Trouble Shooting Guide
Contents
1. Return to other tests for cruise disengage Computer DIP switch settings Refer to the computer installation section of the Installation Manual Section 7 Road Test amp Adjustments in the Installation Manual Section 9 or the section on adjusing the gain in the Operation amp User manual These sections LOW MEDUIM HIGH oo aan HO o a n m Z amm sw2 Page 8 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Wiring diagram J 2 es Fes O lt c i k fo D s V x 0 c 5 i 3 o Y 2 D c 5 i 5 D o c D Q D D V 9 oO c oO Cc D fe Fay Backlight 2 v x oa 2 2 Oy AR a ro ara D ta A gt x DROS E 0 3 La cog COD Page 9 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Loom wiring pin configuration and tests Loom computer plug pin configuration Check continuity of all wires and that the wires go to the correct pins gt Latch on plug body 13 Actuator vacuum yellow m 12 Actuator dump green 14 Speed sensor active blue m 11 Actuator power red 15 Actuator safety dump brown 10 12V Power in pink 16 Tach sensor yellow J 9 Switch On Off Coast brown black resistor in line ge 8 Ground black 1 Switch ground green black 7 D2. yellow 10 13V with brakes released OV with brakes applied n 10 13V with OV pulses with SET key pressed n 10 13V with RES key pressed Pin 15 actuator safety dump brown oV Speed Sensor Pin 14 speed sensor active signal blue See note 1 below Pin 6 speed sensor ground black 0 0 1V Note 1 Speed sensor signal with MCS 027 passive coil speed sensor will be about 0 1V pulse when the magnet passes the wheel Meter needle will flicker on 0 5v range If the cruise is connected to the motorcycles speedometer sender is may produce a similar signal Some BMW use this type of speedo sender or it will be a OV to 4 8V pulse that occures with wheel rotation Tach Sensor Pin 16 Tach sensor yellow DO NOT CHECK VOLTAGE THIS IS AN TACHO IGNITION PRIMARY INPUT AND MAY BE HIGH VOLTAGE Ignition signal may be checked with an oscilloscope if tach input is not working Brake Sensor Pin 3 brake power orange 11 14V max 1V drop with brakes applied Pin 4 brake light sensor grey 0 1V with brakes released Ni 11 14V with brakes applied Page 11 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Power Pin 10 12V power in pink 11 14V Ground Pin 7 diode ground black OV Pin 8 ground black OV Page 12 of 12
3. diagnostic mode See the next line to put cruise control in diagnostic mode Use a speed sensor magnet and place it above OR below the control switch about half way between the front and back of the switch and aligned with the left outside edge of the SET button Hold the magnet in position Press and hold SET key Turn ignition switch ON Release SET key and remove magnet Place ve probe in the back of the computer plug to measure voltages and ve probe to motor cycle frame or on pin 8 ground Control switch Pin 1 switch ground green OV Pin 2 SET amp RES switch signal yellow OV ON OFF switch MUST be ON 11 14V with SET pressed ON OFF switch ON i 3 5V with RES pressed ON OFF switch ON Pin 5 power to switch orange 11 14V Pin 9 ON OFF switch signal brown 11 14V with ON OFF switch OFF A 3 6V with ON OFF switch ON Pin 9 Clutch and or neutral sensor on some models only 11 14V when clutch operated or neutral selected Note On some bikes if clutch and neutral switch are connected to cruise control the bike will have to be in gear to read the 3 6V When the clutch is operated or neutral selected pin 9 will be at 11 14V always Actuator throttle servo Pin 11 actuator power red 10 13V with brakes released 4 OV with brakes applied Pin 12 actuator dump green 10 13V with brakes released OV with brakes applied 0 1V with SET key pressed OV with 10 13V pulses with RES key pressed Pin 13 actuator vacuum
4. twist grip Lube cables with light oil and twist grip with engine oil It may be necessary to lube Back off adjusters on cables from twist grip to give the carburettor throttle spindle Use a maximum free play silicone or Teflon spray Check the free play in the carburettor cable cable from CIU to carburettors by pulling outer cable out of the adjuster until the carburettors start to open Free play between 1mm and 3mm Adjust carburettor cable free play Loosen retaining screw on actuator cable at the CIU Gently pull out the actuator cable Page 6 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Small amount of free play 2 4mm then carburettors start Check CIU for correct assembly to operate broken components incorrect cable spool hole markings see drawing on last page of instructions CIU OK Control switch test Note refer to switch voltage and resistance values at end of guide for detailed check of switch Check kill switch ON Turn ignition switch ON Observe Note Most models only require the ignition LED red light on computer to be turned on others must have the engine going to have power to the cruise Turn cruise control power switch OFF LED on computer ON indicator on switch OFF Check computer power Turn cruise control power switch ON LED on computer OFF indicator on switch green Go to voltage resistance checks Replace control switch Go to voltage resistan
5. MotorCycle Cruise Trouble shooting guide 150 MCS590 Trouble Shooting Guide Problem 1 Cruise will not engage Undertake the following test Perform diagnostic test on next page FIRST NOTE The most common cause of cruise control malfunction is loose or dirty electrical connections Disconnect clean and reconnect ALL electrical connections if the cruise control will not operate in diagnostic mode The usual connections are computer plug control switch plug actuator plug fuse CruiseSafe relay speed sensor or speedometer connection brake light switch ground usually battery negative and either tach ignition primary or the bike s clutch switch 2 Cruise control erratic surges or looses gains speed 3 Cruise lags or overshoots when engaged 4 Cruise disengages Note Carefully check all wiring for intermittent connections 5 Cruise accelerates too slow 6 Cruise will not disengage with brake 7 Carburettor will not return to idle 8 Cruise will not operate at higher speeds above 80 kph 50 mph 9 Cruise will not operate at lower speeds below 60 kph 35 mph Page 1 of 12 a Check computer dip switch settings b Computer power test c Speed sensor test if sensor installed d Actuator test e CruiseSafe actuator power relay test f Vacuum test g Actuator cable test h Brake wire test i CIU test j Control switch test k Loom continuity and voltage resistance tests a Adjust gain check di
6. ce checks Replace control switch Back lighting in switch ON hard to see in bright conditions LED on computer ON Go to voltage resistance checks Replace control switch Resume key held down LED on computer ON Go to voltage resistance checks Replace control switch Control switch OK Page 7 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Tach sensor test Note This test can be used if the cruise control disengages at random without any input from the rider Refer to the installation instructions for the cruise control Find the section Installing the wiring loom which will be in Section 7 of the manual Find the reference to Connecting the tach or ignition sensor In this section you will be shown how to connect the tach sensor wire to the bike s ignition coil or tachometer signal Disconnect the yellow wire on the cruise control loom from the bike s ignition coil or tachometer Reconnect the bike s original coil wire or tachometer wire to its original connection Tape up the yellow cruise control wire to prevent electrical short circuits Test ride the bike to check if the cruise control still disengages randomly WARNING The clutch disengage function on the cruise control will not work DO NOT OPERATE THE CLUTCH WHILE THE CRUISE CONTROL IS ENGAGED Does the cruise operate normally without disengaging at Contact MotorCycle Setup for possible random solutions Reconnect tach sensor wire
7. een tapping yellow to ground RPM hold reasonably steady 6 Increase or decrease in RPM Replace valve pack or diaphragm Actuator OK CruiseSafe actuator power relay test Locate power relay It is attached to the wiring loom near the cruise control computer Turn ignition switch ON turn cruise switch ON Note Most models only require the ignition to be turned on others must have the engine Operate brake lever and pedal going to have power to the cruise Relay clicks with brake light operation Go to brake wire test Faulty relay coil Replace relay Faulty loom Replace repair loom Go to computer power test Faulty loom Replace repair loom Faulty relay Replace relay Yes OV on both red wires to relay when brakes are applied brake lights ON 12V on both red wires on relay when brakes are released Go to computer power test Faulty loom Replace repair loom Faulty relay Replace relay Note Replacement relay MUST have Relay OK a resistor suppressed coil or the cruise control computer will be damaged Vacuum test Engine at idle remove hose from actuator Engine should run rough vacuum pulses should be felt by finger over the end of the hose Vacuum detected and or engine runs rough Kinked pinched blocked vacuum hose or vacuum stop valve faulty or installed backwards Disconnect actuator cable from throttle or CIU Disconnect four way plug at actuator Start engine turn cruise s
8. enoid operation in the vacuum actuator this produces quiet clicks Solenoid felt neard clicking each time brakes are applied Go to computer power test and released place hand on actuator Go to actuator tests Go to CruiseSafe actuator relay test Ensure that the LED red light on the computer and the indicator light on the cruise control switch are visible Place a magnet use the spare speed sensor magnet above or below the control switch about half way between the front and back of the switch aligned with the left edge of the SET button The green indicator light on the switch should come ON HOLD THE MAGNET IN THIS POSITION FOR THE NEXT STEP THIS PROCEDURE PLACES THE CRUISE CONTROL IN DIAGNOSTIC MODE Switch the ignition switch OFF Hold the magnet in position Press and hold the SET Key Switch ON ignition switch Green indicator light MUST come ON Release SET key and remove the magnet Green indicator light should go out Cruise control is now in diagnostic mode Press the ON OFF switch Green indicator on switch ON Go to computer power test Go to control switch test Press the ON OFF switch Green indicator on switch OFF Go to computer power test LED on computer ON stays on for 10 seconds then OFF Go to control switch test Yes Press the ON OFF switch Green indicator ON Depress brake pedal and lever Indicator on switch turns yellow and red LED on computer comes on with brake lights Check brake light
9. erve the control switch indicator and or computer LED The flash rate from the LED depends on the dip switch settings the switches under the rubber cover on the back end of the cruise control computer being correct If the DIP switch settings are correct at 60 kph about 37 mph the LED should flash approximately once per second 10 flashes over 10 seconds between 9 and 11 seconds is OK If the switch settings are wrong the flash rate will be significantly different For example if 10 flashes takes 8 or 12 seconds then the DIP switch settings may be incorrect Indicator and LED flashing Go to speed sensor test Speed signal OK Diagnostic test OK Switch ignition switch OFF to release cruise from diagnostic mode Computer power test Remove 16 pin plug from computer Turn ingnition switch ON Check 12V on pink wire from fuse pin 10 Check fuse power from brake circuit Check ground earth on black wire pin 8 Connect or relocate ground Computer power OK Page 3 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Speed sensor test Magnet s installed Replace magnet s Magnets spaced evenly if more than one Reposition magnets for even spacing Magnets polarity correct all same pole outwards Reverse incorrect magnet Sensor gap correct Adjust sensor gap Check instructions for correct gap for your installation Typical gap 3mm or 1 8 Sensor wires connected and terminals tight Measure r
10. esistance at sensor 350 600 ohms Ok Sensor resistance OK Replace sensor Remove computer plug from computer Measure resistance at computer plug on pins 6 and 14 Sensor resistance OK g Repair or replace loom Sensor and sensor wires OK Actuator test Turn ignition switch ON turn cruise switch ON Note Most models only require the ignition to be turned on others must have the engine Disconnect four way plug at actuator going to have power to the cruise Measure voltage on red wire on the loom NOT the actuator 12 volts on red wire Use clip lead or piece of hook up wire to reconnect red wire to actuator Use clip leads or piece of hook up wire Tap brown green and yellow wires to ground Valves in actuator should click Valve clicking heard or felt Place hand on actuator Replace actuator valve pack Bad actuator power relay Bad loom g Bad computer Test relay loom computer Bad cruise control switch Page 4 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Start engine NOTE use caution with this test Engine revs will increase RAPIDLY when yellow wire is grounded Ground brown amp green wires Momentarily ground yellow wire Engine RPM should increase until brown or green wire removed then return to idle RPM rises then falls to idle Perform actuator cable test then vacuum test Repeat above but hold rom at about 2000 3000 by holding brown amp gr
11. iode ground black 2 Switch signal yellow black 6 Speed sensor ground black 3 Brake sensor power orange 5 Power to switch orange black 4 Brake light sensor grey View from back of loom plug wire entry side Resistance checks Resistance values at loom computer plug for suspected Control Switch fault check with ignition switch OFF and computer UNPLUGGED from loom Use a speed sensor magnet and place it above OR below the control switch about half way between the front and back of the switch and aligned with the left outside edge of the SET button Hold magnet in this position Touch the ohmmeter probes to the pin numbers indicated SET amp RES Pin 2 switch signal yellow amp pin 5 power to switch orange ohms 0 Q ohms when SET button pressed i 1500 Q ohms when RES button pressed Resistance values at loom computer plug for suspected Actuator throttle servo fault check with ignition switch OFF and computer UNPLUGGED from loom Touch the ohmmeter probes to the pin numbers indicated Pin 12 actuator green amp pin 11 actuator relay red O ohms no continuity Pin 13 actuator yellow amp pin 11 actuator relay red O ohms no continuity Pin 15 actuator brown amp pin 11 actuator relay red O ohms no continuity Pin 12 actuator green amp pin 13 actuator yellow 80 100 Q ohms Pin 12 actuator green amp pin 15 actuator brown 80 100 Q ohms Pin 13 actuator yell
12. ow amp pin 15 actuator brown 80 100 Q ohms Resistance values at loom computer plug for suspected Actuator throttle servo amp CruiseSafe relay fault check with ignition switch ON and computer UNPLUGGED from loom Touch the ohmmeter probes to the pin numbers indicated Pin 12 actuator green amp pin 11 actuator relay red 40 50 Q ohms with brakes released O ohms with brakes applied Pin 13 actuator yellow amp pin 11 actuator relay red 40 50 Q ohms with brakes released i Q ohms with brakes applied Pin 15 actuator brown amp pin 11 actuator relay red 40 50 Q ohms with brakes released Q ohms with brakes applied Page 10 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Resistance values at loom computer plug for suspected ground connection fault check with ignition switch OFF and computer UNPLUGGED from loom Touch the ohmmeter probes to the pin numbers or locations indicated Pin 8 ground amp vehicle frame 0 Q ohms Resistance values at loom computer plug for suspected Speed Sensor fault check with ignition switch OFF and computer UNPLUGGED from loom Touch the ohmmeter probes to the pin numbers indicated Pin 14 sensor active amp pin 6 Sensor sheild 350 600 Q ohms if using supplied speed sensor Unknown if units taps into motor cycle speedo Voltage checks Voltage values at loom computer plug check with ignition ON engine running on some models and cruise control in
13. p switch settings b Check carburettor cable free play c Speed sensor test if sensor installed d Actuator test e Vacuum test f Actuator cable test g CIU test if CIU installed a Adjust gain check dip switch settings b Actuator test c Vacuum test d Actuator cable test e CIU test if CIU installed a Tach sensor test b Brake light switch adjustment c Brake wire test d Actuator test a Actuator test b Vacuum test a Brake light switch faulty b Brake wire test c Actuator test d Actuator cable test a Check carburettor cable free play b CIU test if CIU installed c Actuator cable test d Broken throttle spring or sticking carburettors a Speed sensor test gap too small b Too many magnets installed c Incorrect calibration check dip switch settings a Speed sensor test gap too large Magnet s missing Incorrect calibration check dip switch settings op MotorCycle Cruise Trouble shooting guide 150 MCS590 MOTORCYCLE CRUISE TROUBLE SHOOTING TESTS Cruise control diagnostic test Switch ON bike s kill switch switch ON ignition switch Operate front or rear brake lever Listen feel for operation of relay on wiring loom near computer plug this produces very quiet clicks Relay heard felt clicking each time cruise brakes are applied and released place hand on relay Go to CruiseSafe actuator relay test Go to Brake Wire test Operate front or rear brake lever Listen feel for sol
14. s Adjust brake light switches Go to brake wire test Yes Page 2 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Is the cruise connected to the bikes original clutch switch Skip clutch switch check Operate the clutch lever WARNING The bike may have to be in gear as ofien4he neutral light is linked to the same circuit as the clutch switch The rear wheel must not touch the ground if the engine is running Red LED on computer but not the control switch comes on with clutch operation Indicator and LED flashes clicks heard or felt in actuator Test switch no flashes Go to actuator test no clicks Start engine Press SET and RES keys to raise and lower engine speed Delay can occur during these operations be careful not to over rev engine Use brakes or kill switch to switch off engine if revs are too high Engine speed goes up with SET key down with RES key Go to vacuum test actuator test actuator cable test CIU test Speed sensor signal test can only be performed on the center stand on bikes that have speed signal generated from the rear wheel either from a sensor or from the speedometer sender unit Engage 3rd or 4th gear and release the clutch GENTLY If no center stand is fitted or speed signal comes from the front wheel ride the bike and observe the indicator on the cruise control switch and or LED on computer Increase the wheel speed to about 50 60kph 30 35mph Obs
15. witch on Use hook up wire or clip leads to reconnect red wire Ground all three other brown green amp yellow wires from actuator Cable retracts in under 4 secs Perform actuator test Check for vacuum blockage or faulty vacuum stop valve Page 5 of 12 MotorCycle Cruise Trouble shooting guide 150 MCS590 Actuator Cable test Disconnect cable from throttle or CIU Inspect cable for kinks crushing or bends under 3 radius Cable kinked or bent Replace actuator cable Check that cable slides smoothly with no binding Replace actuator cable Cable OK Brake wire test Ensure brake light works Remove 16 pin plug at computer Measure voltage at orange amp grey brake sensor wires at pins 3 and 4 Orange 12 volts always Check connection of brake wires Check brake light fuse Grey at 12 volts only when brakes on Check connection of brake wires Check brake light fuse Brake sensor wires OK CIU test Only models that don t have the actuator cable connected directly to the carburettors Check movement of hand throttle produces corresponding movement of carburettor throttles Carburettors moving Check for broken cables or CIU for correct assembly or broken internal components incorrect cable spool hole marking see Check operation of throttle heavy or stiff drawing on last page of instruc s Is throttle binding at all during operation Back off adjustment of throttle cables to ensure free play at
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