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Monday, February 18, 2008
Written By Guy Caputo
Well this is it folks and by it I mean the very last installment of our epic and thrilling novella. It has taken a whole year to do and all of the other 5 installments were received and well read, I hope you enjoy this one too. I have tried to include everything possible that we have installed, machined, customized and otherwise transformed on this magnificent machine known as the “Tiger”. I’ve shown you the in’s and out’s of every possible product I have used, begged, borrowed and stol…well not stolen but was gifted to me by my sponsors. I want to thank my sponsors for each and every product that was given or discounted for our project and I hope they have benefitedfrom their generosity.
Let’s get started with Chapter 6. Electronics – Electronics – Electronics
 First I think it’s important to show you what we will be discussing by viewing a few naked pictures of the “Tiger”. A “what’s under the hood” so to speak. As you read this article and try and consume all the technical gobbledy gook I’ll be giving you, see if you can pick out the products in the pictures below. Have fun, it’s kind of a
“where’s Waldo.”
As you can see the bike is already wired like the space shuttle and what’s worse is, I don’t have a schematic for anything you see here, it’s all upstairs in the old gray matter. God help me. The only device that you can not see is the Innovate LM-1 data logger unit that is installed in the hump in case you were wondering where it was. I want to present all the technical information correctly and exactly as it is on the websites that offer these products. So I stole…I mean cut and pasted from those websites and put everything right here for you folks who like visual aids eliminating the need for you to see each site. But don’t worry, I have also included the links to each of them anyways because I know how you computer geeks are (like me), you
have to see for yourself.
First I want to start with the heart of my ignition and fuel injection system and that would be my Dynojet PowerCommander III USB from Orient Express.
Power Commander - PCIIIUSB - Suzuki - GSX 1300R Hayabusa
- Works with any exhaust
- +/- 100% fuel adjustability over stock
- Expandable with:
- Ignition Module
- Quick Shifter
- Color LCD display
- Multi-Function Hub
- Easy installation (no cutting or splicing)
 What is a Power Commander?
The Dynojet Power Commander plugs inline with your bike’s stock fuel injection system. It uses OEM (original equipment manufacturer) style connectors making for a easy and quick installation. The PCIIIusb allows a full range of fuel adjustment, as much as +/- 100% over stock. Adjustments can be made either with a Windows based computer or by using the face plate mounted button adjusters. No permanent changes are made to the bike’s system. Once the unit is removed the bike reverts to its stock settings.
Map Database
Dynojet supports the Power Commander Product line with the worlds largest map database. They work with all of the leading exhaust manufacturers from around the globe to bring you pre-tested settings for your motorcycle. No guesswork on your part. Every map that they offer was tested and developed on one of their multiple in house Dynojet Dynamometers using their patented Tuning Link software. New maps are developed weekly for
all popular applications.
Tuning Centers
For custom or specialty applications where it is not possible for them to have a map available, there is a network of Official Dynojet Tuning Centers. These facilities have the required equipment and training to develop custom maps
for your vehicle.
Click Here for a list of centers near you.
Features:
Hassle free USB communication - The Power Commander USB will instantly and automatically connect to the Power Commander Control Center software once it is installed. Simply "power up" the unit and connect the supplied USB cable to the computer and PCIII USB.
Onboard notes storage - The PCIII USB stores the notes from the map in the onboard memory. This makes it easy to see exactly which map is loaded. The notes, just as the map itself, are automatically retrieved upon connecting
to the unit.
Individual cylinder adjustment - All PCIII USB units have a "cylinder trim" adjustment feature that allows you to "offset" fuel to one or more cylinders. Additionally, for advanced users, the PCIII USB allows individual cylinder mapping. Now each cylinder can be mapped individually throughout the entire rpm/throttle position range.
Enhanced "file compare" utility - The PCIII USB software allows you to compare two map files without the Power Commander connected. There is a numerical display as well as a brand new graphical display.
Easier to use "button adjustment" mode - The button adjustment has been made easier by introducing a "startup delay". This lets the user have enough time to start the bike and then switch the PCIII USB into "button adjust" mode. The ranges of the buttons are now displayed in the software. Simply connect the unit to the computer and press one of the buttons. Their ranges are
shown on the screen.
"Expansion port" for upgrades and accessories - The "expansion port" allows easy connection of accessories such as our new ignition module, Quick shifter, Multifunction Hub, Pressure Sensor display and LCD display unit.
Automatic map retrieval upon connection - As soon as you connect the PCIII USB to the computer and launch the software, the map installed in the PCIII USB will be displayed.
9V "Power Up" adapter - Every PCIII USB comes with a "power up" adapter which allows users to program and interface with the Power Commander on their desktop without being connected to the bike. Accelerator Pump - You can adjust: A) The amount of fuel to add, B) The number of engine revolutions during which fuel is added, C) The sensitivity of throttle movement under which the accelerator pump is activated.
The LCD Display connects to any Power Commander USB via a “quick disconnect” cable. It is designed to remain on the bike and is weather resistant. While connected, the unit will display all available data from the Power Commander. When the optional Multi-Function Hub is also installed all of its data is available for viewing as well.
Multiple maps can be stored in the unit (requires optional SD memory card, not included). These maps can be sent to the Power Commander “on the fly.” Additionally, maps can be adjusted using the controls on the display.
The LCD Display has the ability to log the data being displayed later analysis (requires optional SD memory card, not included).
- Displays all Power Commander data "real-time"
- Allows storage & switching between multiple maps
- Data logging capable
- "On screen" map adjustments
- User configurable screens
- USB programmable & upgradeable
- Active matrix TFT LCD 240 x 320 16 bit color screen
All I can tell you other than what has been already said is, once installed, find a good tuning center with a Dyno and have your Power Commander tuned specifically just for you, your bike and the fuel you plan on using. You can click on the tuning centers link above to find an authorized DynoJet tuning center near you. If you can’t find one, the online Map Data center will have something that will work based on your exhaust system. They have a very extensive database and if you can’t find one there, I recommend you try the forums at www.Dragbike.com, www.ExtremeBusa.com or www.SuzukiHayabusa.org
Search for Dynojet maps and I’m sure you’ll find one or meet someone who can steer you in the right direction.
Next up is my Innovate computer data logging system from DynoTune.
LM-1 Wideband Air/Fuel Ratio Gauge with AuxBox
 Tuning an engine for maximum power previously required long trial-and-error sessions on a dynamometer. With the LM-1, precise AFR measurement allows the user to correctly adjust many variables- including carburetor jetting, fuel injection, turbo fuel curves, etc. - without long and expensive dyno sessions. The meter’s digital signal processing technology provides data on exactly how rich or lean an engine is running at any load. The LM-1’s self-calibrating circuitry also compensates for changes in temperature, altitude, and sensor condition. The instrument can sample and store the air-fuel-ratio and the other sensor data internally in operation for later analysis on a personal computer. At a sampling rate of 12 samples/second the instrument can store up to 44 minutes worth of data in non-volatile memory. The data can be downloaded to a personal computer using a standard serial port and viewed/analyzed by the included software or any standard spreadsheet program.
Innovate Wideband Gauge XD-16 kit --COMPLETE KIT--
The Innovate “Standalone Gauge Kit” comes complete with the patented award-winning LC-1 Wideband Controller, NEW! XD-16 (16 in 1) 52mm Programmable Digital Gauge, Bosch 5-wire Wideband 02 Sensor, Bung/Plug Kit, Software CD, and quick start guide.
The Innovate XD-16 dash-mountable Digital Display ships as an AFR gauge, but can also be configured to display any channel of the Modular
Tuning System.
Key features:
- 2 Bezels + 8 faces = 16 combinations
- 3/4” thick, so it's possible to mount even in surface mount configurations
- Fits 52 mm (2-1/16") gauge pods
- 3-character LED display
- Record/Calibrate/Peak Hold button
- Programmable (values and colors) digital needle
- Billet Aluminum bezel
- The basic kit ships with both black and silver bezels, 8 faces
(AFR, Pressure, Temperature, and blank).
Round Digital Nitrous Pressure Gauges
DynoTune Digital Nitrous Pressure Gauges Perform!!!
The DynoTune Digital Nitrous Oxide Pressure Gauge is the most accurate NOS pressure Gauge available. The superior Digital displays are available in RED LED or GREEN backlight LCD. The displays are so good they are even viewable in direct sunlight! The Gauge is Full Billet Aluminum and 2-1/16". Show quality! Racers, pay attention, this help improve your consistency dramatically. You can now purge at the line until the exact NOS pressure is reached, run after run after run. Consistency is the name of the game. Those Other Dial gauges are off by typically 50-80PSI!!! The sending unit on this kit is compact and easy to install. It removes with a quick Disconnect and a complete wiring harness comes with the kit. Works from 9Volts to 14 Volts.
I have tried many of the competition's Nitrous Gauges and they don't even come close to the DynoTune model.
Compare the following features:
- Digital Display
- 1 PSI Resolution
- Direct Sunlight Viewable
- 9-14 Volt Operation
- Super Low Current Draw
- Simple installation
- Billet package
Note: The Sending unit has 1/8" male NPT threads. The Gauge adaptors are sold separately, available in 4AN and 6AN.
Round Digital Fuel Pressure Gauges
DynoTune Fuel Pressure Gauges Perform!!! 100% billet aluminum construction
The DynoTune Fuel pressure Gauge is one of the smallest, lightest, most accurate fuel pressure Gauges available. Show quality 100% billet package, round 2-1/16". The superior Digital meter display comes in RED LED, Blue or Green Backlight LCD. The displays are so good they even work great in direct sunlight!. The kit includes the wiring harness, Gauge and a Fuel pressure sending Unit! The fitting on the sending unit is a male 1/8" NPT.
DynoTune Fuel pressure meters have resolution down to .1PSI, The competition can only get +/- 15psi accuracy. DynoTune Gauges are good for 0 to150 psi, used for, Nitrous, Blowers, Turbos, this meter is a must!
Compare the following features:
- Digital Display
- .1 PSI Resolution
- Direct Sunlight Viewable
- 9-14 Volt Operation
- Super Low Current Draw
- Full Billet 2-1/16" round package
Now that is some trick stuff for sure. The location of the sensors that send the signals to the gauges were the easiest to install, but just remember that every one those DynoTune sensors require 3 wires to be hooked up, switched +12V, Gnd and signal output. Each DynoTune gauge also has 3 wires to be hooked up, +12V, Gnd and signal input. I built a connection block up on the left side intake tube of the bike to secure all the connections and I check the connections frequently due to the vibration hazards when going 200mph+
all the time at Maxton.
Now the heart and soul of my Nitrous delivery systems.
First…The Heart.
PNC-3000 Progressive Nitrous Controller Features
- Fully Programmable Nitrous/Fuel Curves
- Ground or 12 Volt Activation
- Analog Input from Wideband O2 Sensor for Logging
- Safety Shut-off if too lean
- Data Logging of Nitrous/Fuel Solenoid and O2 Input for Tuning
- Hold and Wait Feature with Adjustable Resume Ramp.
- Analog Output for use with Aftermarket Ignitions and Fuel Systems to Retard Timing or Add Fuel Based on Nitrous Percentages or User Designed Graph. (Perfect for Power Commander Hub Kits and other aftermarket units)
- Built in Timer for Second Stage Activation, Retard Activation, or Fuel Enrichment
- Compact Size: 5 1/8 X 3 3/8 X 1 3/16
- Weight: 10 ounces
*Note: This unit does not include a Wideband O2 Sensor or the Hardware to run it. The PNC-3000 only reads the voltage from a Wideband O2 Sensor for safety shut off and recording. You will need either a Wideband Commander
or Wego II separately.
Click for the Product Manual
(you must have Adobe Acrobat installed)
Nitrous and Fuel Operation
The PNC-3000 allows the user to adjust the Nitrous/Fuel delivery for each Pulse of the solenoids during the Progressive Ramp. This adjustability allows the user to tune for Rich/Lean conditions at different points in the Progressive Ramp. Multiple precision timers are included to Delay the start of Nitrous delivery, Advance the Fuel delivery, and to provide an additional +12 volt output to control external devices. A Resume Ramp has been included so Throttle Lift transitions can be controlled and/or Gear change transitions.
Activation—
The system is activated when either a Ground or +12V signal is present on the Activation terminals. Once activated the Main Timer begins counting down and is displayed on the main screen. If the Hold & Wait option is ON the system timers will NOT reset if the Activation signal is removed (throttle lift). If the Hold & Wait option is OFF the system will reset and start over each time the Activation signal is removed and re-applied.
Nitrous Delay—
If this function is set the Nitrous Timers will NOT begin until this Time
Delay has expired.
Fuel Advance—
After the Nitrous Delay has timed out this setting is checked. If a Fuel Advance time has been set the Fuel Solenoids will begin operation before the Nitrous solenoids. For example if a lean spike was occurring the system could be programmed to deliver a 80% Fuel pulse .050 second before the first Nitrous solenoid pulse. It is recommended to check nozzle flow and total volume flow to insure correct fuel delivery.
Nitrous/Fuel Progressive Ramp—
Once activated and the Delay and Fuel Advance timers have expired the system will pulse the solenoids as programmed. The Nitrous and Fuel use independent data to allow greater control. When the End of the Progressive Ramp is reached the system will use the Last Percentage in the Progressive Ramp until the Main Timer expires. When the Main Timer is done the only way to reset the system is to remove the Activation Signal.
IMPORTANT—When the Hold & Wait option is ON the Data Logging function will NOT save the current data until the Main Timer has expired. This allows up to 20 seconds of data to be captured.
Resume Ramp—
This setting controls the Percentage that the system returns to after a throttle lift on the next Solenoid Pulse. Example-the system is at 80% and the throttle is lifted and re-applied, if the Resume Start Percent was set at 50% the first pulse would be 40%. The Resume Ramp will increase at the rate of the Resume Percent per Pulse setting until the system returns to the Percentage it was at before the throttle lift. If the Fuel and Analog Out settings are at a higher and/or lower setting they are scaled so they resume at the same rate as the
Nitrous Solenoids.
+12 Volt Timer Output—
If a setting of 0.000 is entered the Timer Output will turn ON with the First Pulse of the Nitrous Solenoid. This output can NOT be disabled and the user must remove any wires connected to the Output terminal to disable any
device connected.
I use 2 nitrous delivery systems with both a “wet” and also a “dry” system for my nitrous control. I use the PNC3000 for the wet system and now you can see why I chose only the best in Nitrous electronics for the heart.
For my “dry” system I use the Fast FI Mixture Controller from MPSracing.com
Now the Soul
MPS Fast FI Mixture Control
 Fast, quick, easy electronic fuel injection fuel management. That’s what is in the package of every MPS Fast FI Mixture Control. The original “MPS Mixture Control” sold in 1981 was the first motorcycle fuel injection aftermarket product. The second generation Fast FI Mixture Control sets new standards for fuel management with a dry nitrous system incorporating the instant rich feature. The Fast FI Mixture Control was designed to be a universal application and will work on most late model four cylinder electronic fuel injected motorcycles.
The MPS Fast FI Mixture Control P/N 1-0337 is a simple means to adjust the fuel curves on your fuel-injected motorcycle. This allows for tuning after the installation of aftermarket exhausts, intake modifications, or internal motor modifications. It can only richen the fuel mixture. It cannot lean the mixture. The Fast FI Mixture Control has a low speed pot that adds fuel at low speed much like a mixture screw on a carburetor. The accelerator pump pot is an extra enrichment when the unit senses rapid rpm acceleration. This acts like the traditional accelerator pump on a carburetor. The high-speed pot controls the high RPM like the main jet of a carburetor. The high-speed RPM set pot determines what RPM the low speed pot is no longer controlling the mixture and the high-speed pot takes over. The Fast FI Mixture Control has an instant rich feature to work with Dry Nitrous Systems. It locks the fuel injection system in a full rich mode instantly via a signal from the Dry Nitrous System. This means no more reprogramming for NOS operation. The Fast FI Mixture Control looks at the fuel injection map the same way the factory does and adjusts it the same way the factory does.
Now you can all see why I chose the Nitrous products that I have, it has served me well and with all the new goodies like my Dymag wheels and losing another 20lbs since last year, I hope to break my old record and push it up even higher if all goes well and the creek don’t rise.
Now with all that Nitrous being used, I need to pull some timing out of the motor and there is only 1 product I use.
Ignition Retard Unit, Suzuki Hayabusa – Schnitz Racing
The EFIR-13 Retard Module allows the user to retard the ignition timing on the Hayabusa. This is a Must for Bikes with Nitrous. This unit plugs right into the factory wiring harness, and is 12 volt activated. Hook it right up to your nitrous solenoids or a pressure switch on your turbo bike, and retard the timing to save your engine. It is programmable with dipswitches from 0-16 degrees of timing retard, and also has dipswitches to adjust the build time from .1 to 3 seconds.
Never install solid core spark plug wires, as this will cause the retard module and the factory ECU to malfunction. The factory spark plug wires work perfect.
EFIR's are easy to wire, but you have to wire them correctly. If not wired correctly the bike won't start, or will shut off when it's activated, so read first then wire!
What’s the difference in this and the ignition module from Dynojet?
Dynojet’s Ignition module allows a fixed timing based on RPM and Throttle Position. Our unit allows a fixed amount of advanced timing (similar to Dynojet), however, it allows you to retard the timing with a 12 volt signal (you decide how much) and it allows you to do it over a time frame (progressive retard). This is perfect for those with progressive nitrous systems or turbo systems. More nitrous/boost = more timing retard.
Example - Say you’re spraying a 100 shot with a progressive controller. You have the nitrous set at a start percent of 20% and a final percent of 100% with a build time (amount of time it takes to get to 100%) of 3 seconds.
Well, you need to retard the timing... You can either have your timing retarded with a Dynojet module all of the time (less power on motor, very sluggish) or, you can use our unit to retard the timing progressively when the nitrous
(or boost) is applied.
So for your nitrous settings, you would set the retard unit to retard 6 degrees with a build time (amount of time it take to pull all of the timing out) for 3 seconds. With the retard unit set to this setting, it will pull 1 degree of timing out every 1/2 second until it reaches 6 degrees. It will hold at 6 degrees until the 12 volt signal is taken away. (End of run)
Smooth power delivery with smoother timing retard = one fast motorcycle!!!
Click for the EFIR-13 Product Manual
(you must have Adobe Acrobat installed)
I have one other product to tell you about and that’s my new Engine Kill module for my air shifter system from Orient Express. It’s called the BTC 4 coil ignition kill module and it’s the one item that I cussed when installing. I don’t have an individual picture of it, but I bet if you looked hard enough you’ll see it up by the Power Commander. Why did I cuss? Because there 2 wires that must be tapped into the main harness just down from the coils where the grey wires attach to the Orange striped wire. As you can see from the harness that runs along the left side next to the #1 intake, there was absolutely no room for me to work. Now I’m sure that you will not have all this mouse nest to contend with but for me it was a pain in the arse.
But, after all was said and done, it works great and was well worth the
knuckle busting on my part.
Now if you studied the photos carefully, you saw that I have not 1, not 2 but 3 High output batteries on the “Tiger”. I use 2 of them in series for my 24V start system due to the high compression Pro-mod style motor that I built. I use 2 of them in parallel to give double the amperage output due to all the stuff I have wired on the bike. With everything going on, the last thing I need is the voltage to dip because of all the current flow from the NOS solenoids, fuel pumps, electronics and stuff I can’t even think of right now. There is only 1 battery I trust to do the job for me and that’s my Yuasa YTZ14S from Schnitz Racing.
 YTZ14S High Output Battery - 235 Cold Cranking Amps
Battery Family: YTZ Factory Activated, Maintenance Free
Battery Type: YTZ14S
Voltage: 12
Capacity (Amp. Hrs.): 11.2
Dimensions: 6" x 3 7/16" x 4 3/8"
Weight: 8.6 lbs.
Metric Dimensions: 150mm x 87mm x 110mm
Metric Weight: 3.9 kg
Acid Volume: N/A
Charging Current (Amps.): 1.1
C.C.A.: 230
Both the stock battery and the high output battery are the same exact size, the stock battery produced 175 cold cranking amps. The high output battery 230 cold ranking amps will give you the power to start your big Busa engines, or if you need the extra power on a nitrous bike.
Many thanks to my sponsors and companies that have provided such great products for me to use.
And last but not least, My wife.
I also wish to thank the Ohio Air National Guard and
especially those at the
180th ANG Fighter Wing in Toledo, OH.
GO SERVE – GO PROTECT – GO ANG
WWW.GOANG.COM
1-800-GO GUARD
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