RAE-SAN DRAFT D User manual

V1.0 Bike Controller
Module
Installation Manual
DRAFT D
Rae
-
San
3
1
/
10
/20
22

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Rae-San V1.0 Bike Controller Module
Congratulations on your purchase of the Rae-San Bike Control module.
The module is designed to offer a cost-effective means to minimise the wiring on you bike and allow for
custom builds, while offering all the basic functions and a couple of extras.
I wanted a general unit that would accept programmable input polarities from standard controls, and provide
the control outputs with a few whistles -
 Adjustable and selectable Brake flash
 Adjustable and selectable indicator time out
 Low beam modulator able to be turned on an off if enabled
 The ability to use the Harley Davidson style button push left and right indicator controls -so the
ability to latch inputs as well as use the standard on/off controls.
 Selectable gate function to enable/disable starter activation with side stand, gear selection or other
input.
 Kill switch / ignition power control'
 Integrated power control - No relays other than Starter Solenoid / relay
 ZERO power draw when off.
 built in heated grip control - using the existing controls. -
o programmable number of heat steps / enable disable
o Short press of start button with clutch/gate switch deactivate - up a step (cycles around)
o Long press of start button with clutch/gate switch deactivated - turn on / off
o Starter press with clutch/Gate active - normal starter function
 4 button control mode
o instead of the standard controls - all functions can be activated with 4 buttons - in the
recommended layout of an up and down button on each handlebar -
o the 4-button control has a selection of 4 preprogrammed button function mappings that are
chosen from the setup menu - but they are implanted in a simple mapping table in the code
making changes / customisation a very simple matter.
 button activations are short press (< 0.6s), double short press (2 press within 0.8s),
medium press (1-3s) and long press (3-10s).
I had a look at the resettable fuse option - but it adds more cost and complexity than its worth - so instead -
used 30A mostets with two main circuits of master fuse (e.g., 2x10A) or you can fuse the individual outputs
if desired.
Setup is via a simple serial terminal setup.
The software is written in a modular fashion and shouldn't be too hard for people with some experience to
follow.

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Your module should look like the picture on the left – the picture on the right shows the internal view. Most
of the electronics is buried under the controller – and on the underside of the bottom board.
The system is built on the Arduino Nano platform and the source code is open and available for download
should you wish to customise something to your own need or want to implement some other special
function.

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INPUTS
All inputs have pull up resistors so they can sense when pulled low without additional components needing
to be added.
On inputs that need to float low and are pulled high when active the appropriate resistor can be snipped with
a pair of side-cutters to avoid the pull-up function. The resistors for each are labelled below.
If you wire the controls such that that all buttons pull to ground, then there is no need to snip anything, but
the flexibility is there if needed if you have controls that pull high.

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Input Functions
The Normal Function indicates the input function in standard control mode, and the 4-button function is for
when operating with the 4-button input mode. Polarity indicates TRUE - +12V is read as an Active/ON
state, or if FALSE is selected, the input is sensed ACTIVE LOW- where 0V is input ON.
The usual settings for each mode are indicated.
Input Normal function 4 button function Polarity Normal usual
Polartity
4 Button
usual
Polarity
High High Beam Switch Sense
Input
Left UP True – On = +12
False
–
On = 0V
T F
Light Lights On Switch Sense Input No Connect True – On = +12
False
–
On = 0V
T T
Start Starter Button Sense Input Right DOWN True – On = +12
False
–
On = 0V
T F
Brake Brake Active Sense Input No connect True – On = +12
False
–
On = 0V
T T
Left Left Indicator Switch Sense
Input
No Connect True – On = +12
False
–
On = 0V
T T
Kill Kill Switch Sense Input Right UP True – On = +12
False
–
On = 0V
F F
Right Right Indicator Switch Sense
Input
No Connect True – On = +12
False
–
On = 0V
T T
Horn Horn Switch Sense Input Left DOWN True – On = +12
False
–
On = 0V
T F
Gate Gate Sense Input – Clutch or
Side Stand Input
Gate Sense Input – Clutch
or Side Stand Input
True – On = +12
False
–
On = 0V
F F
On Power On Input from Ignition
–
Turn Unit On
Power Input from Ignition –
Turn Unit On
High + 12V on T T

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OUTPUTS
The output functions are listed below and are reasonably obvious – All Outputs drive +12V out when on
through 30A rated MOSFETS, and are protected by one of the two main 10A fuses -
The power circuits are arranged so that the ignition, grips, horn are on one circuit, and the lights on the other
to spread the load evenly.
Output Functions
Output Function Polarity Power
Circuit
HB H
igh
B
eam Power
Out
+12V ON
B
TAIL Tail
Light Power
Out
+12V ON
A
LB L
ow
B
eam Power
Out
+12V ON
B
BRK Br
a
k
e Light
Power
Out
+12V ON
A
LEFT Left
Indicator Power Out
+12V ON
B
IGN Ign
ition Power Out
+12V ON
A
RIGHT Right
Indicator Power Out
+12V ON
B
HORN Horn
Power Out
+12V ON
A
START Start
er Relay Power Out
+12V ON
B
GRIP
Heated
Grip
Power Out
+12V ON
A

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4 BUTTON MODE
When using the 4-button mode – there are several standard mappings of the button presses to functions that
are detailed in the table below.
Map 1 has been designed to make the important safety functions – kill and horn quickly accessible on the
upper buttons – similar to where they would normally reside. This is a good layout to start with
Other maps are variations – and can easily be customized within the code – or if you have a way you want it
to operate can be incorporated.
Press Type Timing
Double press Two press within 0.8s, both longer than 0.06s
Short Press Single press more than 0.3s less than 1.0s
Medium Press Single press more than 1.0s less than 3.5s
Long Press Single press more than 3.5s less than 10.0s
Note that the starter and horn can be timed or toggle functions depending on the map chosen. Horn Timeout = 2s, Starter
Timeout = 3s
Also available in 4 Button mode is Indicate to merge – this will flash the indicator for 4.0 s to indicate a lane
change, rather than the longer timed flash value – or infinite till toggled off flash.
Input Button press Map 1 Map 2 Map 3 Map 4
Horn Time - Toggled Toggled Toggled Toggled
Starter Time - Toggled Timed Toggled Timed
Left UP Double press Horn - - -
Short press High / Low
Beam
High / Low
Beam
Horn High / Low
Beam
Medium press - Modulation
Toggle
High / Low
Beam
Modulation
Toggle
Long press Modulation
Toggle
- - -
Left DOWN Double press Left Merge - - -
Short press Left Indicator Horn Left Indicator Horn
Medium press Heat Grip
Toggle
Left Indicator Heater Up Left Indicator
Long press - - Heat Grip
Toggle
-

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Right UP Double press Kill Toggle - -
Short press Heater Up Heater Up Starter Heater Up
Medium press Lights Toggle Heat Grip
Toggle
Kill Toggle Heat Grip
Toggle
Long press Heat Grip
Toggle
Lights Toggle - Lights Toggle
Right DOWN Double press Right Merge - - -
Short press Right Indicator Kill Toggle Right Indicator Kill Toggle
Medium press Starter Right Indicator Lights Toggle Right Indicator
Long press - Starter Modulation
Toggle
Starter
Heated Grip Function
The Heated Grips function provides drive to heated grips using the stock controls – so you don’t need to add
any extra buttons.
The Heating can be turned on and off and adjusted in level with the number of heat steps being configurable.
The system remembers the last heat setting and returns to it when turned on.
The Heated grip output is a PWM so could be used to drive some other variable function if required.
The heated grip duty cycle talks into account the power relationship to voltage and is calculated to give
equal heating steps.
If disabled in the configuration menu – the Heated grip function will be inoperative.
Using the normal controls the heated grip function uses the starter button –
 when the Gated input is active to allow starting – i.e., in Neutral or the clutch is pulled in then the
Starter button will work as the starter button.
 If however the Gate input is not active – i.e. normal running mode, clutch out and not in Neutral –
then pressing the starter button will be interpreted as a Heated Grip control command
 The Heat setting increases one step on each press and cycles around to minimum from maximum.
Function Normal Mode 4 Button Mode
Toggle Heated Grips ON / Off Starter Button Long Press > 3.5s < 10s
with Gate Inactive
Medium or Long Press of Right Up –
see 4 Button Mode table
Increase Heat One Step – Cycles around Starter Button press short press > 0.3s <
1.0s
with Gate inactive
Short press Right Up –
see 4 Button Mode table

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Headlight Modulation Function
The Headlight Modulation function allows for the rapid variation of the low beam headlight to increase the
likelihood of being seen by other road users.
It varies with country as to whether it is legal to be operated during the hours of darkness – but is generally
fine to be used during daylight hours.
The Headlight intensity is varied at the allowed rate of around 5Hz, and the amount of modulation can be
set. It is always a max intensity of 100% and the minimum can be set from 80 down to 0%. This is needed as
in particular some LED headlights will attempt to compensate and fight against the voltage modulation-
these generally need the modulation depth set to go down closer to zero.
If disabled in the configuration menu – the Headlight Modulation function will be inoperative.
Function Normal Mode 4 Button Mode
Toggle Headlight Modulation ON / Off Set To Low Beam and Switch to High
for Press > 0.1s < 0.5s
( ie quick flick to high beam and back)
Medium or Long Press of Left Up – see
4 Button Mode table

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CONFIGURATION
The configuration menu is available by serial interface over the USB connection –
simply plug in and use your favorite terminal program that supports ANSI sequences - Putty is generally the
easy choice, being universally available and free.
Connect at 115200, 8, N,1 (115200 baud, 8bits, no parity, 1 stop bit) as a terminal
Once connected hit the R key to refresh and you should get the following screen
From here – push the C or c to enter the configuration menu.

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You will be presented with the left screen below – not the key explanation on the screen – repeated here in table
form
Keystroke Function
E or e Enter Edit mode – selected entry will turn RED
N or n Next – move to the next editable entry
P or p Previous – move to the previous editable entry
> or . Change selected Value Up
< or , Change selected Value Down
R or r Refresh / redraw the screen
S or s Saves the current set of values and exist edit mode
Q or q Exit edit mode wtihout saving changes and retunrs to the top level menu
You can move around the values and change those you need to change – and then save or quit.
Values are explained in the table following.
Default values as shipped are shown BOLDED.

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Value
Function / affects / explanation Normal
polarity
setting
Diagram
Custom
4 button
mode
setting
4 BUTTON CONTROL MODE 0 => Normal all input mode
1..4 => use 4 Button map 1..4
0 0 1..4
HIGH Beam Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE FALSE
HIGH Beam Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE FALSE
STARTER Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE FALSE
STARTER Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE FALSE
LEFT Ind Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE TRUE
LEFT Ind Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE TRUE
RIGHT Ind Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE TRUE
RIGHT Ind Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE TRUE
HORN Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE FALSE
HORN Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE FALSE
KILL Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
FALSE FALSE FALSE
KILL Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE FALSE
BRAKE Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE TRUE
BRAKE Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE TRUE
LIGHTS Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
TRUE FALSE TRUE
LIGHTS Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE TRUE
GATE Input POL Hi TRUE => Active on = +12V
FALSE=> Active on = 0V
FALSE FALSE FALSE
GATE Input STATE TRUE => On while Held
FALSE=> Press is Latched
TRUE TRUE TRUE
LIGHTS Off When Crank
Turn Headlights off while
cranking
TRUE
TRUE
TRUE
LOW Beam Active with High
Leave Low Beam On when High On
FALSE
FALSE
FALSE
LIGHTS On With Power On Turn Low and Tail on when powered –
ignore Lights input
TRUE TRUE TRUE
MODULATE Low Beam
Enable the Modulation Function
TRUE
TRUE
TRUE
MODULATION Depth %
(30=100)
Set how Dim the Modulation goes 50 50 50
STARTER Inhibited TRUE => starter can be inhibited by kill or
gate
–
TRUE TRUE TRUE

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FALSE => Starter always available ignore
gate
and kill inputs for starter
STARTER Gated TRUE=> Gate must be active to start
FALSE=> Ignore Gate Input
TRUE FALSE TRUE
STARTER Inhibited by Kill TRUE => Starter wont activate if Kill Active
FALSE => Starter ignores Kill Switch
setting
FALSE FALSE FALSE
INDICATOR MAX FLASH Limit TRUE => Count Flashes for time then stop
FALSE => Flash forever until button
deactivated
TRUE TRUE TRUE
IND MAX FLASH Time Value
Time Limit in Seconds for Flashing (10
–
90)
20
20
20
INDICATOR FLASH RATE Hz
(1
-
5)
Number Of Flashes per Second – nominal
3Hz
3 3 3
BRAKE Warning FLASH TRUE=> Fast Flash Brake Light when first
activated to grab attention
FALSE=>Standard Brake Light
TRUE TRUE TRUE
BRAKE WARN FLASH Number If Warning Flash ON – Number of Flashes (0
–
10)
5 5 5
BRAKE Off when IND On TRUE=> Brake Light turned off when
indicator flashes – used to make integrated
indicator / brakes lights more visible
FALSE=> Brake Light on, Indicator Flash
Normal
–
doesn’t affect brake
light.
FALSE FALSE FALSE
Enable HEATED GRIP Function TRUE=> Enables the PWM headed grip
function-
FALSE=> No Heated Grip
Function
Active
FALSE TRUE FALSE
Heated Grip Heat Steps (2-5) Number of graduations in the heated grips
settings. These are
equally heat spaced
(2
-
5)
4 5 4

Custom control Setup – Easiest approach

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Standard Bike Control Setup

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4 Button Setup – Active low

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Using Stock Fuses

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Adding Heated Grips

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MOTORCYCLE PRODUCT DISCLAIMER
Motorcycling is an inherently dangerous activity, which may result in personal injury and / or death.
While Rae-San (and/or Entities Trading as Rae-San) products are designed to offer superior riding
comfort and performance, no product can offer complete protection from injury or damage to
individuals and property in case of fall, loss of control or otherwise. You should wear appropriate
protective equipment, obey all traffic laws, regulations and use good judgment. Never take alcohol
or drugs (legal or illegal) before riding. Always inspect your motorcycle before riding, and read your
owners manual. You should be familiar with the wide range of foreseeable hazards of motorcycling
and decide whether to assume the risks inherent in such activity, which include damage to property,
serious injury to you or others and death.
RAE-SAN (AND/OR ENTITIES TRADING AS RAE-SAN) DISCLAIMS ANY RESPONSIBILITY FOR INJURIES
OR DAMAGES INCURED WHILE USING ANY OF ITS PRODUCTS. RAE-SAN (AND/OR ENTITIES TRADING
AS RAE-SAN) MAKES NO GUARANTEES OR REPRESENTATIONS, EXPRESSED OR IMPLIED, REGARDING
MATERIALS AND WORKMANSHIP OR THE FITNESS OF ITS PRODUCTS FOR ANY PARTICULAR
PURPOSE, FURTHER RAE-SAN (AND/OR ENTITIES TRADING AS RAE-SAN) MAKES NO GUARANTEES OR
REPRESENTATIONS, EXPRESSED OR IMPLIED, REGARDING THE EXTENT TO WHICH ITS PRODUCTS
PROTECT INDIVIDUALS OR PROPERTY FROM INJURY OR DEATH OR DAMAGE. RAE-SAN (AND/OR
ENTITIES TRADING AS RAE-SAN) DISCLAIMS ANY RESPONSIBILITY FOR INJURIES, DEATH OR
DAMAGES DUE TO IMPROPER INSTALLATION OF ITS PRODUCTS. ANY ACTUAL ATTORNEY FEES FOR
ANY UNSUCCESSFUL CLAIM AGAINST SELLER TO BE PAID BY PLAINTIFF/COUNTER-CLAIMANT.
Modification of a motorcycle by fitting the devices obtained from Rae-San (and/or entities trading as
Rae-San) may void manufacturer’s warranty, state and federal laws and render insurance void. It is
the responsibility of the motorcycle owner to be familiar with these laws. Fitting of any product from
Rae-San (and/or entities trading as Rae-San) constitutes acceptance of the responsibility and
consequences of any legal, insurance, or warranty breach by the motorcycle owner. Furthermore
fitting of any device constitutes acceptance and agreement to indemnify Rae-San (and/or entities
trading as Rae-San) of all damages and liabilities that may arise in the event of accident, misfortune
or failure of a device.
12 MONTH LIMITED WARRANTY AND LIABILITY DISCLAIMER
Rae-San (and/or Entities Trading as Rae-San) warrants this product free from defects in material or
workmanship for a period of 12 months from the date of purchase, except as noted. The product
warranty does not cover damage caused by misuse or abuse; accident; the attachment of any
unauthorized accessory; alteration to the product, improper installation, exposure to harsh weather
and/or chemicals, lack of proper maintenance, lubrication, or any other conditions that are beyond
the control of Rae-San (and/or Entities Trading as Rae-San). Rae-San (and/or Entities Trading as Rae-
San) shall not be responsible for any type of incidental, consequential, or special damages. All

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implied warranties, including but not limited to those warranties of fitness and merchant
accountability, are limited in the total duration to 12 months from the original purchase date. If the
warranty occurs within 30 days from the date of purchase, please contact the dealer the product
was purchased from. Over 30 days from the date of purchase, please contact Rae-San (and/or
Entities Trading as Rae-San) direct at [e-mail]. Customer must contact Rae-San
(and/or Entities Trading as Rae-San) prior to sending warranty product. Claims for lost shipment,
damaged shipments, or other problems regarding freight must be made directly to the responsible
carrier. Warranty is solely through Rae-San (and/or Entities Trading as Rae-San). Service to our
products by anyone other than Rae-San (and/or Entities Trading as Rae-San) authorized installation
centers voids warranty. Rae-San (and/or Entities Trading as Rae-San) disclaims any and all liability for
consequential or incidental damages. Rae-San (and/or Entities Trading as Rae-San) will not be held
responsible for personal damage, bodily harm or any other legal matters.