LeoVince 2009 CRF 250 R User manual

GB
HONDA CRF 250 R 2009
Assembly Instructions
FAST part-no.: 9060

LIST OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. GENERAL GUARANTEE CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.1 GUARANTEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2 EXLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.3 LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.4 RESPONSABILITY FOR DAMAGE FROM DEFECTIVE PRODUCTS . . . . . . . . . .5
4. IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5. PREPARING TO INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
6. WIRING LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
7. POSITIONING OF THE MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . .7
8. REMOVING THE FAIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
9. REMOVING THE FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
10. REMOVING THE ORIGINAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
11. INSTALLATION OF THE FAST ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
12. INSTALLATION OF THE FAST MAPPING SWITCH . . . . . . . . . . . . . . . . . . . . . . .14
13. POSITIONING OF THE FAST MAPPING SWITCH . . . . . . . . . . . . . . . . . . . . . . .14
14. CONNECTING THE FAST MAPPING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . .15
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INTRODUCTION
Dear Customer,
We would like to thank you for choosing our product and we wish to provide you with some information about
this entirely unique and exclusive product, the FAST Box.
In over 50 years of operation, the Sito Group has achieved a series of goals and advances that have con-
tributed towards building a position of leadership in the aftermarket motorcycle exhaust system sector.
The most recent advance is called LeoVince Electronic Systems, a completely new department reporting to
LeoVince’s Research and Development Department. LeoVince Electronic Systems was created for the develop-
ment of electronic control units (ECUs) for engine management, to be used, initially, in conjunction with our own
LeoVince X3 (off-road) systems.
The goal of LeoVince electronic Systems is to create a unique and optimized “system”, i.e. producing an exhaust
system and an ECU, the latter being configured for use with both the exhaust and the motorcycle.
For the initial offering of the FAST Box, motorcycles designed for motocross, enduro and supermotard have been
chosen, ones specifically using a 4-stroke single cylinder engine with carburetor, so the FAST Box can be used
in conjunction with the LeoVince X3 line of exhaust systems.
In this case, the ECU replaces the existing OEM ECU and is not used in tandem with the original, as it is pos-
sible to do on scooters and street bikes with fuel injection.
The LeoVince Electronic Systems engineers have designed and produced the FAST Box entirely within the com-
pany in close collaboration with the technicians who produce our exhaust systems, thereby obtaining a highly
focused and integrated product.
The ECU operates in extremely demanding mechanical, thermal and environmental conditions therefore TÜV
Italia has carried out all the inspection tests, guaranteeing its reliability.
After passing the bench tests, the definitive prototypes were handed over to users and professional riders to
carry out a series of tests “in the field”. Then, after some final adjustments, the commercial product was final-
ized and production begun.
This product represents the first steps in a diversified project, with the development program already looking
towards scooters, single and multi-cylinder fuel injected motorcycles.
Welcome to the FAST age!
FOR FURTHER INFORMATION:
[email protected]
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1. TECHNICAL DATA
LeoVince FAST Kit 9060
Exhaust item X3 LeoVince 3508 (Full 1/1 <<X3>> system - off-road RACING – Full Titanium line “SUPERMOTO”
“MOTOCROSS”)
FAST Electronic Control Unit (ECU) dimensions Size and weight
Length 90.00 mm
Width 64.00 mm
Height 26.50 mm
Weight (without wiring) 222 g
2. WARNINGS
This manual has been written by SITO GRUPPO INDUSTRIALE S.p.A. for use by qualified personnel. Obviously, it would
not be possible, in a single manual, to provide complete mechanical training. It therefore goes without saying that any-
one who uses this text to carry out installation and work on the FAST ECU, must have the knowledge and the basic tech-
niques needed for working on motor vehicles. If this condition is not met and if all the information in the manual is not
adhered to, any attempt to use FAST products on the motorcycle may make the product unfit for use and/or dangerous.
SITO GRUPPO INDUSTRIALE S.p.A. is constantly seeking to improve all its products. Modifications or significant changes
made will be brought to the attention of all the SITO Authorized Retailers and, where applicable, will be inserted into fur-
ther editions of this manual.
NOTE: The drawings and the specifications are subject to change without prior notice.
SITO GRUPPO INDUSTRIALE S.p.A. is not responsible for any damage arising from attempts to tamper with the FAST ECU
or from improper use of it.
The FAST ECU has been designed and produced for motorcycle competitions and its use on the public road is not per-
mitted.
Carry out installation of the FAST ECU with the engine switched off, and if the battery is installed, disconnect it.
Pay particular attention when attaching the ECU, be sure to find an adequate support point.
Pay particular attention, when positioning the wiring, avoiding contact with excessively hot parts, avoiding excessively
tight bends, and avoiding critical points where there could be rubbing or abrasion of the cables.
BEFORE BEGINNING INSTALLATION READ THIS MANUAL CAREFULLY
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3. GENERAL GUARANTEE CONDITIONS
3.1 GUARANTEE
SITO GRUPPO INDUSTRIALE S.p.A. guarantees its own products in accordance with current legislation. In particular it
guarantees conformity defects by repair or replacement within a suitable period of time.
Except where the customer’s request is for the goods to be repaired or replaced, SITO GRUPPO INDUSTRIALE S.p.A.
reserves the right to evaluate whether the remedy requested is objectively possible and not excessively onerous compared
to the alternative.
Repair and replacement will be without additional cost to the consumer.
To make a claim under the guarantee, the consumer must be in possession of a proper receipt and provide information
about the manufacturing defects within two months of the date of their discovery.
The guarantee is valid for two years from date of delivery of the product.
Parts or products replaced under the guarantee become the property of SITO GRUPPO INDUSTRIALE S.p.A.
3.2 EXCLUSION
The guarantee offered by SITO GRUPPO INDUSTRIALE S.p.A. does not apply:
a) to parts used in sporting competitions of any kind;
b) to parts used on motorcycles that are hired out;
c) to parts subject to wear as a result of their normal operation (such as, just for example, rubber supports, aluminium
body)
d) where there is improper use or abuse of the part or the motorcycle by the owner and/or the operator;
e) in the case of unauthorized modifications or modifications carried out by personnel not representing SITO GRUPPO
INDUSTRIALE S.p.A.
f) in the case of parts used incorrectly or for which normal maintenance has not been carried out
3.3 LIMITATIONS
The general guarantee conditions cease to have effect in the following cases:
a) The parts show signs of defects arising from accidental damage, negligence or overloading
b) Nonconforming use of motorcycles, onto which the said parts are assembled;
c) Maintenance of motorcycles, on which the said parts are assembled, is not carried out in the ways set out in the use
and maintenance booklet
d) Parts excluded as indicated in paragraph 3.1 of this guarantee
e) Parts excluded through the owner’s negligence in observing all the obligations specified in paragraph 3.1 of this guar-
antee.
3.4 RESPONSIBILITY FOR DAMAGE FROM DEFECTIVE PRODUCTS
SITO GRUPPO INDUSTRIALE S.p.A. is responsible for damage caused by defects of its product, under and in accordance
with the conditions set out in legislative decree 6.9.2005 no. 206, articles 114 to 127, every other responsibility being
excluded.
SITO GRUPPO INDUSTRIALE S.p.A. declines all responsibility if failure to carry out proper maintenance causes damage
or compromises the normal operation of the product sold.
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4. IMPORTANT INFORMAITON
Information in this manual that is of critical importance is marked with the following symbols:
A danger symbol means BE CAREFUL! YOUR SAFETY IS AT RISK!
Failure to observe the instructions that follow this symbol could cause serious injury, if not
the death of the rider, people nearby, or people engaged in repairing the motorcycle.
This indicates special precautions that must be observed to avoid damage to the
motorcycle.
A NOTE provides key information aimed at facilitating installation instructions or making
them clearer.
5. PREPARING TO INSTALL
Before installing the FAST ECU, follow some simple recommendations in order to carry out a better job and optimize instal-
lation time:
1) Only start work when the motorcycle is cold;
2) Remove every trace of dirt, mud, dust and debris before starting to remove or dismantle parts;
3) Use clean tools and equipment;
4) When removing parts, clean them and put them on a tray, keeping them in the order in which they were removed. This
allows you to save time when re-assembling and to install all the parts correctly;
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WARNING
CAUTION
NOTE

1
3
2
6. WIRING OUT
The following are some guidelines for cable and wiring layout.
1) A loose wire or cable can be a safety risk. After attaching them, check all wires to make sure they are properly secure.
2) Do not squeeze wires against the soldering iron or the end of the clamp when soldering clamps are being used.
3) Secure wires and cabling to the frame with straps. Tighten the straps so that only the insulated surfaces come into con-
tact with wires and wiring.
4) Arrange the wiring so that it is neither excessively tight or loose.
5) Arrange the wiring so as to avoid sharp edges or corners. Also avoid protruding heads of bolts or screws.
6) Protect wires and wiring with electrical tape or ducts if they come into contact with sharp edges or corners. Clean the
surface thoroughly before applying the tape.
7) Do not use wires or cables with broken insulation. Repair them with electrical tape or replace them.
8) Keep wiring away from exhaust pipes or other high temperature areas.
9) After attaching the connectors, check each piece of wiring to make sure it does not interfere with any moving or slid-
ing part.
10) Check that the wiring positioned along the handlebars is neither too tight, too loose or pinched and must not inter-
fere with adjoining or surrounding parts in all steering positions.
11) After completing the layout check that the wiring is not twisted or bent.
12) Check electric wires and the connection elements for any stains, rust, dampness, etc. If there are traces of dampness
dry with a fan. If there are rust/stains, connect and disconnect the parts several times.
13) Clean the connectors thoroughly before attaching the FAST wiring.
7. POSITIONING OF THE MAIN COMPONENTS
Key:
1. Original HONDA ECU.
2. Original connectors (under the side panel)
3. Original connectors (under the fuel tank)
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Fig. 1

8. REMOVING THE FAIRING
Take off the seat removing the nuts shown in Figure 2.
Dismantle the right and left side panels, removing the nuts, shown in Figure 2a.
take special care when undoing the
side panel nuts in position 4 fastened to the radiator.
NOTE: clean all the parts and put them on a tray,
keeping them in the order in which they were removed.
Remove the number plate on the handlebars.
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CAUTION
Fig. 2
1
Fig. 2a
2
1
3
4

9. REMOVING THE FUEL TANK
Before removing the fuel tank make sure the tap is in the OFF position, then disconnect the fuel hose from the engine
(Position 1, Figure 3) and remove the nut that keeps the tap fastened to the frame (Position 2, Figure 3).
Next remove the nut that attaches the fuel tank to the frame (Position 1, Figure 3a) and any rubber fastening bands.
during this operation a small quantity
of fuel may come out.
NOTE: Before removing the hose, place some rags
under the removal point in order to dry up any fuel
leakage.
Once the tank is removed place it on a flat surface
in the upright position.
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Fig. 3
Fig. 3a
2
1
1
CAUTION

10. REMOVING THE ORIGINAL WIRING
Disconnect the original HONDA connectors positioned under the side panels and under the fuel tank that have just been
removed, as shown in Figure 4 and Figure 4a.
NOTE: Check the electric wires and the connection
elements, checking for the presence of stains, rust,
dampness etc. If there are traces of dampness, dry
with a fan. Where there are rust/stains, connect and
disconnect the connectors several times.
If the battery is present disconnect it before carrying
out the operations to remove the original wiring.
Disconnect and remove the original ECU, positioned above the front fender as shown in Figure 4b.
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Fig. 4a
CONNECTORS
Fig. 4
CONNECTORS
Fig. 4b
ORIGINAL ECU

Remove the original wiring.
NOTE: Thoroughly clean the connectors removing
traces of dust, mud or debris.
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Fig. 5
HARNESS
LAYOUT
Fig. 5a
HARNESS
LAYOUT

11. INSTALLATION OF THE FAST ECU
Fix the FAST ECU, placed inside the rubber support, to the frame, using brackets found in the kit, as shown in Figure 6.
Check that the connection between the FAST wiring and the ECU is correct, and if the connection is loose, check the con-
nectors.
Insert the FAST wiring where the original wiring was installed (see fig. 5a) and secure it with straps, making sure not to
fasten it too tightly and leaving a suitable amount of space and slack.
Do not place the cables near the fork stops in order to avoid cable damage.
Do not accidentally wrap the electric cables and flexible hoses.
NOTE: Where appropriate, attach the wiring with straps, being careful not to squeeze the cable excessively while also
leaving a little slack.
Connect the FAST wiring connectors to the corresponding original connectors on the motorcycle, matching the colors of
the connectors and making sure that the connection is properly made and is in no way loose.
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Fig. 7 Fig. 7a
CAUTION
Fig. 6

NOTE: Where the colors of the FAST wiring connectors do not match the colors of the connectors of the original wiring,
refer to the colored guides used to identify the connection correspondence (for example: colored paint dot).
Position the connectors in Figure 7 in the proper clamps on the frame, as shown in Figure 8.
Re-assemble the fuel tank, side panel, seat and the number plate following in reverse order the steps described in para-
graphs 7 and 8.
NOTE: If the battery is present, re-connect it.
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Fig. 7b Fig. 7c
Fig. 8
POSITIONING OF
THE CONNECTORS

12. INSTALLATION OF THE FAST MAPPING SWITCH
The FAST kit also includes the FAST mapping switch, which utilizes a three-position switch complete with wiring, which
makes it is possible to select one of the three different maps stored in the control unit’s memory. There are three positions,
the top position of the switch for full power (map 1), the middle/central position of the switch is the original map (map
2) and the final lower position of the switch is the wet map (map 3).
The control unit has three map formats stored in its memory:
• Map 1, full power, developed to optimise maximum power at all speeds;
• Map 2, original, which is the same as the original control unit’s map format of the bike;
• Map 3, wet, adjusts any functional irregularities, making for a smoother response, ideal for wet conditions.
The rpm limit(redline) has been increased on all three map formats by 200-300 rpm.
The control unit can be used in conjunction with a PC software interface so that in the event of special preparations, it is
possible to download various types of map formats, which can also be customized as required.
The software can be used to alter the engine parameters and is therefore potentially dangerous, unless used by skilled
personnel capable of assessing the most appropriate kind of use according to the type of bike and the engine charac-
teristics involved.
13. POSITIONING OF THE FAST MAPPING SWITCH
The FAST mapping switch is attached to the handlebar of the motorcycle, at the discretion of the rider, so that it is com-
fortable to use in both a sitting and standing position. Attachment of the switch is ensured by means of a clamp and
screws. A picture of the switch is shown In Figure 9. In Figure 9a an example is shown of the switch installed.
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Fig. 9
Fig. 9a

14. CONNECTING THE FAST MAPPING SWITCH
The FAST mapping switch is connected to the ECU via a special piece of wiring (grey connector). See Figure 10.
Keep the wiring away from exces-
sively hot parts and away from moving parts, as to
avoid damage or wear from rubbing. Avoid exces-
sively sharp bends. Where appropriate, attach the
wiring with straps, being careful not to squeeze the
cable excessively while also leaving a little slack.
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Fig. 10
CAUTION

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INSTRUCTION MANUAL
2009 SITO GRUPPO INDUSTRIALE
All rights reserved
Reproduction or unauthorized use
Without the written permission of
SITO GRUPPO INDUSTRIAL, S.p.A.
is strictly forbidden
05/03/’09
Assembly Instructions