Honda Goldwing GL1200 Installation Manual Download | Manualshive

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MotorCycle Setup Pty. Ltd.

Electronic Cruise Control Installation Manual ©

To suit Honda GL1200

This cruise control was developed on a 1987 GL1200 Interstate. Every effort has been made to ensure complete
compatibility with other years and models of GL1200 but this cannot be guaranteed at this time. If difficulties
are experienced due to differences on other models, please contact your dealer or MotorCycle Setup in Australia
by phone on (03) 98082804 or fax on (03) 98082445 or internationally by phone on 61 3 98082804 or fax on 61
3 9808 2445 or email us at [email protected] for assistance.

Your electronic cruise control has been adapted from an Australian designed, automotive cruise control
specifically to suit your motorcycle. Months of testing have resulted in changes to the electronic
circuitry to deliver safe, reliable operation on the motorcycle models listed above. It is essential that you
install the correct kit to your motorcycle and follow the installation instructions precisely so that
electrical interference does not cause the unit to behave erratically or be rendered inoperative.

WE STRONGLY RECOMMEND AGAINST FITTING OFF-THE-SHELF MOTOR CAR CRUISE
CONTROLS TO ANY MOTORCYCLE!

If, after reading these instructions, you feel you are not competent to install this kit, we strongly urge you
to seek the assistance of one of our authorised dealers and installers. Please phone or email us to obtain
the name of your nearest outlet.

CONTENTS

1. I

NTRODUCTION

2. W

ARNINGS

, C

AUTIONS AND

N

OTES

3. T

OOLS REQUIRED

4. P

ARTS

L

IST

5. O

VERVIEW OF

C

RUISE

C

ONTROL

O

PERATION

6. P

REPARING THE BIKE FOR CRUISE CONTROL INSTALLATION

7. I

NSTALLATION

8. D

IAGNOSTIC MODE OPERATION

9. M

ANUAL ADJUSTMENTS TO THE BRAKE PEDAL AND FRONT BRAKE LEVER

10.O

PERATING

I

NSTRUCTIONS

11.S

AFETY

I

SSUES

&

FEATURES

12.

ROAD TEST AND ADJUSTMENTS

13.

T

ROUBLE

S

HOOTING

, T

ESTING

& S

ELF

D

IAGNOSTICS

14.R

IDING

T

IPS

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Summary of Contents for Goldwing GL1200

Page 1: ...1 Motorcycle Electronic Cruise Control Installation Manual For Honda Goldwing GL1200 7 June 1999 Manufactured by MotorCycle Setup Pty Ltd 7 Moritz Street Box Hill Victoria AUSTRALIA 3128 ...

Page 2: ...ration on the motorcycle models listed above It is essential that you install the correct kit to your motorcycle and follow the installation instructions precisely so that electrical interference does not cause the unit to behave erratically or be rendered inoperative WE STRONGLY RECOMMEND AGAINST FITTING OFF THE SHELF MOTOR CAR CRUISE CONTROLS TO ANY MOTORCYCLE If after reading these instructions...

Page 3: ... from ignoring the warning A caution applies whenever damage to the bike or cruise control could result from ignoring the caution and A note applies where other aspects should be considered before any action to do with installation is undertaken EXAMPLES WARNING Always ensure the bike is properly supported on the side or centre stand and cannot accidentally fall off either stand CAUTION Before dri...

Page 4: ...leasing a cable which attaches to the carburettors via the cable interface unit CIU the CIU translates the motion from the throttle grip and the vacuum actuator to the carburettors via a new cable supplied in the kit the speed sensor generates electrical pulses when the bike is in motion the switch sends instructions from the rider to the computer the electrical loom which connects the switch the ...

Page 5: ...U is completed and the CIU is in its final location This is because flexing the cable affects the free play It is shown at this stage in these diagrams to improve clarity After this adjustment is performed the carburettor cable adjustment MUST NOT BE MOVED All future adjustments of free play in the throttle must be performed on the throttle cable from the throttle grip If incorrect free play in th...

Page 6: ...the free play is taken out of all the cables As a result the rider will notice the twist grip moving while the cruise is operating It is possible to roll the throttle off by hand thus opposing the cruise control actuator As this will result in a loss of speed the cruise control computer will read this as the bike going up an incline and attempt to apply more throttle If the twist grip is released ...

Page 7: ...lowing instructions may be used to remove these items Seat removal Remove the lids on the pannier bags Loosen and remove the Allen head screw holding the seat adjusting lever in place on the left side of the seat The lever is about 170mm 7 behind the top shock absorber mount Loosen and remove the Allen head screw on the right side of the seat Slide the seat back to disengage the tag at the front o...

Page 8: ... of the top of the air box and filter element Loosen and remove the wing nut on the top of the air filter housing and remove the top cover Remove the air filter element Loosen and remove the four screws holding the air filter housing to the carburettor plenum chamber and remove the air filter housing Disconnecting the throttle cable Disconnect the opening pull throttle cable from the carburettors ...

Page 9: ...ake it easier to tighten the adjuster Tighten the adjuster GENTLY The adjuster is made of brass and will break if over tightened We have had a couple of instances where the adjusters have broken during installation due to over tightening the adjuster If thread lock compound is used on the lock nut it is not necessary to over tighten the lock nut Reassemble the air filter housing and replace the fu...

Page 10: ... compound on the bolt Undo the small hose clamp supplied in the kit and place it around the fairing frame and the tab on the actuator mounting bracket Gently tighten the hose clamp so that the tab is clamped to the fairing bracket Installing the actuator vacuum hose The actuator uses engine vacuum to operate the throttle It is necessary to remove one of the vacuum port blanking screws and replace ...

Page 11: ...the right side frame tube and the inside of the faring frame BEHIND the fairing frame mount Route the cable back over the coolant reservoir tank Installing the CIU The CIU Cable Interface Unit is mounted to the frame tube immediately behind the coolant reservoir tank Disassemble the CIU noting the positions of the components DO NOT remove the mounting bracket The parts list at the back of the inst...

Page 12: ...n the coolant tank filler neck and the radiator connecting hose the between the two electrical black boxes mounted in front of the coolant tank Place the ball nipple on the actuator cable in the hole in the thin actuator spool and place the spool in the CIU with the semi circular groove facing up Rotate the spool clockwise to fully extend the cable Screw the adjuster on the end of the carburettor ...

Page 13: ...sition and is shown in the photo a little below the pull cable The last few threads on the adjuster are flattened during manufacture to prevent the lock nut coming off This section of damaged thread will make it difficult to thread the adjuster into the CIU Run the lock nut over this section of thread a few times to repair the threads then run the lock nut back up the adjuster Route the cable to t...

Page 14: ...h NOTE The procedure just described sets the free play between the carburettors and the cruise control actuator Too little free play will prevent the carburettors returning to idle Too much free play will effect the response of the cruise control Once set the free play should NOT BE MOVED again unless an incorrect setting is suspected Free play in the throttle grip should be adjusted using the adj...

Page 15: ...gnet The depth of the cavity in the nut should be the same as the height of the stud If the stud contacts the magnet first check the gap under the face of the nut to the disc If the gap is less than 0 5mm 0 020 use one flat washer under the nut If the gap is greater that 0 5mm 0 020 remove the nut and place a 8mm flat washer on the stud then screw the nut back on BY HAND If the nut bottoms on the ...

Page 16: ...ugh range of adjustment the bracket can be bent to achieve the correct gap Installing the control switch The control switch is mounted on a bracket that sits between the bottom faces of the clutch lever assembly mounting clamp Remove the two screws that secure the clutch lever assembly clamp to the handlebar and remove the clamp File 1 0 1 5mm 0 040 0 060 from the bottom face of the clamp The easi...

Page 17: ... on the underside of the computer and place it on the tank so that the side sits against the seam in the tank and the front of the computer is about 50mm 2 behind the fuel filler spill tray Check that the three position sensitivity switch the small slide switch to the left of the 12 pin plug is in its middle medium M position The other positions are low L and high H You will notice that the label ...

Page 18: ...he rear brake light switch Disconnect the rear brake switch plug Plug the matching connectors on the cruise control loom into the free ends of the plugs The cruise loom will bridge the connection and take power and brake signal to the cruise control Tuck the wires back into the space under the CIU and the fuel spill tray Speed sensor connection Route the speed sensor wire down inside the frame bes...

Page 19: ...he throttle is open a significant amount such as when travelling up a hill the time taken for the throttle to return to idle position may mean the engine gains a lot of revs when the clutch is pulled in If the cruise has only applied a small amount of throttle the rate of change in the engine speed may be so slow that the ECS will not detect it at all The engine may reach redline or beyond if the ...

Page 20: ... seconds THIS IS NORMAL AND DOES NOT INDICATE A FAULT IN THE SPEED CONTROL This applies to most operations performed in diagnostic mode Turn the cruise control ON OFF switch to OFF Turn the ignition switch ON but DO NOT start the engine Check that the kill switch is also ON Depress and hold the SET key while turning the cruise control ON Take your finger off the SET key Pull the front brake lever ...

Page 21: ... wheel is spinning at 60 or 70 kph 45 mph Observe the LED on the computer to see it flashes regularly It should flash quite slowly at these speeds at 1 2 second intervals Checking the ECS With the cruise in diagnostic mode with the engine running observe the red LED indicator on the clutch switch and the LED on the computer Quickly rev the engine by blip LED s should illuminate briefly as the engi...

Page 22: ... it has been designed to be very easy to operate Its operating range is from about 40kph not recommended to approximately 180kph also NOT recommended The cruise control operates by monitoring the road speed of the bike and uses a computer to maintain any set speed within its operating range The computer is instantly de activated by either front or rear brake lever pressure sufficient to turn on th...

Page 23: ...ontrol is controlling the bike s speed tapping the RES key decelerates the bike by approximately 2kph per tap 3 If the cruise control is controlling the bike s speed depressing and holding the RES key down decelerates the bike until it is released or the bike slows beyond the cruise control s operating range Releasing the key sets the computer to the current speed NOTE 1 If the bike s speed drops ...

Page 24: ... power relay The MotorCycle Setup CruiseSafe actuator power relay cuts power to the cruise control throttle actuator throttle servo whenever the brake is applied This innovative safety device is unique to the MCS product range and demonstrates the company s dedication to building product to the highest possible levels of safety quality and reliability The CruiseSafe cut off is a simple relay incor...

Page 25: ...n and it must have a resistor suppressed coil If a relay without a resistor suppressed coil is used you will damage the cruise control computer This will not be covered by warranty This relay is a common automotive relay and should be readily available from most automotive electrical outlets NOTE If the bike is fitted with a flasher device on the brake light system this may cause interference with...

Page 26: ...rake levers to turn the cruise control off 4 Use the throttle to accelerate the bike up to 80kph and press the SET key The cruise control should engage and smoothly maintain speed within 2kph If the cruise control loses speed when engaged or is sluggish increase the sensitivity adjustment by setting the sensitivity switch on the computer to the H High position If the cruise control gains speed whe...

Page 27: ...nt It is recommended the switch be covered during washing The staff at MotorCycle Setup hope you enjoy using your new cruise control and use it wisely and safely Remember that cruise controls are not a licence to concentrate less while riding We recommend you approach all other road users with greater care when using the cruise control and use substantially larger safety margins when riding in tra...

Page 28: ...uel spill tray as shown in the photos using double sided self adhesive foam tape or similar material Connect the loom plug to the computer as shown Return to P17 of the instructions for loom routing Mounting the ECS on bikes equipped with seat adjustment release lever Mount the switch on the fuel tank as shown Clean the tank with methylated spirits wood alcohol and mount the switch with small self...

Page 29: ...12 pin b Speed sensor connectors c Brake switch and power connectors Green and white link wires brown and orange feed wires d Fuse holder 3 amp fuse e Earth connector green wires f Switch plug 4 pin g Actuator plugs Red black white wires h ECS plug orange and violet wires MCS 1344 Switch assembly 13 1 MCS 019 Switch 14 1 MCS 004MH Switch bracket 2 2 gauge x 1 2 pan head self tap screw 15 MCS 1345 ...

Page 30: ...sher 34 1 MCS 073 Sensor magnet assembly 35 2 8mm plated flat washer 10 150mm cable ties 6 200mm cable ties 1 MCS 1340ECS Electronic clutch switch 2 MCS 028B Self adhesive pads Instructions Trouble shooting guide Warranty sheet 31 h 29 15 g 22 23 20 b a 12 d c C C otor M ycle ruise 1 2 e f 4 34 26 27 25 33 17 18 19 21 23 24 16 35 28 32 32 30 RES DEC SET ACC OFF ON 13 3 5 6 7 11 14 8 9 11 10 Dual S...

Page 31: ...e repaired unit will be returned with all postal charges prepaid Coverage under this warranty is limited to the original purchase of the product at retail When requesting warranty service a copy of the sales receipt or guarantee card must be submitted The warranty period for cruise controls is limited to a period of 12 months from the date of purchase No warranty is implied for the installation an...

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