2008 ZX10R Race ECU on 2006 ZX10R

Notes on fitting a 2008 ZX10R (E model) Kawasaki Race ECU to a 2006 ZX10R (D model) (and leaving all functions intact for road use).

2006 Kawasaki ZX10R D Model

On hand we have:

- Stock 2006 ZX10R D model
- Kawasaki 2008 ZX10R E model R ECU 21175-0212
- Kawasaki 2008 ZX10R E model Race ECU Interface Box 26031-0240 (for programming above ECU)
- Kawasaki 2008 ZX10R E model Race ECU Sub harness 26031-0700 (for original Meter & Original Main Harness)

We also have a switch we are told is the speed restriction switch, in which event it should be part 27010-004.

Basically this task is to remap the pins on the two connectors to the right of the picture above to allow the 2008 Race ECU to be connected to the 2006 D Model ZX10R stock loom.

Parts compatibility:

Part
 Part 2006 number
 2008 Number  
 Cam Sensor
  0064  21176-0101  
 Water Temp
  1120  21176-1120  
 Inlet Air Temp  2106  21176-0048  
 Inlet Pressure
  0058  21176-0058  
 Ambient pressure
     
 Crank sensor
  59026-0009 0031
 
       
       

Documentation on hand (for wiring diagrams etc):

- 2006/07 ZX10R D Model Service Manual
- 2008 ZX10R E Race Kit Manual
- 2008 ZX10R E Service Manual

2006 ECU Pins orientation:

2008 ECU Pins orientation (note, the 2008 race ECU has gray keyed connector on the left, black on the right):

Because we don't have a 26 pin connector to replace the subharness gray 34 pin connector we will be using the middle 26 pins of the gray 34 pin connector.  This allows the locking tab to still function although we may have to trim off some plastic.. (the alignment key so we connect gray to black type, and also some of the shell).

Race ECU Specific connections (additional to stock functionality) on the Sub harness 26031-0700

Aside from the 2008 RACE ECU connecting to the stock 2008 loom in place of the stock ECU via the Sub harness 26031-0700 , the sub harness also has 3 additional connections.  The 2008 Race kit manual documents 3 additional functions available:

Engine Speed Restrictor:

Is the Gray 2 pin breakout connector (sense wire is R/G to pin 5 of the Gray connector on the ECU side)

The race manual says:

In case of using harness (26031-0698) for the original meter, the head light beam (Hi/Lo)
change switch on the left switch housing “4” functions as a speed limit switch of the
pit-road and passing switch functions as well.
In case of using the kit meter harness (26031-0699), firstly connect the speed limit
switch “4” coupler with the switch (27010-0040).
Make “A” side stamped on the switch means OFF the speed limit and “B” side means
ON the speed limit.

Rev Spike Control (This NOT traction control, dammit):

Is the 2 x Bayonet breakout connectors (sense wire is BR to pin 23 of the Gray connector on the ECU side)

Autoshift Sensor:

Is the BLUE 2 pin breakout connector (sense wire is G/BK to pin 4 of the Gray connector on the ECU side)

The 2006/2007 Kawasaki workshop manual electrical diagrams show incorrect mapping to the ECU however the text is correct, so we have remapped the connections below:

2006 D 34 Pin ECU connector Local/ECU Pin Observed colour Per DFI chapter (text differs from wiring diagrams and appears correct) (italics means I'm not so sure..) Bold means is not connected when using 08 Race ECU 2008 Race ECU pin equivalent Colour of sub harness connection once remapping is complete (for final checking ..)
Top Row  1  - Unused    -
   2  G Sub throttle actuator 2  G
   3  BK/BL Sub throttle actuator  3  BK/BL
   4  W/Y Gear position switch 4  W
   5  BK Crankshaft sensor (-) 30  BK
   6  BL/Y Speed sensor 12  BL/Y
   7  BL Power supply to sensors 7  BL
   8  Y Inlet air temp sensor 8  Y
   9  Y/G Vehicle down sensor 9  Y/G
   10  GY Exhaust butterfly valve sensor    
   11  G/W Atmospheric pressure sensor 11  G/W
   12  - O2 sensor #2 if fitted    -
   13  BR/Y Fuel pump relay 67  BR/Y
   14  W/R Battery monitor 14  W/R
   15  W/BK ECU power supply (from battery) 15  BR/G
   16  R/Y KDU see Note 1 below 16  R/Y
   17  R/BK Gnd for control system 17  BK/Y
Bottom row  18  - Unused    I
   19  Y/BK Subthrottle valve actuator  19  Y/BK
   20  P Subthrottle valve actuator  20  P
   21  LG/BK External comms line (Immobiliser/KDS)    -
   22  R/BL Crankshaft sensor (+) 29  R/BL
   23  - Unused    -
   24  Y/R Camshaft position sensor 13  Y/R
   25  O Water temp sensor 25  O
   26  Y/W Main throttle sensor 26  Y/W
   27  BL/W Subthrottle sensor 27  BL/W
   28  Y/BL Inlet air pressure sensor 28  Y/BL
   29  - O2 sensor #1 if fitted    -
   30  P/BL Radiator fan relay    -
   31  - Unused    -
   32  W/BK ECU power supply (from battery) 32  BR/G
   33  BR Ignition switch 23  R
   34  BR/BK Ground for sensors 34  BR/BL
2006 D 26 Pin ECU connector Local Pin ECU Pin Observed colour Per DFI chapter (differs from wiring diagram) Bold means is not connected when using 08 Race ECU 2008 Race ECU pin equivalent
Colour of sub harness connection once remapping is complete (for final checking ..)
Top Row  1  35  G External comms line (immobiliser/KDS)    -
   2  36  - Immobiliser amplifier if fitted    -
   3  37  BR/R Warning Indicator (FI/Immobiliser) 36  BR/R
   4  38  R/B Air switching valve    -
   5  39  BK/Y Engine gnd 41  BK/Y
   6  40  R/G Starter lockout switch    -
   7  41  W/R Exhaust butterfly valve actuator (-)    -
   8  42  BK/R Starter button 56  BK/BR
   9  43  - Unused    -
   10  44  BL/BK Injector 3 44  BL/BK
   11  45  BK/W Coil 3 66  BK/W
   12  46  BL/R Injector 1 63  BL/R
   13  47  BK Coil 1 49  BK
Bottom row  14   48  LG KDU see Note1 below 33  LG
   15  49  GY Immobiliser (to ignition switch)    -
   16  50  - Immobiliser if fitted    -
   17  51  LB Tacho 35  LB
   18  52  BK/Y Engine Gnd 58  BK/Y
   19  53  G/BK Sidestand switch    -
   20  54  W/BL Exhaust butterfly valve actuator (+)    -
   21  55  P Gnd    -
   22  56  - O2 sensor heater    -
   23  57  BL/Y Injector 4 48  BL/Y
   24  58  BK/O Coil 4 68  O
   25  59  BL Injector 2 (wire should be BL/BK) - Checked the wire and its physically BL 46  BL/G
   26  60  BK/G Coil 2 51  BK/B

Note 1: The wiring diagram for both 2006 & 2008 models show this connector but not labeled (may be part of the Immobiliser / KDU conector (is it 4 or 8 pins?)) pins 16 & 48 above connect to this..  (For the purposes of this exercise, until confirmed, we will assume it is the Immobiliser / KDU as well).

 

Now we can map from the 2008 Race ECU through the Sub harness 26031-0700 to the 2006 Loom to ECU connectors

Note that we will using the Gray Sub loom to stock loom 34 pin connector to

Black connector
 Local Pin ECU Pin
 Subharness  to stock loom connectors pin (confirmed physically) Sub harness 26031-0700 colour confirmed physically (colour in brackets after is colour on 2006 stock loom) Function
 2006 Model ECU Pin  Action  Checked
Top row  1 1  Unused        -  
   2 2  2 G Sub throttle actuator 2  -  ok
   3 3  3 BK/BL Sub throttle actuator 3  -  ok
   4 4  4 W (W/Y) Gear position switch 4  -  ok
   5 5   Unused      -  
   6 6   Unused      -  
   7 7  7 BL Power supply to sensors 7  -  ok
   8 8  8 Y Inlet air temp sensor 8  -  ok
   9 9  9 YG Vehicle down sensor 9  -  ok
   10 10   Unused      -  
   11 11  11 G/W Atmospheric pressure sensor 11  -  ok
   12 12  12 BL/Y Speed sensor 6  Move  ok
   13 13  13 Y/R Camshaft position sensor 24  Move  ok
   14 14  14 W/R Battery monitor 14  -  ok
   15 15  15 BR/G (W/BK) ECU power supply (from battery) 15  -  ok
   16 16  16 R/Y KDU 16  -  ok
   17 17  17 (shared in sub harness) BK/Y (R/BK) Gnd for control system 17  -  ok
Bottom row  18 18  Unused        -  
   19 19  19 Y/BK Subthrottle valve actuator 19  -  ok
   20 20  20 P Subthrottle valve actuator 20  -  ok
   21 21  Unused        -  
   22 22  Unused        -  
   23 23 Joins to ECU-24 via the sub harness R (BR) 2008 calls this 'Power supply to ECU (from ignition switch)' 2006 simply calls it 'Ignition switch' 33  -  
   24 24 24 (shared in sub harness) R   33 Move  ok
   25 25 25 O Water temp sensor 25  -  ok
   26 26 26 Y/W Main throttle sensor 26  -  ok
   27 27 27 BL/W Subthrottle sensor 27  -  ok
   28 28 28 Y/BL Inlet air pressure sensor 28  -  ok
   29 29 29 R/BL Crankshaft sensor (+) 22  Move  ok
   30 30 30 BK Crankshaft sensor (-) 5  Move  ok
   31 31 Unused        -  
   32 32 32 (shared in sub harness) BR/G (W/BK) ECU power supply (from battery) 32  -  ok
   33 33 33 LG KDU
 48  Move  ok
   34 34 34 BR/BL (BR/BK) Ground for sensors 34  -  ok
Gray connector
 Local Pin ECU Pin
 Subharness  to stock loom connectors pin (confirmed physically) Sub harness 26031-0700 colour (confirmed physically) Function
 2006 Model ECU Pin
  Action  Checked
Top row  1 35 35 LB Tacho 51  Move  ok
   2 36 36 BR/R 2008 says 'ECU Communication Line (to Meter Unit)', 2006 says 'Warning Indicator (FI/Immobiliser)' 37  Move  ok
   3 37 Unused        -  
   4 38 Breakout (Blue plug) G/BK Shift sensor    -  
   5 39 Joins to ECU-24 via the sub harness R/G Starter lockout switch    -  
   6 40 Unused        -  
   7 41 41 BK/Y Engine gnd 39  Move  ok
   8 42 Unused        -  
   9 43 Unused        -  
   10 44 44 BL/BK Injector 3 44  Move  ok
   11 45 Unused        -  
   12 46 46 BL/G (BL) Injector 2 59  Move  ok
   13 47 47 O/G Injector 2 (secondary) -  Disconnect  
   14 48 48 BL/Y Injector 4 57  Move  ok
   15 49 49 BK Coil 1 47  Move  ok
   16 50 Unused   Shows on diagrams for both Stock and race 2008 as 'Indicator light' but no physical connection in sub harness and stock 08 manual DFI section text says O2 heater..    -  
   17 51 51 BK/BL (BK/G) Coil 2 60  Move  ok
Bottom row  18 52 Unused        -  
   19 53 Breakout (Interface box) Y      -  
   20 54 Breakout (Interface box) O      -  
   21 55 Joins to ECU-24 via the sub harness R Sidestand switch    -  
   22 56 56 BK/BR (BK/R) Starter button 42  Move  ok
   23 57
 Breakout (Bullet connectors) BR Rev Spike Switch    -  
   24 58 58 BK/Y Engine Gnd 52
  Move  ok
   25 59 Unused        -  
   26 60 Unused        -  
   27 61 61 O/BK Injector 3 (secondary)    Disconnect  
   28 62 Unused        -  
   29 63 63 BL/R Injector 1 46  Move  ok
   30 64 64 O/R Injector 1 (secondary)    Disconnect  
   31 65 65 O/Y Injector 4 (secondary)    Disconnect  
   32 66 66 BK/W Coil 3 45  Move  ok
   33 67 67 BR/Y Fuel pump relay 13  Move  ok
   34 68 68 O (BK/O) Coil 4 58  Move  ok

 

Unbundled before any change:

After completion & rechecked again, 2008 Race ECU connectors on the left with red bundle containing 4 insulated secondary injector connections.  The gray loom connector yet to have its shell etc trimmed down for mating with the stock 26 pin connector.  We will rebundle once we are happy it works correctly.

First run through:

Bike started ok with a little throttle, wouldn't idle. (Expected to be rich as 2008 primary injectors will be smaller.  Also we still had the Power Commander in circuit).

Tacho worked ok, temp displayed ok.

Missing functionality

Exhaust valve:

Kawasaki assume anyone running the race ECU will have no need for an exhaust valve.

Air valve:

As above

Fan switch:

We will need this for road use. Refer here for the solution