Introduction

The instructions below are offered free of charge and are without warrantee of any kind.  I have executed these modifications on my bike with very favorable results, however, I have no knowledge of your bikes condition relative to modifications you might have made or factory supplied variations that I am not aware of.  Any of these possible changes could render this installation dangerous.  The bike I have fitted this to is a 2003 model RST1000.  Use this device at your own risk.  You bear all responsibility for safety testing your installation and safe operation of your bike.  Be sure to read and follow the precautions listed in the Precautions section at the end of this document.  Failure to follow the precautions listed will increase your likelihood of a sudden total power loss on your bike while riding.  This unintentional shutting down of the engine could cause severe injury or even death depending on the circumstances.  Read these instructions completely before you begin this project. 

Materials Required

The following is a list of the materials required to complete the wiring job.

• Crimp wire splices (available at Radio Shack)
• Zip ties (7 should be sufficient)
• Velcro hook and loop with adhesive back (Use the high shear available at Radio Shack)
• Thor Alarm system with remote
• Omron off delay timer (Grainger Catalog number 1A983 OMRON H3CA   1/16 DIN, Digital-Set, Solid State Timer )
• Socket base for timer (Grainger Catalog number 6X156)
• Electrical tape
• Solder (with resin core)
• 12 volt automotive relay (available at radio shack with 30 amp contacts)
• Wire

Tools Required

·        Wire cutters
·        Pliers
·        Knife
·        DC voltage tester
·        Phillips screwdriver
·        Standard screwdriver
·        Metric Allen wrenches
·        Soldering gun

Disassembly of the instrument panel
 

First remove the fuse box cover.

Then remove the outer windscreen supports

Next pull of the left and right instrument panel covers.

The instrument cluster comes off with 4 screws two at the top shown here and the two that were holding the fuse cover on that you removed in the first step of disassembly.  The Fuse cover has two small silver bushings under it.  Be sure to not lose these.  I found mine fell out easily when I removed the instrument panel.

Pull the covers off of the electrical plugs on the back of the instrument panel. And then remove the plugs while squeezing the clips in.

Pre-Wiring the timer with the automotive relay attached as shown

You must solder all connections to the automotive relay.  All wires attached to the relay base with screws should have the wire ends stripped no more than 3/8” and then soldered to prevent fraying.

1.      Jumper from pin 2 to pin 11. The brown wire from the alarm will attach to 2.

2.      Pin 10 to ground wire with line 86 from the automotive relay.

3.      Red and Yellow Engine start line will splice to a line attached to pin 9.

4.      Automotive relay terminal 30 will attach to pin 3.

5.      Automotive relay terminal 87 will attach to pin 6

6.      Set timer to (D 015 [0.1sec]) my photo shows 013 but I feel this is not quite enough for cold starts.

7.      The blue wire from the alarm/remote start will attach to line 85 of the automotive relay.

The automotive relay (attached to the side) is needed to give the timer relay it’s initialization signal.  When the timer sees a momentary connection of pin 6 to pin 3 it starts the timing function on the 12 volt output through pin 9. This is the start signal to the starter solenoid on the Rotax engine.  There are no open sets of contacts on the alarm system that operate momentarily like a starter button.  The automotive relay takes the starter signal from the remote and uses it (through the automotive relay) to close the connection (pin 6 to pin 3) and start the timer.  The timer then sends the starter relay on the bike it’s starting signal of 1.5 seconds duration through pin 9.  I use 1.3 seconds on my bike but I have trouble starting in weather colder than 38 degrees.  I think the 1.5 second setting will not have this problem.  The placement of the relay on the bike makes it possible (but not easy) to adjust this after assembly.  Notice the two Velcro pads on the relay.  They are used to hold the relay in position in the left side of the front faring as shown below.  I really wanted to get some of the higher shear Velcro double hook that Radio Shack sells.  However, this is doing a good job so far and I think it will do fine in the long run.  I put the base to the inside and have the display and buttons on the outside where I can’t get to them very well.  This is necessary due to the size of the base on the relay.  You might be able to modify this in some way to make the adjustment easier without disassembly of the panel.  Be sure to verify that nothing interferes with your steering.

Wiring the bike

The siren (round red object) has adhesive backing.  Place it on top of the main alarm box on the surface shown in this photograph.  The main alarm box has adhesive backing as well.  Place this on the inside right side of the faring with the antennae wire closest to the right rear view mirror support.  You will want to put the antennae wire into this mirror support so you can gain greater distance for your signal. 

The photo above shows some of the connections needed to complete the wiring.  You can use this to verify some of your connection locations.  Notice the location of the alarm control box with the 125db speaker.

Next is a modified schematic of the Futura showing all the needed connections for this modification.  Use the schematic in the back of your owners manual for comparisons and the color code chart.  Remember all wiring is done in the front faring.

Here is a rather redundant rundown of the connections on the base of the timer relay by pin.

1.      Not used
2.      Alarm Brown wire & Yellow ignition switch wire and a jumper to pin 11
3.      Wire from Automotive relay pin 30
4.      not used
5.      not used
6.      Wire from Automotive relay pin 87
7.      not used
8.      not used
9.      Wire to the Red and Yellow start button circuit
10.  Wire from Automotive relay pin 86 and a wire to a solid ground point on the bike (see photo below for ground attachment point)
11.  Jumper to pin 2

Here is a list of connections for the bottom of the automotive relay

·        Pin 85 is soldered to the blue wire coming from the alarm/remote start device.

·        Pin 86 is connected to pin 10 (ground) of the timer off delay relay.

·        Pin 30 is connected to pin 3 of the timer off delay relay

·        Pin 87 is connected to pin 6 of the timer off delay relay

The black ground wire from the alarm/remote start device has a large diameter crimp fitting on it.  It fits nicely between the clip-on nut and metal bracket for the upper right instrument cluster mount. 

Testing

The main concern here is that all loose wires are tied up but not put into a bind when the steering is moved full left to full right.  All wires not attached at the relay should be either connected with the crimp type splices or with soldered connection.  All bare wires and cut wire ends should be taped with electrical tape.  You will not need to plug the instrument panel back in to test the alarm and remote start.

Using the remote, test the following functions and verify the correct results.

Button                                                                         Resulting action

Center LOCK button.                                                  Lights flash once and siren chirps
 

                                                                                    Movement of the bike sets off alarm

Upper left UNLOCK button                                         Lights flash twice, siren chirps twice

                                                                                    Bike can now be moved

Upper right BELL button                                              Bike flashes and chips until unlock is

                                                                                    Pressed

Lightning bolt button                                                     Press twice within 3 seconds to start

                                                                                    The engine.  Unlock shuts it off.

Re-Assembly

If I need much of an explanation here you probably should not have started this project in the first place.  Put it all back in the reverse order of the disassembly instructions.

Precautions for the remote start

Never operate the motorcycle with the pendant control inside your pocket.  Always place the pendant outside of a coat pocket away from potential impact that might press a button.  Pressing the Un-lock button will stop the engine immediately.  Pressing the Alarm activate button will set off the alarm and kill the engine a few seconds later.  Pressing the find function will sound the alarm and start the turn indicator lights flashing and mislead other drivers as to your intentions.  Any of these results at the wrong time could cause you severe injury or even death.  The use of a pocket with a zipper to close in the keys while letting the pendant hang clear of potential impact areas is one possible way to control this.  In any case, use these products and instructions at your own risk.  One side effect of this installation is the parking light position on the key switch will operate as an ignition switch position and should not be used.  The change was necessary to allow for keyless driving at night.  Without this change the tail light does not come on when driving keyless.   Be sure to keep a set of keys with you to allow for locking of the steering and access to the fuel tank for fill ups.  Always wear a DOT approved helmet and leather outer garments.  Take a motorcycle safety training course.  Don’t ride in the rain.  Don’t ride in the wind.  Don’t ride on a sidewalk.  Don’t ride on a street.  Stay off the grass.  Stay out of the dirt.  Don’t go outside.  Ok, I think that about does it.  OH!  And if you don’t stop that you’ll go blind!

Have fun with this neat modification.  You’ll appreciate the attention it gets!

Bob Davis
General Manager/Owner
Modern Die Systems Inc.
Elwood, IN 46036

Bob.davis@moderndiesystems.com   ß be sure to put Aprilia in the subject of any E-mail