Nemesis-TCS 'Traction Control System Installation manual KTM
Contents
1. by a label R1 and should be connected between the central primary coil connector and the loom connector Rear Cylinder e GandH have no label and should be connected between the side mounted secondary coil connector and the loom connector Rear Cylinder Front speed Connectors J and K The front speed sensor 3 way triangular connector can be found under the instrument housing This 3 way connector also provides the power and signal 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 CSW1324 e CSD1341 This small plug in module must be fitted at all times to connector L It acts as a signal dividor allowing a single front soeed sensor to drive both the TCS and the standard dashboard Without this module neither the TCS nor the standard dash will read the front speed Speed connectors Copyright Bike Sport Developments Ltd 2012 Bike Sport Devel ts Ltd UK Te 0044 0 327 263942 aah A A E Bike Sport Installation TCS_4C KTM RC8R Twin Coil AA v02 Developments Author Mick Boasman Rear speed Connector Q 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 Wiring Battery connections R This vital con2. 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 Copyright Bike Sport Developments Ltd 2012 Bike Sport Devel ts Ltd UK Te 0044 0 327 263942 ae eE A E Bike Sport Installation TCS_4C KTM RC8R Twin Coil AA v02 Developments Author Mick Boasman Quick shift Connector S Any type of quick shifter with either an active high or active low output can be used Refer to the WinTc manual for setup of this input a 3 fo 2 1 Battery 1 7 PC communication Connector T 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 Display TC Pod Connector M Connect this 8 way directly to the TC Pod display unit Pit limiter switch input Connector C The pit limiter switch CSP1041 links at point N 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 PC Setup Your TCS module should be loaded with the following bike BIKE RC8R_TCOIL BIKE TYRE T
3. 378 CSD1416 CSP1031 CSP1032 CSP1033 CSD1323 CSP1046 CSP1051 CSF1051 CSF1045 Part No CSW1415 CSP1043 CSP1015 TC Pod CSD1321 CSD1320 CSP1018 CSP1016 CSP1035 CS972 CSD1326 Part No CSP1021 CSP1022 Copyright Bike Sport Developments Ltd 2012 Checked Checked Bike Sport Developments Ltd UK Tel 0044 0 1327 263942 mail bikesportdevelopments co uk Bike Spor t C Developments Installation TCS_4C KTM RC8R Twin Coil AA v02 Author Mick Boasman TC Module Mounting CSF 1045 M4x8 Screw Y CSF 1050 Spring washer CSF 1051 a M4 Nyl ae Nle ST CSP 1033 i lt M5 Nyloc nut CSF 1052 Me CSP1032 M5 plain washer TH Nyloc nu Plain washer CSP 1046 10x17 rubber mount CSP 1051 The TCS module mounts on the underside of the plastic tray pictured in image 1 This tray must be modified by drilling out the 4 corner positions to be clearance on the M5 screws supplied with this kit The TCS module attaches to the aluminium plate using the 2 short male male rubber mounts at the front and the two female female rubber mounts at the rear When installed correctly the module should rest horizontally as see in these images Because the module can be physically installed either way around It is vitally important that the drawings and images are analysed to ensure you fit the module in the correct orientation Re fit the plastic panel and suspend the new aluminium panel beneath it using the 8m
4. Bike Sport Devel ts Ltd UK Te 0044 0 327 263942 aie e A E Bike Sport Installation TCS_4C KTM RC8R Twin Coil AA v02 Developments Author Mick Boasman NEMO CS Nemesis TCS Traction Control System Installation manual KTM RC8R twin coil Suitable for standard and race seat 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 performance 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 Bike Sport Developments Ltd 2012 Bike S
5. he 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 Low profile cap bolts Copyright Bike Sport Developments Ltd 2012 Bike Sport Developments Ltd UK Tel 0044 0 1327 263942 mail bikesportdevelopments co uk Bike Spor t C Installation TCS 4C KTM RC8R Twin Coil AA v02 Develop ments Author Mick Boasman Wiring Disconnect and remove the battery Then route the wiring loom starting from the back of the bike and along the left side as shown in the diagram below Now pass the connections for front cylinder coils A B C D rear soeed Q and throttle link P over to the right side of the bike just in front of the battery ONIN e Bla E E or gt s C A 8 _ _ Ignition coils The front coils A B C D are split into 2 groups e Aand B are identified by a label F1 and should be connected between the central primary coil connector and the loom connector Front Cylinder e Cand D have no label and should be connected between the side mounted secondary coil connector and the loom connector Front Cylinder The rear coils E F G H are also split into 2 groups e E and F are identified
6. m long spacers M5x40 cap screws and nyloc nuts If necessary to ensure that the module is level after installation use the spare M5 washers we supply in the kit SP1031 M5 x 40 a SP 1032 M5 plain washer pe eae Mbdule to be HORIZONTAL Rubber mount when installed CSF 1052 Plain washer CSF 1050 Spring washer a CSF 1051 iD Pa M4x8 Screw M4 Nyloc EEE Copyright Bike Sport Developments Ltd 2012 Bike Sport Developments Ltd UK Tel 0044 0 1327 263942 mail bikesportdevelopments co uk Bike Spor CA Installation TCS_4C KTM RC8R Twin Coil AA v02 Developments Author Mick Boasman 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 75 cap bolt x 1 o M3 x 8mm Button head screw x 2 m The push button assembly is Image 4 s i E mounted on the left side handlebar clutch clamp as seen in image 4 using the spacer and longer screw Rear Wheel Speed i e Your TCS kit comes with a set of 5 new CAP bolts to replace the hexagonal ones used to 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 t
7. nection R must be connected directly to the battery negative connector not to the engine block or any other ground source IMPORTANT Failure to fit the ground securely can lead to misfire engine not starting TCS module damage This is the main power ground for the coil system Wiring TCS module and ground Connect the wiring loom to the TCS module at connector X It is vitally important that the small ground wire with the 4mm eye W be connected securely to the M4 stud using the M4 Nyloc nut Without this the module or coils could be damaged as well as TCS not functioning correctly Throttle B 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 on the next page 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 the sleeve
8. o suit your installation CONFIG TCS _4C Base 35 01 CONFIG Status Position offset value Stronger 0 21 to 0 32 Refer to WinTC View Data Normal 0 32 to 0 37 Refer to WinTC View Data Weaker 0 37 to 0 47 Refer to WinTC View Data Note The WinTC installation guide can be found in the manual Win TC 4C manual_v2 05_a pdf Copyright Bike Sport Developments Ltd 2012 Bike Sport Devel ts Ltd UK Tel 0044 0 1 327 263942 aiid aesd ao uneeiad Bike Sport Installation TCS_4C KTM RC8R Twin Coil AA v02 Developments Author Mick Boasman Copyright Bike Sport Developments Ltd 2012
9. port Developments Ltd UK Tel 0044 0 1327 263942 mail bikesportdevelopments co uk Bike Spor t C Developments Installation TCS _4C KTM RC8R Twin Coil AA v02 Author Mick Boasman Kit part No TCS 4C KTM_RC8R TCOIL_AA Application KTM RC8R Twin coil version 2010 onwards standard and race seat configuration R speed pick up components Part No Checked Qty Rear speed bracket M8 x 20 low head zinc disk bolts Ducati spec Pt No 7070 083 20 Speed sensor M6 x 16 SS Allen dome head screw Speed sensor Traction module components Part No Checked Qty Traction Control Module 4c TCS 4C Horizontal back panel TCS mounting panel M5 x 40 zinc cap screw M5 plain washer zinc M5 Nyloc zinc Upper spacers D 8 ID 5 2 L 8 Bobbin Dia 10x17 M4 female Small bobbin 10mm dia 8mm long M4 male M4 Nyloc Nut M4 x 8 SS button head Allen screw Opto coupler module CSD1341 Throttel signal quick link red Display module components Part No Checked Qty TC Pod Display module TC Pod Spacer round stepped tube TC Pod mount bracket M3 x 8 button head black M6 x 35 s s cap head screw black M6 x 75 zinc cap screw Push button assembly blue green TC Pod Handlebar spacer 11mmOD x 9mm long 6 5 ID Miscelaneous components Cable ties 200mm x 4mm Printed TCS manual Printed TCS 4C KTM_RC8R TCOIL_AA manual Nemesis TCS stickers CSD1322 CSP1034 23813030401 CSP1019 CSP1048 CSD1
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