Alternative Throttle Position Sensor (TPS)
I have heard that an alternative replacement for the TPS on a '99+ FI tube framed Buell is from a Ford Mustang. I have found this to be untrue in most cases. My findings show that the TPS needed is from a 2nd Generation Ford Explorer 302 V8. The TPS sensor i installed on my bike if from a 1997 Explorer to be exact. I started looking into this when I was 900 miles from home and had my TPS fail. The Harley dealers seemed to be of little help so I had to resort to the local auto parts stores.
Pictured below is a TPS from a '99+ FI tube framed Buell.
Here is a 1987-1993 Ford Mustang sensor (left) and a 1997 Ford Explorer V8 sensor (right)
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All of these sensors are 3 wire, However, the Ford Explorer V8 3 wire sensor has a 4 wire plug. The plug from the original sensor off your buell can be easily swapped. Once swapped its a direct bolt on / plug in. I tried using a Mustang sensor as shown above on the (left) but the area in which the wires come out interferes by hitting a fin on the Buell head making it impossible to use, even though the plug is a direct plug in. With this said, there is a possibly that some brand Mustang sensors are the same as the Explorer sensor and therefore would be direct bolt on / plug in unit. Visiting my local AutoZone and Advanced Auto that is not the case. The ONLY sensor that i found to fit was the Explorer sensor with the Buell plug swapped over.
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(Left) is the 4 plug Explorer connector, and (Right) is the 3 plug Mustang connector. The Mustang and Buell connector are the same and is easily swappable to the Explorer sensor to make it a direct plug in.
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To do this you will need a small straight blade screw driver and a 7mm wrench. Remember that after swapping a TPS sensor, a TPS reset will need to be preformed. Now is also a good time to reset you AFR to 100% as well. Both performed using ECMSpy.
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