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Post Info TOPIC: Warning on notching 2000 model A1 ECUs


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Warning on notching 2000 model A1 ECUs


In order to download and/or reprogram the map of a ZX-12 ECU you will need to 'notch' the back of the ECU in order to expose the BDM connector CN3 on the back of the board.

view of notched 21175-1079 ECU

After doing a couple of these I went to notch a 2000 model A1 ECU and got a nasty suprise.

close up of 21175-1065 ECU

view of 21175-1065 A1 ECU

The A1 circuit board completley fills the case and thinking I had room to spare I ended up cutting about a 1/4" into the circuit board on both sides and cutting through about a dozen traces and god knows how many inside, it's a 4 layer board.

Obviously in hindsight I should of realized that there was a reason why the case was 3/4" longer then the circuit board on the newer ECUs. The board was a newer rev and smaller than the original boards the case was designed for. The A1 is the first model ECU and you notice it fills the entire case.

Hopefully someone else will learn from my mistake.

On the bright side the A1 also appears to have the BDM programming connector and hopefully I will be able to repair it to the point where I can at least download its software and map. This is actually a 21175-1065UK version and I was hoping to compare it to the 21175-1069US version.



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Here is an image showing the location of the plug.

a1_position.jpg

It has the same CN3 connector as the newer boards so I'm pretty sure it will be programmable like the others. Of course I won't be able to verify that until I repair the traces I damaged.

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Here is a photo of a successfully notched A1

1069notch.jpg



-- Edited by RidgeRacer at 21:19, 2007-07-09

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For some reason the PDF file with the notching instructions won't open up for me.
Your picture locates the side to side dimension but what is the dimension from the edge of the case to the CL of the 8 pin header? I would like to machine a coin slot on both the top and bottom to allow the header to be soldered in by you. Would that give you enough room to solder the header?
I have a 2000 ZX-12R.

-- Edited by hondo at 08:32, 2008-01-30

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On the 2000 A1 model from the back edge of the case to pin center line is 0.45 inches. The connector is 0.225" wide and 0.825" long. So I would make the slot 0.250 by 0.850 to give a little extra clearance.

If you make a cut that big in the outer plastic shell, top and bottom I could remove the potting and solder in a plug.



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Thank you for the quick reply! I needed an excuse to get the 12 out of storage. The plastic parts are in the basement protected from the cold so pulling the ECM will be a snap. One last question, what is the spacing on the pins? I'm trying to locate a header that will sit higher off of the board so I can repot the board when finished. I seem to get caught out in the rain a lot.

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It uses a very common spacing of 0.1 inch

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Thank you for initiating and maintaining this site.
My 2000 12 is in the garage now along with my other two motorcycles so I pulled the computer and it's as expected, a 21175-1069 with a small label, "Exterior >PBT<"
"Interior >PUR<"
This label is between the edge (with the connectors) and the Denso label. Any clue what this means?
I've just finished 6 consectutive 12h night shifts so I've not had much time to look for taller header connectors but I think I've located a couple. They are called PCB board connectors, new to me but not to you. If I can get a connector with the correct height to extend above the case then I can fill the slots with something after you do your magic. If not, even your connector would allow a little potting something or other to be applied to help protect the board on the connector side. For sure I'm going have you place the connector and do some modification i.e RPM limit and timing on one of the maps and RPM limit on the other map. I want the two map function and a MAD box also. You'll be hearing from me soon, I've already registered on your ordering site.

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The PBT PUR labels are for recycling / disposial and list what materials makeup the case

Polybutylene terephthalate (PBT) is a plastic that is used as an insulator in the electrical and electronics industries. It is a thermoplastic crystalline polymer, and a type of polyester. PBT is resistant to solvents, shrinks very little during forming, is mechanically strong, heat-resistant up to 150C (or 200C with glass-fibre reinforcement) and can be treated with flame retardants to make it noncombustible.
The PUR is PolyURethane

The MAD box is still being tested, (ie I've been busy and kind of forgot about it) I only have the one prototype and I've never actually fully tested it on a real bike. Also I've never resolved the plug issue. The only way to plug it in right now would be to cut off the stock connector and wire in your own.

Also to be clear the rev limit is not map selectable. If you change the revlimit it is for all maps, A/B. But as you want it on both that shouldn't be a problem.


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Hello RidgeRacer,

Some PCB header/socket samples are being shipped to me and if they are not what I had in mind I'll send my computer to you for your header/socket. I can't wait until spring!

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