Real cruise control on a Classic or Nomad

[andyvh1959]

Since its winter in Green Bay, the only riding to be had is riding Ebay for parts.
Got to thinking, the old mid-90s ZG 1200 Voyager came with factory cruise control. There are lots of ZG 1200 parts on Ebay, cheap, including the major components for cruise control such as: handlebar controls, main switch controls, brain box, cables, throttle actuator. Its all there.

Since the Classic and Nomad already have the switches for the clutch, brake, sidestand, etc, and since the Classic and Nomad have a similar two-cable throttle setup like the old ZG 1200, makes me wonder if the cruise control from a ZG 1200 can be fitted/modded to work on a VN1600?

I am searching for a complete wiring diagram from a ZG 1200, I may even buy an old service manual to study the cruise system. If it can be adapted to the VN1600 it may be an option to fit cruise on these great older cruisers. I know Gadgets has details to install an aftermarket Audiovox cruise control for a car onto the Vulcan. But that involves a vacuum actuator, vacuum tank, etc.

Any thoughts? Ideas? Knowledge?

[DragonLady58]

Or you can shop at DakotaDigital.com they have a nice cruise unit there.

Or look into MCCruise.... https://www.mccruise.com/ .....a mechanic friend that worked at the same dealership as I installed one recently, said it wasn't hard, worked very well.... https://www.dmme.com.au/MCCruise.htm .... A little more expensive, but totally works....
*Heres their info PDF...its very well documented and very informative, walking you thru some installs....https://cdn.shopify.com/s/files/1/01...00086177965579
And at Rostras website, they list this due to popularity of bike cruise controls..... https://www.murphskits.com/product_i...roducts_id=369 has a complete rostra kit for bikes, also....
If you do use a Audiovox, this my help you immensely....all has been figured out here.... http://rvbprecision.com/machine-tool...e-control.html


Hopes this helps folks whom are looking into electronic cruise units for their Vulcan Baggers....

[andyvh1959]

Thanks!! Those are good options, and since others have done it is proved out. But being cheapo me, I won't be spending $1000+ to get it done. I actually have a new, complete Audiovox aftermarket cruise in my inventory of stuffs. I had installed one waaaay back in the early 80's on my Toyota and it worked great. Since the throttle setup on the old Toyota is similar to a motorcycle it should work on my Vulcan. Thanks for the link to rvprecision, with that and the article on the Gadgets page I know I could make it work.

I just thought an older Kawasaki ZG1200 factory cruise might be an option. The major components are readily available through numerous cycle salvage parts places, and the prices aren't too bad. I'll still research that option, first I have to find a ZG1200 wiring diagram and factory service manual to get the full details on the system components, wiring and setup. The ZG1200 option does it with an electric throttle actuator (no vacuum needed) and it has factory handlebar controls that could work on the VN1600.

[DragonLady58]

Yea zg1200 used to have a cruise control bulletin from MaKawa....I tried to pull that page up from the Kawa archives, guess what, its long gone....
I can still get into the repair books since retired, but that one was erased along time ago....
Will probably have to hang out at one of the zg1200 sites ans soak up some info there if your gonna use that one. The Audiovox unit has been around so long, folks pretty well have things figures out on them....
Even see alot on the earlier harleys....

[andyvh1959]

I still think the old Voyager 1200 cruise could be adapted to the 1600: because
1. The old Voyager had a cruise stepper motor to control four carb slides, it'll handle the 1600 two throttle plates easily
2. Both the old 1200 and the 1600 have double throttle cables, pull in both directions to control the throttle plates
3. The stepper motor from the 1200 has a cable actuator to connect to the throttle cam on the 1600 throttle body.
4. Both the 1200 and the 1600 had 1" handlebar ends, so the RH control cluster would fit on the 1600 handlebar end.
5. The stepper motor to actuate the throttle is small enough to fit somewhere under the fuel tank, the cable actuator could be extended to allow it to locate somewhere else.
6. The control console on the fuel tank of the 1200 is only a main power switch and indicator lights. Those could easily be integrated to the tank console on the 1600.
7. Since it'd all be Kawasaki factory parts I bet the wiring harness color codes would mostly work with the 1600 wiring harness.
8. The old 1200 Voyager has a very active forum group that could help trouble shoot any issues getting the old system figured out.

If you do a search "cruise, Voyager 1200" on ebay all the system components come up and they are all very reasonable. I bet the entire system can be put together for less than $200.

[DragonLady58]

If....If you can find a old wrecked 1200 voyager, I'd say yes, you could grab all the parts you need and be off at the races.
The old voyagers never heard any bad things about them other than being large and rather top heavy....
Should work great if you can get the matching pieces parts....I've seen a couple of running 1200's up here for really cheap....

[andyvh1959]

I agree, a complete ZG1200 donor would be the most easy to get all the parts. But all the parts are easily found on ebay. The main parts are: actuator/stepper motor, ECU, main control console, RH handlebar control cluster, and wiring harnesses. The center console is just a main power switch and indicator lights, something like them could be adapted into the 1600 fuel tank console. The ECU, wiring and harnesses, being Kawasaki products are common enough to the current 1600 wiring harness, so it takes some work but I bet it can be done.

Could even possibly use the RH handlebar control cluster from a 1700 which has all the cruise control functions built into it already. Just have to make the connections from it to the ECU from the ZG1200.

The only trick may be just where the ZG1200 cruise controller gets the speed message from as an input to the ECU. If it's electronic, like from a speed sensor on the driveshaft, or from a wheel speed sensor. The ZG1200 has a cable driven speedometer off the front wheel, so its mechanical. But there could be a signal from the speedo cluster to the cruise ECU.

[Kawi_addict]

Sounds awesome!!! Let us know how it works out

[DragonLady58]

Originally Posted by andyvh1959

I agree, a complete ZG1200 donor would be the most easy to get all the parts. But all the parts are easily found on ebay. The main parts are: actuator/stepper motor, ECU, main control console, RH handlebar control cluster, and wiring harnesses. The center console is just a main power switch and indicator lights, something like them could be adapted into the 1600 fuel tank console. The ECU, wiring and harnesses, being Kawasaki products are common enough to the current 1600 wiring harness, so it takes some work but I bet it can be done.

Could even possibly use the RH handlebar control cluster from a 1700 which has all the cruise control functions built into it already. Just have to make the connections from it to the ECU from the ZG1200.

The only trick may be just where the ZG1200 cruise controller gets the speed message from as an input to the ECU. If it's electronic, like from a speed sensor on the driveshaft, or from a wheel speed sensor. The ZG1200 has a cable driven speedometer off the front wheel, so its mechanical. But there could be a signal from the speedo cluster to the cruise ECU.

You can get a magnetic strip and the pickup with bracket from dakota digital....aka hall effect pickup....if this helps....Have done several DD's and a few AudioVox installs. The AudioVox setup can be adapted to most anything....Put one a 60's classic pickup, early Nova musclecar, a 70's ElectraGlide, 80's WideGlide, 80's naked GoldWing.....

[andyvh1959]

Right. Back in 1980 I installed the earlier version of the Audiovox system in my Toyota Celica and it never failed me. I actually have a brand new unused Audiovox system that I must have bought some time way back when I was getting parts together for a vintage pickup I planned to build, but that never happened.

One thing about the Audiovox system is the vacuum actuator. Kinda big, so it would require some finesse to find a spot to hide it on the bike. But it is a cable connection to the throttle cam like the ZG1200 actuator cable setup. The ZG1200 system though is smaller, and the controls are built into the handlebar cluster so it would look like a factory setup rather than an add on control. But 1st I'll research the ZG1200 manual to figure out where the speed signal comes from for the cruise. I'm just surprised as to why no one else had previously figured out how the ZG1200 system could be adapted to the 1600.

A hall effect sensor on the rear wheel may provide a speed signal to the system, if it comes to that. The rear tire OD of the ZG1200 and the 1600 is within a 1/4" of each other. So whatever speed sensor system is used, if its reading the rear wheel speed at highway speed it will be nearly identical between the two bikes. Engine speed though will be lower in 5th gear on the 1600 versus the ZG1200. On the 1600 engine there is a speed sensor above the tranny output. I need to study the manual to determine the sensor function and if I can use the output signal for the cruise functions. But I will also check the ZG1200 factory manual to find out if a speed sensor is also on the tranny output. Guessing the sensor puts out a volts signal relative to speed.

[Kawi_addict]

So what did your study find? Update!!

[andyvh1959]

A bit. The 1600 and the 1700 both have a three wire speed sensor. On the 1600, the speed sensor wire colors in the harness are BK/Y, LG/R and LG/BK. On the 1700, the speed sensor wire colors in the harness are BR/Y, BL and LG/R. The speed sensor on each bike is different from the other, they mount similarly, but the shape of each is different enough that one can't replace the other. Each one puts out a voltage signal. On the 1700 the manual says the speed sensor has a output voltage range of 0.05V to 4.9V. On the 1600 the manual only gives a test to check the sensor output by registering a "twitch" on a voltmeter when a screwdriver blade is waved over the end of the sensor. Perhaps the 1600 speed sensor does produce a specific voltage output but the 1600 manual does not specify any range. When I get to that point I'll test the sensor on the 1600 to the test parameters for the 1700 speed sensor to see if the 1600 sensor sends the right signal to the gauge panel.

Both speed sensors send signals to the ECU and to the turn signal cancel system on each bike. Since the 1700 has cruise control, the speed sensor sends a signal to the instrument cluster on the LG/R wire. I assume that is to show the "set" speed on the gauge center section. Aside from that I have not found where else on the 1700 sends a signal from the speed sensor.

On the 1600, the speed sensor wire colors in the harness are BK/Y, LG/R and LG/BK. On the 1700, the speed sensor wire colors in the harness are BR/Y, BL and LG/R. Perhaps one of the wires from the 1600 speed sensor can send a signal to the LG/R wire on the 1700 gauge set. I'm guessing on your wiring of the gauge set you did not use the LG/R wire yet?

[andyvh1959]

This may be another alterative to add cruise control to the 1500 and 1600:

https://www.corvettemods.com/rostra-...iABEgKPWfD_BwE

http://www.rostra.com/aftermarket-cr...ra.php#2503592

I have no experience or knowledge of this system. But it may be adaptable to a bike. The Rostra website makes no reference to any motorcycle installation. But their systems are based on applying to a cable controlled throttle system (that's nearly any bike). Also, they offer a slick small control module, and the actuator is not a vacuum operated system like the Audiovox.

[Monkeyman]

I never added cruise control to my '07 (1600) and my '14 (1700) came with it, stock, but I can recall multiple threads about adding the Rostra cruise control to the 1500/1600s. I think it was a different brand but same item. If I recall correctly (and I'm getting older so I may not), the vacuum module/canister was usually put under the left side cover.

[andyvh1959]

Yup, read about that setup, and its on the Gadgets page for Vulcans. The Rostra system I posted about above does not use a vacuum module. The actuator is electric. May be a lot simpler system to install and more like the electric system on the 1700.