MCCruise control revisited

Aprilia Caponord ETV1000 Rally-Raid MCCruise CIU throttle servo cablesWhile the Caponord was stripped for the vacuum check-valve replacement, I decided to get my act in gear and finally, once and for all, unequivocally ….. Sort out the MCCruise control/throttle cables. Last year I relocated the CIU (Cable Interface Unit) to the left hand side of the throttle body. This had pros and cons ……….. The upside was a lighter feel on the throttle grip, the downside, the Servo/CIU and CIU/Throttle body cables were overly long and the Servo cable fed into the CIU from the wrong side. However, the cruise was working perfectly and so it became one of those ‘mañana’ jobs!

Well today is that tomorrow! First I jotted down a list of what had to be done:

Aprilia Caponord ETV1000 Rally-Raid MCCruise CIU cable interface unit1. Make a spacer to fit onto the side of the CIU. This is to move the throttle cable adjuster further out and make the inner cable a better fit on the spool.
2. Drill new cable holes in the CIU so it can be rotated 180° so the Servo cable enters from the rear not the front as is the current arrangement.
3. Shorten the CIU/Throttle cable while allowing for the new spacer at the CIU – 350mm down to 190mm.
4. Shorten the 1,150mm Servo cable to a more reasonable 750mm!

I have to say here and now that I do like learning new skills or adapting old ones to suit a new task. I also have to admit that in a good few years on this Earth, I’ve never made up or adjusted Aprilia Caponord ETV1000 Rally-Raid throttle cablethe length of clutch/choke/throttle cables before! So time to adapt the electronics soldering skills and brush up on required technique courtesy of the Internet. Now I’m not going to bore you to tears telling you how to do it – there is tons of advice on various websites/YouTube. Suffice to say, sort out the duff advice from the good, have the right equipment to hand and practice, practice, practice  …… do the job once and do it right! All the cable bits and pieces I needed came from Venhill in the UK.

By late afternoon everything was buttoned up and the cruise control recalibrated after the throttle bodies were rebalanced, fault codes cleared and TPS reset via TuneECU. As the sun faded behind the hills I cracked open a cold beer happy with how the day played out …. Time then to put the tools away and get back to revising for the next Amateur Radio Exam!

Aprilia Caponord ETV1000 Rally-Raid MCCruise controlThe MCCruise has been installed for approx. 25,000 miles and worked perfectly throughout. The CIU was relocated because the initial location proved to be problematic – causing slight binding of the throttle cable. This meant that the cables supplied in the kit (as specified by me) were now the wrong length and the orientation of cable entry into the CIU was wrong.This is not the fault of MCCruise, what they sent is what I asked for! Should anyone else wish to go down this route I will of course be glad to provide notes/measurements etc so a kit will be a simple bolt-on job.

Stuff …. 6 months and 12 months on

Aprilia Caponord ETV1000 Rally-Raid dashboard - new right-hand indicator repeater!A couple of anniversaries this week ….. firstly the dashboard. Yes a full 12 months since it was finished and put back into the Capo for the last time, resplendent with its new inlay to complement the electronic changes. The auto-dimming back lighting and split indicator repeaters have been absolute winners – I couldn’t go back to a standard board again without missing them. Moving the side-stand and low-fuel lights toAprilia Caponord ETV1000 & Rally-Raid Voltmeter and re-located side-stand light on dashboard accommodate the twin indicator repeaters has had no impact, positive or negative. The voltmeter has been a different kettle of fish …. generally unused as the Sparkbight battery monitor handles voltage feedback when riding around – however it has proved a real benefit during start-up when the dashboard goes through its self-test phase. Now it’s become second nature to eye-ball the tacho needle to see what the battery voltage is pre-start. >12.6v and I know I should get a good kick from the battery!

Aprilia Caponord ETV1000 & Rally-Raid MCCruise controlThe second anniversary, although shorter at 6 months and a tad over 11K miles, is the MCCruise cruise control. After a rushed install (not clever) I knew I had a heavier throttle than pre-installation ….. this was purely down to throttle cable routing and nothing to do with the cruise control itself. It simply didn’t like being re-routed behind the radiator, so I gave up and relocated the CIU (cable interface unit) to a new location by the throttle bodies. Now everything works fine – a light throttle and a happy cruise control. It’s been 100% Aprilia Caponord ETV1000 & Rally-Raid New MCCruise CIU locationreliable and functional. As a demonstration of its finesse I ran the bike in 1st gear at 25mph and let the cruise control take over the (100 horsepower!) throttle – all I can say is WOW! I would never have believed that the system could have the sensitivity to operate the throttle with such precision, but it did – up hill, down dale – never an ounce of jerkiness. Ok I admit no one wants to ride around in 1st gear …. but as an experiment, it proved to me that MCCruise have indeed developed an absolutely fantastic piece of kit.

Where the hell did July go!

Aprilia Caponord ETV1000 Rally-Raid. Basking in the Bologna sunshine!Crikey time flies. It seems an age since ACIM and all the stuff that happened before and after that great weekend, so I’ll start off the week before ACIM – the great cruise control saga. On the 3rd July TNT delivered the package to customs in Ciampino (Rome) Airport – a full week before ACIM, unfortunately it was from here on I became embroiled in a constant round of emails and phone calls in an effort to get the kit cleared to complete its journey. On the Thursday 10th (day before) ACIM it looked like I might be able to collect it from the local TNT depot on the way up …. ‘call us after 9am’ I did ….. Customs still had issues, call again on Monday. So that was that, no kit fitted or available to show. Frankly I was fed up to the back teeth with the whole thing and looked forward to a stress free weekend to unwind!

ACIM 2014 San Marino 11th-13th July

Aprilia Caponord ETV1000 Rally-Raid. ACIM San Marino - Saturday ride outWhat a great weekend, new faces, names to faces and names who’s threads/posts I’ve read for years – a bit of hero worship going on here! A 560 mile round trip that shook the Capo down nicely for the big trip a few days later – with a very enjoyable spirited ride back to the hotel on Saturday evening with two Capo riders across some stunning scenery……we had a blast, thanks guys!

Other than that, I’ll let Jan fill you in with more details and pics from her website – Janet’s Edublog and end by saying a big thanks to the organisers for a fantastic weekend and we look forward to meeting up with you all again soon.

MCCruise control

Aprilia Caponord ETV1000 Rally-Raid. MCCruise goodies!!!After ACIM, with the Capo tucked up in the barn on Sunday night, I could focus back on the cruise control and my impending trip. Time was short … too short. Either the cruise control had to be cleared by customs on Monday/Tuesday or sent back to Australia – it was that simple. If the window of opportunity was missed, then frankly the cruise control was a waste of time, effort and money as I’d have to travel and hope my wrist held out. Not only that but I’d be away for the next 14 days!

Aprilia Caponord ETV1000 Rally-Raid. MCCruise - ready for actionIn the end, at 10am on Tuesday, I stood at the TNT depot (Chieti Scallo) and marvelled as the sun glinted off the packing tape of a big brown box full of goodies! We whizzed home in double-time and the spannering started in earnest ……

….. by Wednesday afternoon the kit was fitted, calibrated and given its first brief test – and worked like a charm! Now I was out of time, bags were packed, Capo loaded and refuelled and at midnight I dropped onto the A14 North and the cruise was engaged for the first mile of many – and it performed faultlessly throughout.

Transcontinental run

Aprilia Caponord ETV1000 Rally-Raid - 60,000 miles and countingThe next 25hrs took me door-to-door and the Capo gained another 1,350 miles under its belt. The cruise had been engaged for well over a 1,000 of those miles (night-time motorways) and the odometer slid over to 60,000 miles on the M25/M40 slip road, a half hour short of Oxford. The next 13 days were a blur of activity with the Capo grabbing an MOT somewhere along the way ….. And before I knew it, the Capo and I were heading back to Dover again with panniers groaning with tea-bags, cheddar cheese and bacon!

The return run was a real mix of (summer?) weather, dense fog in France, rain and sleet in Aprilia Caponord ETV1000 Rally-Raid. 2013-14 quite a busy year!Switzerland and 36C sunshine in Italy! Once again the Capo did what it does best, kept on running faultlessly mile after mile and so finally, at 1am on Monday 4th August we rolled into the barn with the odometer now at 61,860 – just 277 miles short of the magic 62,137 ………. Or 100,000Km to be precise!

As the sidestand took the weight from my aching knees and I eventually convinced my right leg to ease its way over the saddle for the last time, I saw Jan in the red glow of the tail-light all warm smile and a cold beer! Now that’s a way to be welcomed home …….. 😀

mccruise ……. active electronic motorcycle cruise control Pt1.

MCCruise cruise controlLet me start by saying that as of now, the cruise control project I’ve been working on has been put on hold indefinitely ………. why?

A couple of weeks ago I contacted MCCruise in Australia about buying a couple of parts to make my own cruise control install go a little easier – off the shelf stuff, not impossible to do myself, but just easier to purchase rather than make. After a lengthy phone call with Tony Guymer, I was convinced to take an in-depth look at the new electric servo kit* with the view to fitting it to the Capo. Unfortunately, of the current 120+ kits they make, none are for Aprilia. I’d have to start with a universal kit.

Now I’ll say loud and clear, here and now …… I’m not keen on the word ‘universal’. So the idea of a universal kit just doesn’t do it for me at all and that goes for a cruise control. Maybe it’s just me, but I hate the one-size-fits-all approach to anything, they never quite look right, not factory-fit enough for me I guess. No, it has to be a bespoke kit to fit the Capo and this is where Tony eventually sold me on the idea.

Aprilia Caponord ETV1000 Rally-Raid. Mock parts and mounts tested for fit, in this case the 'CIU' that connects the throttles.Tony suggested that if I were to get some data from the Capo – measurements, connector types and locations, wiring routes and mounting places for the main units, then between us we could map out a bespoke fitment kit, a kit as close to plug’n play as is possible. Now I like that idea and being able to get involved is the icing on the techie cake for me!

So last week the Capo was stripped …… dozens of photographs, pages of notes and CAD plans for mounting brackets were compiled and sent to the MCCruise in-tray. After a few quick techie emails back and forth, Tony gave the green light on the kit and as you read this it should be working its way across the planet to little old me!  😀

I just hope that after all this time, effort and expense my wobbly-wrist appreciates it! 😉

At the end of the day, they need to sell 10+ kits for it to be viable for them, so to offer a helping hand I’m hoping to have something to show at ACIM in a few weeks time and I’ll also stick a few flyers on the bike when its parked up to nudge a bit of interest.

*Tech details in Pt2. / **Fitment details in Pt2. as well, kind of a Pt2+ I suppose! 

That’ll teach me!

Cruise servo in place at the back of the tool trayHi all ….. a quick post about the cruise control and a word of caution!

I finally got the cruise control servo unit mounted into the tool-tray of the Capo today. A relatively straight forward job, requiring only a minor rework of one of the mounting lugs, a new bracket fabricating and a couple of holes drilled in the under-tray.

The old throttle cable was removed from the unit and a new 6mm Teflon lined sheath fitted ready to run forward to the throttle bodies. It fits a treat down the side of the two 30A fuses and there’s already a cut-out in the undertray for it to run through, talk about made for the job! I’ll refit the old in-line adjuster and look at routing it along the engine/throttle bodies next week. So far so good!!! 😀

And so everything had gone beautifully, with a final firm slap the rear seat was locked in place …………. Only to realise that the key would no longer release it! Yes the dreaded can’t-remove-the-rear-seat syndrome. My fault entirely, as I should have checked the cable-outer was secure at the latch when I put the luggage rack/deck back in place. So here for your info is how to sort out what seems a very daunting situation to be in. Others may have a different technique, but this one worked for me.

Firstly stop twisting the key harder and harder, while bashing the seat in a vein hope it will pop off ….. it won’t ….. The noise you can hear when you turn the key is simply the cable outer and spring moving – NOT the latch.

Secondly, remove the rear deck bolts (x4). Of course you may have to remove a topbox and associated mounting plate first – no one said it was going to be easy! Now grip the deck just above the rear light and lift, at the same time slide something like a ½” drive 12” extension into the gap to hold the deck up. You’ll need to get the extension right the way in, enough to expose the latch mechanism. With the mechanism visible, slide a flat bar or long screwdriver in and gently push on the tab where the cable end is visible – from the rear of the bike, push to the left. And you should hear a satisfying click as the seat pops up. Reseat the cable-outer, reassemble the bike and sink a cold beer, you’ve earned it!

What a muppet …. anyway, I hope you’ve learned a little something from my foolishness and don’t make the same mistake!

……. now to connect the servo unit to the throttles.

Finger on the pulse

Aprilia Caponord ETV1000 Rally-Raid. Speedometer pulse from the rear-wheel sensorWhile the wrist is healing nicely on light-duties and (thankfully) out of the heavy and restrictive cast, I’ve had a chance to play with the idea of an active cruise control for the Capo. An active system will adjust the throttle automatically to maintain a given speed even as the road rises and falls unlike a passive system which is nothing more than some form of throttle locking mechanism.

Arduino cruise control sketchThe system I’m thinking about will, when all parameters are met (speed, revs etc) lock onto the chosen speed when the ‘Set’ button is pressed. The microcontroller will then look at the error between the chosen speed and actual speed and adjust the throttle as neccessary to try and maintain the error at zero – this is done using PID (proportional-integral-derivative) in the controller. If cruise is stopped (operation of brake or clutch) or the PID error goes beyond a pre-determined maximum (high gear on a steep hill for example) the requested speed is stored and can be re-activated by pressing the ‘Res’ume button. And while in cruise, the speed can be adjusted in 1Kmh increments by using the same two buttons, now working as ‘Acc’elerate and ‘Dec’elerate. That’s the theory anyway!

Aprilia Caponord ETV1000 Rally-Raid. Opto-isolated and cleaned Speedometer input signalInputs

  • Power – 12v on/off switch
  • ‘Set/Acc’ &Resume/Dec’ buttons – 12v
  • Front and rear brake light switches – 12v
  • Clutch lever switch – 12v
  • Speedometer signal from the dashboard (output on pin 14 of the 16-pin connector) -12v square wave 85% duty cycle frequency modulated
  • Tachometer signal -12v square wave 50% duty cycle frequency modulated.

Honda GL1800 Cruise ServoOutputs

  • Two colour LED for power, cruise engaged & error codes – 5v
  • Motor drive signal – 5v PWM to motor control board.

To date the inputs and safety stuff has been written and from the tacho/speedo signals it’s calculating what gear the bike is in pretty quickly, but I’m sure it can be speeded up …… I just need to learn more programming! The operating parameters I’ve decided on are:

  • Cruise enabled between 50Kmh and 160Kmh (30mph – 100mph)
  • Cruise enabled between 2,750rpm and 6,000rpm but might change the lower limit to 3,250rpm in 6th gear
  • Cruise enabled in 4th, 5th and 6th gears only.

At the end of the day, I just want a system that will give my old worn out wrist a rest at motorway speeds on the run between Italy and the UK, taking into account the (very!) variable speed limits and ascents/decents especially through Switzerland. If it can do that I’ll be a very happy bunny indeed.

Of course this is all well and good, but I’ve got to get all the bits talking to each other first and make it robust enough for long-term and safe use on a motorbike ….. the problem is that in amongst all this enthusiasm my wrist still has a way of letting me know who’s really in control while swanning around on light duties!