ECU ASSEMBLY

Assembly

1. Make sure the PCB will fit in the case. Some trimming of the edges may be required. The edge nearest the ECU connector may need trimming to allow the connector to seat properly.
2. Check all the PCB holes are clear. A soldering iron should quickly clear any solder.
3. Solder in the 5 surface mount transistors.
4. Solder in the resistors.
5. Solder in the capacitors - 12 x 0.1uF, 2 x 27pF, 1 x 0.01uF and 2 x 47uF.
6. Solder in the 40 pin IC socket.
7. Solder in the diodes and zener.
8. Solder in the 2 BD139s and BD140 transistor and the LM2940 regulator
9. Solder in the 8Mhz crystal.

Testing

1. Make sure the microprocessor is not in its socket for these initial tests.
2. Apply the negative of a 12V voltage source to the edge of the board ( the PCB track going around the board is 0 volt ).
3. Apply the positive of the 12V to the upper leg of R10 ( the leg that goes to connector 1 ) and check that nothing is getting warm. The voltage drop across R10 should be less than 1 volt.
4. There should be 5V on pins 10,30,32 of the 40pin socket
5. Pin 33 and pin 4 should be 2.5V and pin 3 should be 2.7V.
6. Disconnect the power and connect the RS232 adapter to My16M using the network cable and connect to the PC's COM1 port ( if you need COM2 or other, the ECUController has a configuration dialog that can be used to select the required port). Insert the CPU with pin 1 to the left
7. Start ECUController and apply power to My16M. You should now see ECUController updating.The temperature analogs should be at full scale, the voltage should display correctly. They others will float around 1/2 scale.
8. You should see a 10V square wave on the collector of T5 ( the tacho signal )
9. Complete the assembly by mounting the power transistors.Check the voltage at the lower leg of R28 (near T7). You should see it go to 5V for 2seconds after connecting power. Check that the gates of the 4 FETs(leftmost pin) are all at 0V
10. Now double check your handywork and fit the PCB into the case and connect the ECU to the bike.Set all switches off except SW1. It would be best to have the ECUController or Optimiser connected.We ARE NOT going to try to start the bike yet. Being careful to monitor for smoke or heat, turn on the ignition. You should hear the fuel pump turn for 2 seconds.The tacho my vibrate a little.Check the analogs with the ECUController or Optimiser. They should all be correct and the throttle should be tracked.
11. Well done, at this stage construction is complete. Proceed to the

RS232 Adapter board

C1 - 10uF C2-5 - 1uF U1 - MAX232 The tantalum capacitor is polarized and must be inserted the correct way.