This article is intended to help you install your flatshifter system correctly
Figure 1.0 - An original but far too short motorcycle selector link.
Figure 2.0 - Professionally made selector arm on MSS Kawasaki.
Figure 3.0 is a picture of the Flatshifter gear shift actuator incorrectly installed, why !! because they have just connected to the standard gear shift linkage which in this case is far too short instead of extending it to the correct length every gearbox is different and you must follow the directions carefully as highlighted yellow below to get the exact position ie 25mm of travel in each direction is required.
Figure 3.0 - Gear Selector
Figure 4.0 - This is also wrong. Actuator is connected to the standard linkage which in this case is way to short.
Figure 4.0 - Gear Selector from the bike (Wrong)
Figure 5.0 is a simple but effective way to extend the standard gear selector linkage.
Figure 5.0 - Simple way to extend the Gear Selector Linkage
Most common statement,
Q the actuator is not powerful enough to change gear !!
Answer , Yes it is , you have not installed the actuator correctly see please read carefully the highlighted in yellow section below.
Some of the most common mistakes to definitely avoid that customers & professionals commonly make when installing the Flatshifter Expert /& Max electric gear selector systems.
No 1 Please follow exactly what the instructions say in the manual , remember it will be far quicker and easier to install it correctly the first time than than have to remove and refit it a second time.
Max electric gear selector system
Most common problem by far !!!!
No 2 (see pictures at top of page)
The Max electric gearshift system actuator has an effective stroke of 25 mm or (1”) in either direction, since the effort produced is progressive over the length of this travel it is very very important to utilise the full stroke. This will dictate the point along the length of the link from the gear selector shaft or gear-lever at which the actuator has to be connected. In most instances this will be at or towards the end of the lever. in this instance near enough is not good enough i.e. if the actuator is placed in the position where 23 mm of movement is used to put fully in gear the actuator will try to extend to 25 mm i.e. it is trying to damage something if it is was fitted say at 27 mm then the actuator will still only move 25 mm so it will not be fully into gear & you will get missed gears . please pay close attention to all angles and measurements in your installation manual and please remember NEAR ENOUGH IS NOT GOOD ENOUGH, often this will require the gear selector link to be extended if not the Max system will not work properly THIS LAST POINT IS VERY VERY IMPORTANT and is the most common mistake made when installing the Max system.
SO A MEASUREMENT OF 25MM TRAVEL IN EACH DIRECTION IS ESSENTIAL TO GET RIGHT.
THE GEAR SELECTOR LINKAGE IS CONNECTED TO THE SPLINED GEARBOX SELECTOR SHAFT WHEN IT MOVES UP & DOWN TO SELECT DIFFERENT GEARS THE END CONNECTED TO THE SPLINED SHAFT WILL MOVE UP & DOWN VERY LITTLE THE OTHER END WILL MOVE UP AND DOWN A LOT MORE, BUT IN BETWEEN THE 2 ENDS IS A POINT WHERE WHEN YOU MOVE THE GEAR-LEVER UP AND DOWN THE GEARS, A SPECIFIC POINT WILL ONLY MOVE 25MM UP AND 25 MM DOWN TO PUT IT FULLY INTO GEAR THIS POINT IS WHERE THE ACTUATOR NEEDS TO BE CONNECTED TO, THE GEAR LEVER MAY NEED EXTENDING IN SOME CASES BUT NOT ALL.
No 3 Applies to both systems do good quality electrical connections (not crimped) or wires twisted together etc and attach earth & live wire directly back to your vehicle`s fully charged battery .
No 4 Do not solidly mount the actuator only use the swivel mounting supplied it MUST follow the arc of the gear selector arm .
No 5 If it does not work properly you have not fitted it properly, well over 6000 kits supplied.
No 6 Check the gear linkage for free play; this represents an effective loss of stroke. Tighten or replace any ball joints or other linkages as necessary
No 7 Make sure you have a good quality battery fitted, the charging system should also be carefully checked and should deliver between 13.5 and 14.5 volts, also very important Check the state of your battery – it should give a voltage of between 12.6 and 13.2 volts if fully charged. A battery which reads 12.2 volts or less is flat and needs either charging or replacing.
No 8 Check that you have the correct level of oil in your gearbox, if the oil level is low the gears will run hot after a short period and become tight.
2 Check that the clutch is clearing properly, any clutch drag will cause the gears to mesh and prevent you changing gear cleanly.
3 Check that the chain is in good condition and correctly adjusted with not to much slack.
4 Please pay close attention to all angles and measurements in your installation manual THEY ARE VERY IMPORTANT the better the installation the better your Max kit will work.
5 Qustion the Max system is not powerful enough to change gears ( YES IT IS ) this means you have incorrectly located the Max gear selector actuator see the section highlighted in yellow above, continually operating the actuator to see if it magically starts working will over heat your actuator and could burn your actuator out, this will not be covered by your warranty / Guarantee.
Any questions problems etc. please do not hesitate to call or email us.
Expert system problems
No 1 mistake when fitting the Expert system, you need to cut into the 12v supply wire to disconnect the power to the ignition coils this will enable full or part throttle clutchless up gear shifts, but the same 12v supply wire feeding the ignition coils often has another wire branching off to supply 12v to the engine ecu and or fuel pump,and you can unknowingly be disconnecting your ecu & pump as well the Expert system ,you must only be disconnecting the power to the ignition coils nothing more, you will get a very jerky gear shift if the whole engine is turned off every time you make a gearshift. in this instance just run a separate live feed to the ecu/ fuel pump.
No 2 The vacuum supply from your throttle bodies for the clutchless downshift system needs to be of an adequate size ie the vacuum supply hole in the throttle bodies needs to be approx 2.5 mm all the way through, not enough vacuum and the blipper will not work properly or not at all, and only connect into a single cylinder vacuum take off, you will not get more vacuum connecting into all or multiple cylinders.
No 3 Clutchless systems are set up to work as supplied to you ,if you have a problem after installation do not mess with the adjustments it will not be that, recheck everything else , as supplied your system will work really well only sometimes requiring a small final adjustment to work great.
Applies to both systems do good quality electrical connections (preferably not crimped) and attach power & earth wires etc preferably back to the vehicle battery terminals if possible.
No 4 The throttle blipper is very light but it is very important to fit the stainless steel support strip supplied with the kit, as when going over a bump at speed the threaded shaft of the blipper can bend so make sure the support strip is fitted in such a way as to actually stop it moving up and down .
No 5 Check the throttle return spring is not too heavy and is not over powering the throttle blipper.
No 6 make sure the original throttle closing cable has been removed.
No 7 If it does not work properly you have not fitted it properly,the better the installation the better your Expert system will work.
No 8 Adding an additional vacuum tank , will not make an incorrect installation work so please do not waste your time , if it needed one we would supply it in the kit !!
No 9 Some Suzuki engines have a wiring connector that supplies the ignition coils with +12 volts from the main supply wire that runs the length of the wiring loom.
All six wires are connected together with a six leg U shaped metal contact.
The only way to connect our Flatshifter correctly to this connector is to cut the metal contact along the lines shown on the drawing and solder a wire onto each side of the cut.
This is not easy and is difficult to insulate properly.
The best way to connect the Flatshifter wires is to cut all four wires after this connector and join the ends together .
FLATSHIFTER BRIEF PRODUCT SUMMARY.
Full throttle clutchless up shifts & auto throttle blipped clutchless downshifts with many competitive advantages, Button or paddle operated electric gear selector kit see website for full details connect the 2 together for gearshifts with out using the clutch or gear-lever
Flatshifter Club system enables Full or part throttle clutchless up gearshifts only.
Flatshifter Expert Full or part throttle clutchless up & clutchless down gearshifts (race version of the Pro kit above) for faster riders & drivers essential for highway, track days & race use.
Flatshifter “Blip” Independent clutchless add on down shift system works with all makes & types of engine ecu`s or quickshifter systems.
Flatshifter Max Electric solenoid, fast effortless up and down gear selection system operated by buttons or Flatshifter Paddles.
Max kit can be used with any of the quickshifters above.
Flatshifter Paddles For all electric & pneumatic gear shift systems choice of 2 different paddle kits
Flatshifter “Shift” Strain gauged gear knob for use with Flatshifter or any other make of quickshifter system
Flatshifter Dualever Motorcycle twin clutch/brake lever & master cylinders, for disabled motorcycle & trike riders.
Flatshifter Slik-shift Virtually eliminates missed motorcycle engine gearshifts & lighter, faster, more positive gearshifts.
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