Picking out the pebbles
Projects » 2008 ZX10R Race ECU on 2006 ZX10R
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