Name: AllOEMManuals
Address: 316 Brandywine Ave, Streetman, TX, 75859, US
Telephone: +14699867883
Price range: $$

Disconnect TP sensor harness connector and throttle opener vacuum hose. Using hand vacuum pump, apply 20 in. Hg vacuum to throttle opener to move throttle lever to idle position. Insert .012" (.30 mm) shim thickness gauge between throttle lever and throttle stop screw. See Figure .
Connect ohmmeter between terminals "C" and "D" of TP sensor connector. See Fig 1 . Loosen TP sensor mounting bolts and turn TP sensor fully clockwise. Turn TP sensor counterclockwise slowly to find position ohmmeter reading changes from infinity to zero ohms. Tighten TP sensor mounting bolts at that position.

Fig 1: Throttle Position (TP) Sensor Terminals
Courtesy of SUZUKI OF AMERICA CORP.
Ensure continuity does not exist between terminals "C" and "D" when .016" (0.40 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw.
Ensure continuity exists between terminals "C" and "D" when .008" (0.20 mm) shim thickness gauge is inserted between throttle lever and throttle stop screw.
If continuity is not as specified in steps 3) and 4), TP sensor zero adjustment is incorrect. Start adjustment sequence again. If results are the same after readjusting, replace TP sensor. After final adjustment is completed, reconnect TP sensor connector and vacuum hose to throttle opener.

When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.

• Brakes feel soft, pull hard to one side, or make grinding noises.

• The engine overheats, stalls repeatedly, or misfires under load.

• You are missing required tools, torque specs, or safe lifting equipment.

• You are not confident in the next step or safety outcome.

Safety Warning

TP Sensor Adjustment