Audiovox CCS-100 Cruise Control Installation - Kawasaki Versys Forum
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post #1 of 23 (permalink) Old 12-31-2018, 07:10 PM Thread Starter
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Audiovox CCS-100 Cruise Control Installation

I guess the first statement I should make is this disclaimer:

I will not be responsible if you crash because your throttle sticks open and you dont hit the kill switch in time.

I felt the need for an Electronic cruise control on my2015 Versys 1000.

This installation turned out to be a bigger job than originally planned because of my desire to hide the servo cable (from the actuator to the throttle). My solution was to fabricate an assembly with a precision ball bearing sourced from one of my scrap boxes. This bearing was originally a carriage bearing in a Craftsman radial arm saw. The purpose of the bearing assembly is to change the direction of the pulling force from horizontal (left to right) to vertical (straight down).

The largest component of the cruise kit is the servo module. The two most obvious places to mount it seemed to be under the seat or under the fairing on the left side of the fuel tank beside the rectifier / regulator. I chose the latter because I have used up much of the space under the seat with relays, wiring, and the compressor for a Stebel Air Horn. The other bulky component is the vacuum reservoir which I mounted on the opposite side of the tank near the coolant reservoir bottle.

The next thing I to do was determine how to make the connection to the throttle. I knew from previous installations that connecting directly to the throttle bellcrank is not a good idea (not enough mechanical advantage). I drilled and tapped 2 tiny holes for 4-40 threads in the tab of the throttle and fabricated a small arm about inch long to provide some added leverage to rotate the throttle shaft. There is a beaded chain connector in the cruise parts kit that attaches to the end of this arm via small hole (about 1/8 inch). The pull direction is straight down.

At this point I needed to decide how to route the servo cable and where to position the end of the cable to pull on the beaded chain. My first version was a simple 90 degree bracket to position the end of the cable directly under the throttle bellcrank arm. This bracket attached to the frame using a long 10mm bolt (about 50-60mm) to replace the original bolt that is 35mm long (I also needed to run a tap through the hole to thread the last 1 or 2 mm since the original bolt hole was not threaded all the way thru). This method worked ok but it left a lot of exposed servo cable. I didnt take any pictures at this point because I was not satisfied with the appearance (exposed servo cable).

The only way I could figure out to hide the servo cable was to fabricate a pulley that would allow the beaded chain to change direction by 90 degrees. I did this by making a 2 piece assembly that bolts in under the throttle bellcrank. The first piece is a simple L shaped bracket that attaches to the end of the before mentioned 10mm x 50 mm bolt. The second piece has the large grooved bearing (as described above) and a hole for the end of the servo cable to be attached and adjusted for ball chain slack. This allows all components to be completely hidden when the covers are put back on. The attached pictures should make this more clear (I hope). The slack in the ball chain is a critical adjustment.

The cruise control can use either a magnetic pickup (magnets and coil) at the rear wheel or engine RPM from a tach signal or coil wire. I tested it with a coil wire attachment to the #1 coil and it functioned properly but I decided to use the speed sensor at the rear wheel (personal preference, actual speed vs engine RPM). I also had several of the necessary magnets on hand (leftover from a McCruise installation on my FJR1300). 2 of the tiny magnets are inserted in brake rotor bolt heads 180 degrees apart.

The down side to using the magnetic coil as the speed sensor is that you loose the automatic over-rev protection provided by the RPM sensor. I got around that by adding a clutch switch and relay that will kill the cruise instantly, similar to touching front or rear brake levers.

Since the Versys 1k has a LED brake light a relay needs to be added to simulate the filament of an incandescent brake lamp bulb. This circuit (the purple wire in the cruise wiring harness) requires a ground for the cruise to operate. I used normally closed contacts of the 2 added relays (clutch and brake) in series to ground for this safety disengagement circuit.

I chose not to use the included CCS-100 control panel because it is hard to mount it cleanly and is awkward to use the switches (also not waterproof). A simple momentary toggle switch (SPDT) is all that is needed for set/dec and res/acc. This switch is mounted inside the kill switch housing. The cruise on/off is accomplished with a mini toggle switch mounted to the right of the instruments.

One last thing to stress is to be certain that there is no possibility for the beads to become tangled or stuck on any nearby hardware when the throttle is being opened manually (not under servo control). The design of my pulley assembly prevents this from happening.

Pictures to follow soon (I hope)

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #2 of 23 (permalink) Old 12-31-2018, 07:15 PM Thread Starter
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Control Switch


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #3 of 23 (permalink) Old 12-31-2018, 07:17 PM Thread Starter
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Audiovox Servo Location


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #4 of 23 (permalink) Old 12-31-2018, 07:18 PM Thread Starter
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Magnetic Pickup at Rear Wheel


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #5 of 23 (permalink) Old 12-31-2018, 07:20 PM Thread Starter
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Pulley Assembly connected to Servo Cable


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #6 of 23 (permalink) Old 12-31-2018, 07:22 PM Thread Starter
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Pulley Assembly another view


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #7 of 23 (permalink) Old 12-31-2018, 07:24 PM Thread Starter
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Servo Cable fully extended (before connection)



Fully Assembled Pulley and Chain ready to ride

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control

Last edited by onewizard; 01-01-2019 at 05:38 PM.
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post #8 of 23 (permalink) Old 12-31-2018, 07:26 PM Thread Starter
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Cruise on/off Switch and heated grip switch


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #9 of 23 (permalink) Old 12-31-2018, 07:28 PM Thread Starter
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Mounting bolt for Pulley Assembly (longer than stock)


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #10 of 23 (permalink) Old 12-31-2018, 08:29 PM Thread Starter
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Fully Assembled Pulley and Chain ready to ride


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control

Last edited by onewizard; 01-01-2019 at 05:37 PM.
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post #11 of 23 (permalink) Old 12-31-2018, 08:34 PM
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Terrific write up Tom! So how well does it work?
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post #12 of 23 (permalink) Old 12-31-2018, 09:52 PM Thread Starter
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.

Quote:
Originally Posted by Buffalo_Bob View Post
Terrific write up Tom! So how well does it work?
The cruise has operated flawlessly for the last few months. I don't expect any issues. The Audiovox cruise has always been rock solid for me!

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #13 of 23 (permalink) Old 01-01-2019, 09:32 AM
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Thanks for posting

I used the garbage bin to extract copies of your post then combine ; https://www.kawasakiversys.com/forum...ccs-100-a.html
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post #14 of 23 (permalink) Old 01-01-2019, 10:15 AM Thread Starter
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Better View Throttle Bellcrank to Pulley

I found a couple more pics, this one shows more clearly the entire view from the throttle bellcrank down to the pulley assy. The throttle is at idle (see idle stop adjusting screw bottom center)

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control

Last edited by onewizard; 01-01-2019 at 05:40 PM.
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post #15 of 23 (permalink) Old 01-01-2019, 10:22 AM Thread Starter
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Throttle Bellcrank Arm Extension

This picture is of the throttle bellcrank extender arm. The 2 small holes are for the short 4-40 screws that thread into the throttle bellcrank. The larger hole near the end is for the beaded chain connector that comes with the CCS-100 parts kit. All of the fasteners have locktite applied.


AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #16 of 23 (permalink) Old 01-01-2019, 10:30 AM Thread Starter
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Thanks for combining images!

Quote:
Originally Posted by onewizard View Post
I used the garbage bin to extract copies of your post then combine ; https://www.kawasakiversys.com/forum...ccs-100-a.html
I hope I'm not making extra work for you onewizzard. This was my first attempt to post pictures and I struggled with it.

Is there a way I could have done that (stringing all images in 1 post) myself or are admin powers required?

Will your "combined" version eventually replace my original thread?

Is my image from post #10 missing? (not complaining )

thanks!

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #17 of 23 (permalink) Old 01-01-2019, 12:19 PM
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Cool Excellent write-up!

Thanks for posting!
jaaklucas likes this.

I still have a full deck.
I just shuffle slower.
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post #18 of 23 (permalink) Old 01-01-2019, 04:40 PM Thread Starter
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Wiring Instructions Audiovox Cruise

Here is a summary of my wiring. This is different (simpler) in a few ways from the instructions that come in the box.

If using set/resume switch cut off 4 pin connector and wire up red, brown, green, yellow as indicated below (referred to as 4 pin connector wires)

Brown, Yellow, Green, Red, Purple, Black, gray/black pair to speed sensor coil are the ONLY wires needed (6 colored wires plus the shielded pair for the speed sensor coil)

Don’t need orange, gray, blue wires

1. Mount Servo in left front fairing

a. Steel bracket behind bolt for reg/rectifier (I think)
b. Route servo cable under battery box and loop back under throttle
c. Install vacuum lines and vacuum canister (with internal check valve), If no internal check valve in your canister you will need to add one between vacuum source and canister.

2. Install speed sensor coil and magnets at rear wheel

a. GRAY and Black (shield) pair from CCS-100 harness connect to the coil

3. Install Cruise Control power switch SPST 5amp rating

a. Wire from ACC +12V VIA NEW 2 amp fuse to Cruise on/off switch Common
b. Wire from Cruise Switch N/O to CCS-100 harness Red and Brown
(4 pin connector) RED and BROWN are tied together!!!!!

4. Install SET / RESUME switch SPDT Momentary 2 amp rating in kill switch housing

a. Wire from switch common (center) to Brown wire at 4 pin conn (switched +12v)
b. Wire from switch SET side to Green at 4 pin connector
c. Wire from switch RESUME side to Yellow at 4 pin connector

5. Install switch on clutch arm at engine case preferably waterproof

a. Wire from ACC +12v to clutch switch contact Common
b. Wire from clutch switch contact N/O to clutch relay coil plus

6. Install brake relay under seat

a. Wire from ground to brake coil neg. and brake relay Common
b. Wire from brake LED hot side to brake relay coil plus
c. Wire from brake relay contact N/C to clutch relay contact N/C

7. Install clutch relay under seat

a. Wire from clutch relay contact N/C to brake relay contact N/C (see 6c above)
b. Wire from clutch switch contact N/O to clutch relay coil plus (see 5b above)
b. Wire from ground to clutch relay coil neg
c. Wire from PURPLE (CCS-100 harness ********) to clutch relay contact Common

8. Black wire Chassis Ground (at or near battery)


4 pin connector wires:

Brown to switched +12V (connect to red wire see step 3b)
Green (SET wire) to set side of momentary cruise switch (rider view right side)
Yellow (RESUME) to resume side of momentary cruise switch (left side rider view)
Red Cruise Power from on/off switch (also tied to brown CCS-100 wire)

Blue (tach) wire not used (do not cut)

end

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control

Last edited by AuroraTom; 01-03-2019 at 10:17 AM. Reason: add vertical spacing
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post #19 of 23 (permalink) Old 01-01-2019, 04:48 PM Thread Starter
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Sorry about the formatting of the last post. I did a copy / paste of a text document and it didn't come out the way I wanted.

AuroraTom
Aurora, CO
USMC 1963-1967
2015 V1K Orange
Givi Crash Bars
Kappa Trunk
Givi Windshield
LED amber fog/driving lights
Panel mounted digital voltmeter
Garmin 2610 GPS (ancient like me)
Audiovox CCS-100 Cruise Control
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post #20 of 23 (permalink) Old 01-01-2019, 05:53 PM
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Quote:
Originally Posted by AuroraTom View Post
I hope I'm not making extra work for you onewizzard. This was my first attempt to post pictures and I struggled with it.

Is there a way I could have done that (stringing all images in 1 post) myself or are admin powers required?

Will your "combined" version eventually replace my original thread?

Is my image from post #10 missing? (not complaining )

thanks!
It took me about 3 minutes total, I copied to a thread in the garbage bin so no edited posts would show on your thread, since it is apparent I did this, I copied post 10 &14, I also added post 10 to post #7, try using edit on post #7, you will see how it is done, only limitation I think is 20 photos using BB Code and a maximum of 10,000 characters, when that happens, a message will pop up and not update your post, when in doubt while editing, if you delete something accidentally
don't hit save or anything else, unless you have added text, anything you added up to the mistake, copy
, then hit the back arrow on your browser, also if you have been editing for say a hour or more, open a second browser to make sure you are logged in, very easy to get logged out, hitting post will lose your post and gone forever. Very easy to just open another browser, enter Kaw and enter, if logged in it will show , you can then go to the first browser and post. If text only, I have just right clicked and copied my text, very easy to paste it if logged out once logged in.
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