Nemesis-TCS 'Traction Control System Installation manual KTM
Contents
1. Horizontal coil wiring from bike Disconnect the loom wiring from the rear coil and use the CSW1323 4 cs wiring loom to bridge the gap as Coil H shown below Vertical cod wiin tern bike Connect the 6mm earth connection either to the rear cylinder head or the battery negative Failure to fit a Coil V secure earth link will damage the TCS module and cause the engine to stop Should it ever be necessary to isolate all TCS functions and return the bike to normal operation simply remove these links and re connect the coils back to their original loom connections Copyright Competition Systems Ltd 2010 Competition Systems Ltd UK Tel 0044 0 8707 444666 Fax 0044 0 8707 444888 E mail mail competitionsystems co uk www competitionsystems co uk Installation KTM RC8 single coil AA Author Mick Boasman WIRING IMPORTANT Do not connect any of the three TCS connectors directly to any standard bike loom connectors even if they fit These 3 connectors must only be linked to the blue banded connectors of the wiring we supply Damage to the equipment or bike components may occur if this rule is ignored Inputs and CAN wiring Ensure all cables are not trapped when suspension or steering is moved and that the wire routes chosen do not restrict any control movement of the bike Front speed Connectors G and H The front speed sensor 3 way trian2. Competition Systems Ltd UK Tel 0044 0 8707 444666 Fax 0044 0 8707 444888 E mail mail competitionsystems co uk www competitionsystems co uk Installation KTM RC8 single coil AA Author Mick Boasman NEMESIS TCS Nemesis TCS Traction Control System Installation manual KTM RC8 single coil Type AA UK Tel 08707 444 666 Fax 08707 444 888 mail competitionsystems co uk For several years now a professional and well developed traction control system for motorbikes has only been available to those with larger budgets or a top level superbike team behind them All of this has now changed Copyright Competition Systems Ltd 2010 Competition Systems Ltd UK Tel 0044 0 8707 444666 Fax 0044 0 8707 444888 E mail mail competitionsystems co uk www competitionsystems co uk Installation KTM RC8 single coil AA Author Mick Boasman Kit components Kit nart No TCS KTM RC08 AA Application KTM RC08 single plug version R speed nick un comnonents Part No Checked Rear speed bracket CSD1322 M8 x 20 low head zinc disk bolts Ducati spec Pt No 7070 083 20 CSP1034 Speed sensor 23813030401 M6 x 16 SS Allen dome head screw Speed sensor CSP1019 Traction module components Part No Checked Traction Control Module TCM Carbon panel and 4 x 8mm spacer tubes CSD1310 M5 x 40 zinc cap screw CSP1031 M5 plain washer zinc CSP1032 M5 Nyloc zinc CSP1033 Bobbin Dia 10x15 M5 x12mm C
3. SP1012 M5 Serrated FlangeNut CSP1017 Wirina Part No Checked Coil wiring CSW1323 Inputs and power wiring CSW 1324 Throttle signal quick link red CSP1015 Disnlav module comnonents Part No Checked Otv TC Pod Disnlav module TC Pod TC Pod Spacer round stepped tube CSD1321 TC Pod mount bracket CSD1320 M3 x 8 button head black CSP1018 M6 x 40 S S cap head screw black CSP1025 M6 x 75 zinc cap screw CSP1035 Push button assembly blue green TC Pod CS972 Handlebar spacer 11mmOD x 9mm long 6 5 ID CSD1326 QO Miscelaneous components Part No Checked Printed TCS over view manual manual Nemesis TCS stickers CSP1022 IMPORTANT To be read by ALL installers and owners Terms of use The presence of the Nemesis TCS does not take away the responsibility of the rider to operate the bike correctly within their own abilities the track conditions and the laws of physics The system is designed to achieve greater on track performance by the use of power modulation during wheel slip events but in no way should it be considered possible for the system to recover from every conceivable loss of grip The onus for safety always rests with the rider to stay within his or her own abilities and to ensure that the on bike equipment is programmed setup correctly and an appropriate TC level selected for the skill of the rider the bike and the track conditions This equipment is intended for racing or track day performa
4. e sleeve of the throttle input wire on the TCS loom so that 8mm of inner metal core is exposed Push this into the red cap as seen here on the right with inner core showing Screw this cap and wire into the main body ensuring that metal inner core and wire cores are sandwiched and held securely Shrink sleeving can be put over this quick link if required PC Setup Your TCS module should be loaded with the following maps 118 RC8_1_Sxx_Rxx S19 Sxx Slip map version Rxx revision version Status position offset value 0 30 to 0 40 Refer to WinTC View Data Note The WinTC installation guide can be found in the Nemesis TCS manual Copyright Competition Systems Ltd 2010
5. gt t 2 1 C Copyright Competition Systems Ltd 2010 Competition Systems Ltd UK Tel 0044 0 8707 444666 Fax 0044 0 8707 444888 E mail mail competitionsystems co uk www competitionsystems co uk Installation KTM RC8 single coil AA Author Mick Boasman Display TC Pod Connector J Pit limiter switch input Connector K The pit limiter switch CSP1041 links at point K and may be mounted to any convenient place accessible by the rider We do not however make a specific handlebar mounting kit for the RC8 This item is an optional extra and not supplied as part of the kit Throttle The throttle input is the single wire B of this loom This needs to be attached to the white signal wire multi block connector image 6 located on the right side of the air box using the red quick link provided in the kit as shown in the steps below The quick link is made up of three parts as seen here on the right Using the green section with the slot push it over the orange throttle signal wire of the bike loom until the wire rests at the bottom of the slot The large red centre section must be fitted the correct way around or the link will not work Locate the end with the sharp pointed tip protruding from the end of the outer body and screw this end onto the green section until it rests firmly against the wire The sharp tip will pierce the outer sleeve but not sever the inner core of the wire Strip back th
6. gular connector can be found under the instrument housing This 3 way connector provides the power and ground to the TCS as well as the front speed signal e Disconnect the front speed sensor and bridge the gap using the male and female 3 way connectors of the new wiring CSW 1324 e Use the cable ties we provide to give strain relief to these connections Rear speed Connector A e Route the rear speed sensor along the right side of the swinging arm using the brake hydraulic line as a guide e Use the cable ties provided and ensure this cable cannot be damaged or trapped during suspension movement TCS module Connector 3 Locate the 4 way connector 3 with the blue band on the wiring loom and connect to the 4 way connector on the TCS module TCS module Connector 2 Locate the 8 way connector 2 with the blue band on the wiring loom and connect to the 8 way connector on the TCS module PC communication Connector E All PC communication is achieved via the 4 way connector this connector is live and should be protected from water ingress when not being used Quick shift Connector F Any type of quick shifter with either an active high or active low output can be used Battery
7. mount the rear disc These should be tightened and fitted using the same specifications of the standard bolts e Fit the new speed sensor to the bracket using one of the M6x16 dome head cap screws fit using a non permanent thread lock agent o Note that you may find it easier to remove the rubber O ring from the sensor and push it into the bracket first e Fit the sensor mounting bracket to the rear disk hanger The bracket will locate in the 10mm dia hole and is secured using the remaining M6x16 dome head screw Fit using a non permanent thread lock agent e The sensor gap is fixed and no adjustment is required by the user The design gap is between 1mm and 2 5mm New low profile cap bolt WIRING IMPORTANT Do not connect any of the three TCS connectors directly to any standard bike loom connectors even if they fit These 3 connectors must only be linked to the blue banded connectors of the wiring we supply Damage to the equipment or bike components may occur if this rule is ignored Coil Wiring Locate the wiring loom with yellow identification CSW1323 Connect the 6 way connector with the blue banding to connector 1 of the TCS Module Route the wiring along the right side of the bike following the original wiring route Disconnect the wiring from the Front coil and use the CSW 1323 wiring loom to bridge the gap as shown below
8. n panel beneath it using the 4 thin spacers M5x40 cap screws and nyloc nuts The Image 2 on the right shows the orientation of the carbon plate with the plastic plate removed for clarity e When finished the upper carbon face of the TC module should be uppermost and level with the floor when the bike is resting on its wheels TCS Module orientation should be as seen in the diagram e If necessary to ensure that the module is level after installation use the spare washers we supply in the kit TC Pod Display Fitting e The Display pod is fitted to the left side of the headlight assembly as seen in Image 3 e The mounting assembly uses these parts o M6x 5cap bolt x 1 o M3 x 8mm Button head screw x 2 e Important note The TC Pod supplied as part of the TCS kit is not the same as the standard TC Pod as used on many Ducati bikes Do not attempt to swap parts The push button assembly is mounted on the left side handlebar clutch clamp as seen in image 4 using the spacer and longer screw Copyright Competition Systems Ltd 2010 Top View carbon face d Front of bike Competition Systems Ltd UK Tel 0044 0 8707 444666 Fax 0044 0 8707 444888 E mail mail competitionsystems co uk www competitionsystems co uk Installation KTM RC8 single coil AA Author Mick Boasman Rear Wheel Speed e Your TCS kit comes with a set of 6 new CAP bolts to replace the hexagonal ones used to
9. nce use only and where exhaust emission controls are not applicable By installing and using the Nemesis TCS you automatically indemnify Competition Systems Ltd our suppliers and our authorised dealers from all first party or third party loss or damages Normal components warranty is not affected Copyright Competition Systems Ltd 2010 Competition Systems Ltd UK Tel 0044 0 8707 444666 Fax 0044 0 8707 444888 E mail mail competitionsystems co uk www competitionsystems co uk Installation KTM RC8 single coil AA Author Mick Boasman TC Module Mounting e The TCS module mounts on the underside of the plastic tray pictured in image 7 This tray must be modified by drilling out the 4 corner positions to be clearance on the M5 screws supplied with this kit e The TCS module attaches to the carbon plate using the 3 rubber bobbins we supply in the kit But it is important to fit some of the M5 washers under these bobbins in order to angle the TCS module forward by degrees Refer to Image 2 o Under position 1 add 4 plain washers o Under position 2 add 3 plain washers o Under position 3 add 2 plain washers e Note that these washers can be fitted either side of the bobbin to increase the length When finally installed this should result in the module being horizontal with the ground with the bike resting on the wheels Image 2 is shown without the plastic tray for clarity e Re fit the plastic panel and suspend the new carbo
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