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Honda CBR1100XX EFI Installation Manual
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Honda CBR1100XX EFI Installation Manual

Honda CBR1100XX EFI Installation Manual

Electronic cruise control (fuel injected models only)
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See also: Owner's Manual
otor
M
C
C
ycle
ruise
Motorcycle
Electronic Cruise Control
Installation Manual ©
For Honda CBR1100XX EFI
(Fuel injected models ONLY)
20 June 2005
MotorCycle Cruise Controls
MotorCycle Setup Pty. Ltd.
A.B.N. 94 798 167 654
6 Kingston Street
Mount Waverley, Victoria, 3149
AUSTRALIA

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Summary of Contents for Honda CBR1100XX EFI

  • Page 1 Motorcycle Electronic Cruise Control Installation Manual © For Honda CBR1100XX EFI (Fuel injected models ONLY) 20 June 2005 MotorCycle Cruise Controls MotorCycle Setup Pty. Ltd. A.B.N. 94 798 167 654 6 Kingston Street Mount Waverley, Victoria, 3149...
  • Page 2 Honda CBR1100XX EFI – all models © Electronic Cruise Control Installation Manual © REFER TO THE INFORMATION, SET UP AND OPERATION MANUAL FOR INFORMATION ABOUT THE CRUISE CONTROL, SETTING UP, CALIBRATING AND USING THE CRUISE CONTROL The cruise control computer used has been purpose built for motorcycle applications. Testing has resulted in programming to deliver safe, reliable operation on a variety of motorcycles, from 250cc up.

  • Page 3: Parts List

    Honda CBR1100XX EFI – all models © This manual contains several cautions, warnings and notes, which are prominently displayed. The convention used is: A warning applies whenever injury could result 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.
  • Page 4 Honda CBR1100XX EFI – all models © Disconnect the battery negative terminal. • Loosen and remove the negative battery terminal bolt and disconnect the wire. CAUTION: - Ensure that the wire is secured away from the battery terminal and cannot touch the battery terminal accidentally.
  • Page 5 Honda CBR1100XX EFI – all models © • Undo and remove the top screw and nut holding the fairing screen on both sides. • Undo the hex head screws at the rear edge of both panels. • Lift out both panels. This can be a little awkward to do.
  • Page 6 DO NOT PULL ON THE WIRES. NOTE: - Supporting the rear of the fuel tank with the bikes axle wrench is the method shown in the Honda workshop manual. In practise, we found this did not allow enough room under the fuel tank. We used a piece of wood about 180mm (7”) long instead.
  • Page 7 Honda CBR1100XX EFI – all models © Things you will need to remove the fuel tank: • A container that will hold about two cups of fuel that will fit under the rear of the fuel tank (you can lift the rear of the tank to get it in there);...
  • Page 8 Honda CBR1100XX EFI – all models © • Temporarily install the M12 x 25 (1.25mm pitch) bolt in the fuel hose banjo, using the original washers and the fuel tube sealing nut and tighten the nut. • Re-install the small service bolt in the bottom of the fuel tank, using the original sealing washer.
  • Page 9 Honda CBR1100XX EFI – all models © The air filter housing. • Pull off the connector from the sensor on the top rear of the air filter cover. There is a latch on the connector. DO NOT PULL ON THE WIRES.

  • Page 10: Installation

    Honda CBR1100XX EFI – all models © • Take the nipple out of the throttle spindle spool and withdraw the cable. • Screw BOTH lock nuts off the end of the adjuster then screw them back onto the adjuster. This will repair the flattened section of the threads on the adjuster.
  • Page 11 Honda CBR1100XX EFI – all models © • If needed to hold the actuator in place, replace the two fuel tank mounting bolts as shown in the photo. • Route the actuator cable forward around the right side of the engine above the brake fluid lines, forward UNDER...
  • Page 12 Honda CBR1100XX EFI – all models © • Locate the new ‘carburettor’ cable in the kit. Screw the ball nipple end of the cable into the threaded, un-slotted hole in the CIU. • Place the ball nipple on the ‘carburettor’ cable in the marked hole on the BACK (roll pin side) of the dual spool.
  • Page 13 Honda CBR1100XX EFI – all models © Attaching the carburettor cable. • Feed the free end of the carburettor cable into the cable connection point on the throttle bodies but DO NOT place the adjuster in the mounting bracket. Feed it in as far as it will go to give you as much free length as possible.
  • Page 14 Adjust the throttle free play with the throttle cable adjuster at the CIU to give 1mm to 3mm (1/16”~1/8”) of free movement at the outside diameter of the handgrip. See your Honda owners’ manual for details. CAUTION: - The handgrip MUST have some free play to prevent the throttle cables binding and preventing the throttle from returning to idle when it is released.
  • Page 15 Honda CBR1100XX EFI – all models © • Re position the crank case breather hose as shown in the photo, so that the ACTUATOR CABLE is in front of the hose (shown in white in the photo) and the ORIGINAL THROTTLE CABLE is behind it.
  • Page 16 Honda CBR1100XX EFI – all models © • Route the control switch wire down the front of the fluid reservoir, between the fluid reservoir and the handle bar. Route the wire down and around the front and to the inside of the fork tube with the clutch fluid hose.
  • Page 17 Honda CBR1100XX EFI – all models © Alternative mounting arrangement for higher handlebars. • If higher bars are fitted to the motorcycle, there is an alternative mounting bracket available that places the switch under the left handlebar. See the note at the start of these instructions for more information.
  • Page 18 Honda CBR1100XX EFI – all models © • Push the short length of the vacuum hose onto the vacuum hose fitting. • Route the hose as shown in the photo. The purpose of the routing is to keep the hose elevated to prevent fuel pooling in the hose at any low points.
  • Page 19 Honda CBR1100XX EFI – all models © • Stretch the foam block lengthways and carefully insert the computer into the hole in the foam block. • Place the computer in the rear compartment. Position it as high as possible so that the back of the foam block is above the light globe holders for the rear light, and the front of the computer if facing downwards a little.
  • Page 20 Honda CBR1100XX EFI – all models © All the connectors you need to professionally finish the installation, so that you do not need to modify the motorcycles wiring AT ALL, are provided. There is also a set of terminals provided for the cruise control computer plug. These are to allow you to shorten and re-terminate any of the wiring connections that are too long INCLUDING those that are already terminated (control switch, actuator and ground wires).
  • Page 21 Honda CBR1100XX EFI – all models © Re-terminating computer plug connections (control switch and actuator wires). In order to shorten any of the wires that are already terminated (control switch and actuator wires) you will have to remove the wires from the computer plug, cut them, fit a new terminal to them and then replace them in the computer plug.
  • Page 22 Honda CBR1100XX EFI – all models © • In the event of a wire pulling out and leaving the terminal inside the plug, a paper clip or any piece of wire up to 1mm (0.040”) can be used to push the terminal out. DO NOT USE WIRE LARGER THAN 1mm DIA.
  • Page 23 Honda CBR1100XX EFI – all models © • The crimp will look like this using these crimpers. • If you don’t have access to suitable crimpers, the other alternative is to solder the terminal to the wire. A small vice to hold the terminal or an assistant with pliers and a steady hand is VERY helpful for this process.
  • Page 24 Honda CBR1100XX EFI – all models © 7 No connection 6 Control switch ground - green/black 8 Actuator solenoid power - red 5 Control switch back light - brown/black 9 Actuator vacuum solenoid - yellow 4 Power in from fuse - pink...
  • Page 25 Honda CBR1100XX EFI – all models © • When all the terminals are inserted, the terminal lock must be pressed back into place. If it will not go, DO NOT FORCE IT, there will be one or more terminals not completely inserted.
  • Page 26 Honda CBR1100XX EFI – all models © • Insert the blanking plug into position 25 (white square). You can see that position 13 is now free (white circle). • Insert the speed sensor ground terminal into position 13. Use a paper clip to assist in pushing the terminal home (see previous page for terminal insertion).
  • Page 27 Honda CBR1100XX EFI – all models © NOTE: - You will have suitable terminals and housings to make all connection on the bike without cutting any wires on the bike. Alternatively, you can connect the wires using your own methods. We would recommend that you solder the wires together rather than use ‘Quick Tap’...
  • Page 28 Honda CBR1100XX EFI – all models © 80mm (3.5") of orange wire Orange brake power wire from cruise control loom Receptacle terminals Tab terminals Orange Orange Grey Grey 2 way receptacle housing 2 way tab housing 80mm (3.5") of grey wire...

  • Page 29: Tach Sensor Connection

    Honda CBR1100XX EFI – all models © Tach sensor connection. • Locate the left side ignition coil. It is mounted on the left side of the air filter housing. This has two wires going to it. Disconnect the ‘active wire’. This should be blue with a yellow trace.
  • Page 30 Honda CBR1100XX EFI – all models © • Crimp or solder the wires to the terminals provided and make up a ‘patch’ connection as shown. Use some of the excess blue wire from the cruise control loom for the link wire.
  • Page 31 Honda CBR1100XX EFI – all models © • The pink wire is the active signal wire. The blue core wire from the black co-axial speed sensor wire must be connected to this wire. The black shield wire must be cut back and not connected to anything.
  • Page 32 Honda CBR1100XX EFI – all models © Ground connection. • Cut and re-terminate the ground wire for connection to the battery negative terminal. • In this installation the ground branch will have to be about 90cm (35”) long. CAUTION: - do NOT reconnect the battery negative terminal yet.
  • Page 33 Honda CBR1100XX EFI – all models © • The gap between the face of the sensor and the head of the mounting bolt on the brake disc should be 2~4mm (1/16”~3/16”). If this is incorrect, bend the bracket to get the gap right. Use a drill bit between the magnet and the sensor to gauge this gap.
  • Page 34 Honda CBR1100XX EFI – all models © • Route the wire under the brake caliper and down to the speed sensor. • Connect the wires to the sensor terminals. It does not matter which wire connects to which terminal. Draw any excess length of wire back up into the battery box area.

  • Page 35: Diagnostic Mode Operation

    Honda CBR1100XX EFI – all models © • Tighten the nut gently until the fuel tank can be lowered. • Place a new sealing washer on the service bolt and install the service bolt in the banjo in the bottom of the fuel tank.
  • Page 36 Honda CBR1100XX EFI – all models © HONDA CBR1100XX EFI (Fuel Injected) Parts list for MCS 4070 kit Item Part Number Description MCSU 400C Computer MCS 001 Foam mounting block MCS 1473 Vacuum actuator assembly MCS 574 Vacuum actuator MCS 1473A Actuator bracket 6g x 3/8”...
  • Page 37 Honda CBR1100XX EFI – all models © JD020 Brake switch connector 2way H2858 Terminals for above JD021 Brake switch connector 2 way H3739 Terminals for above JD022 Speed sensor connector 3 way H2858 Terminals for above JD023 Speed sensor connector 3 way...
  • Page 38 Honda CBR1100XX EFI – all models © otor ycle ruise S E T Dual spool hole marking...