Installation manual

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CCS-100 Cruise Control Installation: 2000 Road Star

December 2, 2010

By Scott Anderson

Introduction

The following is a summary of the information required to install a CCS-100 cruise

control system on a 2000 Yamaha Road Star. This information is provided for reference

only, and is not intended to replace the CCS-100 Installation Manual. If installing this

system on another model year Road Star, consult the appropriate Yamaha Road Star

service manual and verify all electrical connections.

This document is not intended to be a training course on how to install automotive

cruise controls on motorcycles. It is intended to be a supplement to the CCS-100

Installation Manual, for those persons that choose to install the CCS-100 cruise

control system on their motorcycle. Persons using this document, or any part thereof,

must accept full responsibility for their own actions in regard to the installation, and

subsequent operation of the motorcycle with the installed cruise control system.

In providing this information, I am assuming the reader is technically competent to do an

installation such as this, and has a basic understanding of the Yamaha Road Star; such as

removing the fuel tank, 12V wiring, etc. It will be necessary for the installer to fabricate

(or purchase from Murphs') a bracket for the keypad, mount the servo unit, mount the

vacuum canister, make electrical connections, as well as throttle and vacuum

connections.

I suggest you read this entire document, and become thoroughly familiar with the manual

before you proceed. Once you know what you need to do, the CCS-100 is not that

difficult to install. Everything that follows is based on the installation I did on my 2000

Road Star. I spent a lot of time just looking at different ways to mount the components,

and the instructions below should work just fine for the majority of installations.

You are welcome to use any or all of my ideas as you see fit. This is the way I did it on

my 2000 Road Star, and it works well. There are, no doubt, other ways to do the

installation and still end up with a safe and functional cruise control installation.

About the Author: I have worked as a Researcher & Designer of specialized conveyor

systems. I have fabricated specialized conveyor systems from 8 pound to 40 ton

machines. I spent 21 years working in blue print reading CAD designs of systems from

ground up to the fabrication, welding, electrical wiring, fluid hydraulics, pneumatics,

computer software to run the machines, to shipping and installing systems. I did own my

own company working on automotive repair for 8 years. I also work on small engines

from 2 stroke engine to 4 stroke gas engines. Weed eaters, lawn mowers, boat engines,

Summary of content (24 pages)

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CCS-100 Cruise Control Installation: 2000 Road Star December 2, 2010 By Scott Anderson Introduction The following is a summary of the information required to install a CCS-100 cruise control system on a 2000 Yamaha Road Star. This information is provided for reference only, and is not intended to replace the CCS-100 Installation Manual. If installing this system on another model year Road Star, consult the appropriate Yamaha Road Star service manual and verify all electrical connections.
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and 4 stroke engines. I repair and or build computers, cell phones and home appliances. I also have done industrial electrical and electronics work. Currently I am semi retired. I started riding motocross bikes at the age of 14. I do all my repairs to my motorcycles as well as fellow rider’s machines for the past 38 years. I bought my first street bike at the age of 19 and have been riding since then and still do my own repairs as well as fellow rider’s machines.
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Schematic diagram of the CCS-100 cruise control system, based on the installation manual: This is the basic wiring diagram of the system. The VSS wire but it is not needed and the dipswitch is set to off.
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2000 Road Star Wiring Diagram. Installation steps: Print, scan and enlarge wiring diagram. Read the install manual a few times so to know about where you intend to place and or connect your cruise control unit. Remove the gas tank and the side covers. Install the keypad on the left handlebar, and route the wiring down to the left side. Set the DIP switches in the servo unit. Cut off the mounting tab Turn Signal Relay/Relay unit. Install the servo unit to the right side under side cover.
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Connect the short “throttle wire loop” to the servo cable, using the beaded chain. I used 5 links. Connect the cable mounting bracket to the pull side of cables. NOTE: Road Stars use a push pull setup for dual cable routing. Make wiring connections, per the installation manual. Make vacuum connections. Power up the system, make sure it turns on/off from the Control pad and that both brake levers actions read 12V on a volt ohms meter at the Purple wire.
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Control pad Gray wire is for backlighting of the keypad. In a car, you would connect this wire to the instrument lighting dimmer circuit. I just spliced it inline with the inline fuse at Red wire at handle bars. Servo unit magnetic sensor Gray and Black (pair). Cut off extra wire. The black is just a shield wire. So cut it off about 8” back leaving the Gray wire and tape the ends. I hooked up the gray wire to the VSS sensor @ the ignition module. That is the White wire coming from the speed sensor.
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A look from the bottom of the home made bracket and where I bolted it to.
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Front view of switch. The key pad lights are bright so I may put a small ¼ watt resistor inline to deal with the issue. 5. Install the control pad/bracket assembly, and route the control pad wires along the left side down the frame. I have a Batwing Fairing on my Road Star so I already have the convoluted tubing running down the frame already.
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Cut the mounting tab off for the relay’s on right side. Mount the Servo Unit and vacuum canister 1. Remove the bracket from the servo unit 2.
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SW7 ON Selects “coil” as the source of timing pulses Jumper (next to the DIP switches) must be “open” to select manual transmission. Pull the jumper off the header pins, turn it 1/4 turn and reinstall it on just one of the pins. Notes: The manual says to remove the 10-pin connector when changing the DIP switches, but doesn’t say why, so just do it with power off. This should be done before hooking up the Servo unit. Low and Medium sensitivity work quite well. (Medium is the recommended setting) 3.
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4. Mount the vacuum canister sot that the vacuum line is facing toward you.
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5. Mount the servo unit as seen in the left hand side. Re install the right hand side cover. Use cable ties and metal strapping to hold servo. It is a tight fit and it is hard to move without cable ties. The engine bolt needs to be shaved down about ½ inch then put countersink bolt in hole with the metal strapping. The picture shows to use rubber. I used double sided emblem tape so servo would not move. I used a die grinder to recess the bolt head down about 3/8 to ½ inch.
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Vacuum line connections 1. Run the vacuum hose to the intake. If you still have the factory AIS system installed move the check valve to the intake to make the T connections. If not just cap off one end like in my picture. The larger end of check valve goes to the intake. There are a few riders out there that do not use a canister but the speed is not so stable. And for $10.00 it is worth the piece of mined. My test rides held my Road Star right on the exacted speed down hill and up hills.
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Servo Cable Installation: 1. Route the servo cable along the right side. Then under the frame to the left side right before the middle motor mount bracket. Bring it back though to the left side looping over the right side gas tank mount. Then down to the throttle cables. The Roads Stars have a push pull system for the throttle cables. We are going to hook to the pull side of the cables with the attached bracket supplied in the kit.
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Throttle connection 1. First remove the carburetor from the intake. Remove choke knob and fuel lines. Disconnect the heater unit wires and the throttle position sensor wires. Leave the throttle cables on, just loosening the pull cable. I drilled an 11/64” hole just behind the pull cable link for the short wire loop supplied in the kit. Bolt is also in kit.
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2. Connect the beaded chain to the short “throttle wire loop”. Note: Use a scratch awl or small screwdriver to open up the bead chain couplers – they are very tight. Once installed, use pliers to carefully close them. 3. Connect the servo end with the wire loop with 5 beads of chain and the snaps in kit. 4. Reconnect throttle cable to the stock bracket on the top of carb. The throttle barrel from the throttle plate should line up with the pull cable with just a little clearance.
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NOTES: Make sure there is no binding or interference between the throttle wire loop and the throttle cable. The throttle cable guide is only designed for one cable thickness, so it was necessary to move the wire loop past the pull cable barrel end. Test with wide open throttle from handlebars to see if cable follows in line with pull cable. There will be slack in the servo cable so make sure it follows cable guide on carb every time.
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Wiring to the rear fender, Brake light Purple to Yellow. I ran the control pad power supply off the tail lights. I have a Tour-pak on my Road Star with a batwing fairing. I run leds in all the lights but the turning signals. If you do have leds as your stock brake lights you must install a relay. The cruise control circuit can not get a true 12v though an led. Not enough resistance.
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In the newer 2004-2010 Road Stars and Roadliners/Straoliner the brake light is led so you will need a simple mod for that also. Put the Diode and the two resistors in a water tight bottle. Drill holes for wires and seal with silicone. Or do the relay mod. You can also use a relay like this. Final steps: 1. Turn on the ignition key. Check to see that the CCS-100 turns on/off from the control pad. 2.
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3. Be sure all wiring, servo cable, and vacuum lines are secured. Be sure the beaded chain and loop do not rub on any wiring, vacuum lines, etc. 4. Reinstall the fuel tank and side panels 5. Use cable ties on servo cable and loose wires every where there is any loose play. Make sure not to make fast turns in servo cable. If the cable stays in place the better the cruise control response is. Testing the system: Find a convenient stretch of highway.
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Here are a few links you may look over where other model motorcycles have installed the CCS-100 and the Rostra cruise control. Rostra kits are going to be around $100.00 more to install. http://www.paulmilner.com/yamaha/handbuch/Rostra_Electronic_Cruise_Control_Stratol .pdf http://www.linerwiki.com/liner/Audiovox_CCS100_Cruise_Control_Installation.pdf http://www.murphskits.com/catalog/product_info.php?products_id=422 http://gadgetjq.com/electronic_cruise.htm http://www.murphskits.