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Post Info TOPIC: HOW-TO modify (Notch) your ECU


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HOW-TO modify (Notch) your ECU


NOTE: THIS FIRST POST DESCRIBES THE OLDER METHOD THAT CUTS A BIG CHUNK OUT OF THE ECU. SCROLL DOWN FOR THE NEWER LESS INSTRUSIVE METHOD.

This document covers the basics of notching your ECU.

ECU_notch.pdf

The part about using the dremel brushes is a little vague but its kind of hard to describe. Maybe the next one I do I'll shoot some video.

Dremel brush

I find the 'cup' brushes work best.



-- Edited by RidgeRacer on Sunday 22nd of July 2012 05:00:35 PM

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I updated the document to include info on installing the connector.

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You might want to check out this thread too.

http://www.activeboard.com/forum.spark?forumID=99460&p=3&topicID=15162064

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Hello to all, these threads are the inspiration I need to bring my Red 2000 12 out of storage. Unfortunately, the link doesn't work for the PDF file. I keep getting, "the webpage has declined to show this webpage". I also am logged into Bikeland.org at the same time.
Help!

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Here is a drawing that details the location of the BDM port on the various 16bit ECU models. You can use it to cut a slot over the connector or as a guide to cut the larger notch.

ECU slot dimensions





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More info on 'slotting' as opposed to notching an ecu


Since we have exact measurements of where the plug is http://www.bikeland.info/downloads/ecu/ECU_BDM_SLOT_001.pdf

You can do a less invasive slot as opposed to a notch.

topslot640.jpg

botslot640.jpg

If your just going to do a one time rev limit increase then I suggest just doing the bottom slot and temporarily solder the cable to the plug pads, flash it, then remove the wires and epoxy it back up. It is a lot quicker than cleaning out the board and the solder holes and installing a plug.

I made the slot with a rotary 3/8" cutting bit for a dremel tool and a small wire brush bit.

notch01.jpg

Calipers make a good combo measuring tool and scratch awl.


notch02.jpg

Btw I add 0.125 to the 'C' dimension in the drawing to get a center line instead of an edge line


notch03.jpg

Here are the bits


notch04.jpg

I have a piece of wood bolted to the drill press table to act as a fence/guide so I can slide the ECU back and forth under the bit and get a nice straight line.


notch05.jpg

Now just slowly lower the bit as you slide the ECU back and forth. The two edge lines should go to mid bit on each side


notch06.jpg

Once you have cut through the hard shell. Switch to the wire brush and go after the chewy center. There are no components you need to worry about under the brush but don't go crazy as you could wear away the copper traces. Slow and Steady wins the race as they say.



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