WE HAVE NOT COVERED YET. LED: HAS REGULATED POWER IN AND IS GROUNDING OUT THE SWITCH AND LED ITSELF. ALSO YOU HAVE A FREE RUNNING BLACK WIRE WE HAVE NOT COVERED YET.

TAKE YOUR FEMALE CONNECTORS TAKE YOUR FEMALE CONNECTORS. (OPTIONAL) TAKE NEEDLE NOSE PLIERS AND REMOVE THE PLASTIC CAP. *YOU CAN CRIMP THE WIRE INTO THE PLASTIC CAP IF YOU WOULD LIKE. I USE SOLDER ON EVERYTHING. YOU DON’T HAVE TO. FIND YOUR YELLOW AND BLACK FREE RUNNING WIRES. THESE WILL MAKE CONNECTING YOUR MULTI-METER MUCH EASIER. THEY HAVE SOME THAT HAVE A PLASTIC COVER OVER THEM ALREADY. I SUGGEST COVERING THE METAL SO YOU DON’T SHORT OUT YOUR CIRCUIT. ELECTRICAL TAPE WILL WORK.

CONNECT YOUR WIRES TO THE FEMALE CONNECTOR. REPEAT FOR BOTH WIRES.

CONNECT ONE MORE PIECE OF WIRE TO ONE SIDE OF THE FEMALE CONNECTOR CONNECT ONE MORE PIECE OF WIRE TO ONE SIDE OF THE FEMALE CONNECTOR. THIS WIRE WILL GO TO YOUR TPS. REPEAT STEP FOR BOTH WIRES. (PIC. 2: HOW I DO MINE.)

TAKE YOUR GREEN WIRE AN PUT A FEMALE CONNECTOR ON ONE END TAKE YOUR GREEN WIRE AN PUT A FEMALE CONNECTOR ON ONE END. THIS WIRE DOES NOT CONNECT ANYWHERE ON THE REGULATOR. ****YOUR COLORS WILL VARY IF YOU CHOOSE DIFFERENT COLORED WIRES****

THIS IS WHAT YOU SHOULD HAVE. EASY ENOUGH…RIGHT???!!!

USING YOUR NEW TOOL BRAAAAAAAAAAAAAPPPPPPPPPPPP

**CONNECTIONS FOR YOUR TOOL** YOU WILL NEED TO FIGURE OUT HOW TO CONNECT YOUR NEW TOOL TO YOUR TPS. I HAVE PINS FROM WHEN I HAD TO REPLACE MY CONNECTOR. I USED THEM. SOME SAY THEY USE ALLIGATOR CLIPS. YOU WILL HAVE TO GIGURE IT OUT ON YOUR OWN. JUST MAKE SURE THEY DON’T TOUCH EACH OTHER AND SHORT OUT.

BLACK: TOP- GROUND YELLOW: MIDDLE-POWER IN GREEN: GOES TO YOUR (+) METER

ON YOUR MULTI METER- BLACK PROBE TO BLACK WIRE RED PROBE TO GREEN WIRE ON YOUR MULTI METER- BLACK PROBE TO BLACK WIRE RED PROBE TO GREEN WIRE. YELLOW- NOTHING

SET YOUR MULTI METER TO “20” AND TURN ON YOUR TOOL. THROTTLE CLOSED YOU SHOULD HAVE ALREADY CONNECTED YOUR 9 VOLT BATTERY. **YOUR READING WILL PROBABLY BE DIFFERENT. DO NOT GO OFF OF MY READING. LOOK IN YOUR MANUALS.** THROTTLE WIDE OPEN

END THIS WAS JUST A GUIDE TO MAKE YOUR OWN TOOL. I HAVE NOT GOTTEN TO TESTING ANY VARIBLES OR ADJUSTING THE TPS. MAYBE I’LL MAKE ANOTHER POWERPOINT TO SHOW HOW TO MAKE ADJUSTMENTS WITH SPECS. ETC. OR MAYBE SOMEONE ELSE CAN MAKE SOMETHING FANCY FOR US ON THAT TOPIC. GOOD LUCK AND I HOPE THIS MAKES THE PROCESS EASIER THAN THE OTHERS I HAVE SEEN. ANY QUESTIONS FIND ME ON KTMTALK.COM. Username: smcarthur