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Table Of Contents

Installing the Audiovox CCS100 Cruise Control on the

Honda Pacific Coast PC800 Motorcycle

Contents

Introduction..................................................................................................................................... 1

Materials ......................................................................................................................................... 2

Preparations..................................................................................................................................... 3

Remove plastic body panels ........................................................................................................3

Alternative 1: For Servo Installation In Right Roll Bar Cover (Fairing Protector)................ 3

Alternative 2: For Servo Installation In Left Front Upper Cowl ............................................ 4

Remove the air cleaner housing assembly...................................................................................4

Vacuum System .............................................................................................................................. 5

Making the Vacuum Canister ......................................................................................................6

Attaching the Vacuum Canister...................................................................................................9

Vacuum Connections...................................................................................................................9

Servo ............................................................................................................................................. 12

Servo Setup................................................................................................................................12

Servo Installation.......................................................................................................................14

Alternative 1: Right Roll Bar Cover (Fairing Protector) ...................................................... 14

Alternative 2: Left Front Upper Cowl .................................................................................. 15

Combined Servo & VC Mount ..................................................................................................... 17

Several Views of the Combined Servo & VC....................................................................... 19

Throttle.......................................................................................................................................... 20

Actuator Cable Anchor..............................................................................................................20

Alternative 1: Forward Pulling ............................................................................................. 20

Alternative 2: Rear Pulling ................................................................................................... 21

Carburetor Connections.............................................................................................................22

Alternative 1: Downward Bellcrank For Forward Pulling Actuator..................................... 22

Alternative 2: Upward Bellcrank For Rear Pulling Actuator ............................................... 24

Chain Connections.....................................................................................................................25

Electrical System .......................................................................................................................... 26

Handlebar Control Unit .............................................................................................................26

Main Wiring Harness.................................................................................................................27

Wire connections .......................................................................................................................28

Afterwards..................................................................................................................................... 29

Reactivate the electrical system.................................................................................................29

Replace the body parts...............................................................................................................29

Test ride. ....................................................................................................................................29

ON/OFF .....................................................................................................................................29

SET SPEED...............................................................................................................................29

ACCEL ......................................................................................................................................29

COAST ......................................................................................................................................29

RESUME ...................................................................................................................................30

DISENGAGE.............................................................................................................................30

Summary of content (32 pages)

PAGE 1
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Contents Introduction..................................................................................................................................... 1 Materials ......................................................................................................................................... 2 Preparations.......................................................................................................
PAGE 2
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Disclaimer These instructions reflect the efforts of Dave Steven, Chuck Chiodini, and Bruce Pickett to install the Audiovox CCS100 Electronic Cruise Control into each of their Honda Pacific Coast motorcycles. We would like to thank Alan Hall and Rick Corwine for their efforts in reviewing this document.
PAGE 3
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Introduction When riding on long stretches of roadway, motorcyclists often find it convenient to relax their grip on the throttle handle and rest their hand. Many PC800 riders use the Throttlemeister and Vista Cruise throttle locks, or the Throttle Rocker wrist rest, because these are easy to install and inexpensive.
PAGE 4
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Materials • • • • • • 1 - Audiovox Model CCS100 cruise control kit 2 - U-bolts, 3/4" dia.
PAGE 5
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Preparations Read everything before doing anything! Remove plastic body panels Alternative 1: For Servo Installation In Right Roll Bar Cover (Fairing Protector) The following plastic body panels must be removed regardless of which servo mounting location is chosen. Additional panels must be removed for mounting the servo in the Left Front Upper Cowl (see Alternative 2).
PAGE 6
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Alternative 2: For Servo Installation In Left Front Upper Cowl In addition to the panels removed for Alternative 1, the following panels must be removed (numbers in parentheses refer to panel numbers in the PC800 Service Manual): • Mirrors (#1) • Wind screen (#2) o air duct grill o garnish o frame o screen o rubber seat o air duct • Meter Panel (#9) • Meter Visor (#6) Removal of the following additional panels may make
PAGE 7
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Vacuum System The CCS100 cruise control requires a constant source of vacuum. Vacuum is what supplies the mechanical power for the throttle actuator. The Pacific Coast's two carburetors each have a vacuum source. The vacuum source on the #1 (left) carburetor is used to provide vacuum to the auto fuel valve; however, the one on the #2 (right) carburetor is normally unused and is capped off.
PAGE 8
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Making the Vacuum Canister Ready-made vacuum canisters that include internal vacuum check valves are available at many auto parts stores that sell cruise controls kits - JC Whitney, a major catalog auto parts retailer, sells one for around $10US. The JC Whitney vacuum canister is about 4 inches in diameter and about 5 inches long, with an internal volume of about 60 cubic inches.
PAGE 9
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Drill two holes in the end of one of the end caps that are sized appropriately for the adapters that you are using. Dry thread the barbed adapters into the holes so that threads are cut into the plastic. Remove the adapters and clean off any loose particles. Apply JB Weld to the new threads in the cap holes and reinsert the adapters, tightening them down flush.
PAGE 10
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle The vacuum canister pictured above has an internal volume of about 18 cubic inches. If this does not provide sufficient vacuum reserve for the servo, multiple vacuum canisters may be constructed and connected in series. The picture below shows two identical vacuum canisters joined together by JB Weld and cable ties.
PAGE 11
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Attaching the Vacuum Canister The vacuum canister is attached to frame struts under the front left fairing near the connection point for the left mirror. With the hose barbs on the vacuum canister pointed down and to the rear, attach it to the lower of the two fairing side struts with several long, sturdy cable ties. Make sure that there is sufficient space to attach the vacuum hoses to the hose barbs on the canister.
PAGE 12
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Locate the capped-off vacuum port on the #2 (right) carburetor; this is an "L" shaped tube near the lower, front, right corner of the #2 carburetor. Remove the vacuum cap and its spring clip (you may want to save it for the future, "just in case", but you don't have to). Secure a length of vacuum tubing to this port - its length will be trimmed to fit later.
PAGE 13
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle If the vacuum canister does not have an integral check valve, then a separate one is needed in the vacuum line to prevent the vacuum reserve in the VC from being lost when carburetor suction decreases. The check valve may be installed at any convenient location in the vacuum line between the carburetors' vacuum source(s) and the vacuum canister(s).
PAGE 14
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Servo The servo is the electronic brains as well as the mechanical muscle of the cruise control system. It should be protected as much as possible from heat and electrical interference. The servo sensitivity and other settings are set via the internal DIP switches.
PAGE 15
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle The choice of sensitivity settings depends a great deal on the length of the bellcrank arm, and the desired responsiveness of the system. The shorter the bellcrank, the higher the sensitivity needed to actuate it. Higher sensitivity settings require more vacuum since the actuator is required to move more frequently. Systems using short bellcranks of 1" to 1-1/2" may need the sensitivity set to "high".
PAGE 16
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Servo Installation The servo and vacuum canister have successfully been located in several different locations and orientations on the PC800. Two alternative mounting locations are discussed below.
PAGE 17
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Alternative 2: Left Front Upper Cowl • • • • Advantages Keeps electromechanical components away from engine heat, electrical interference, and road spray Substantial empty space for installing servo and vacuum canister Easy access to fuse block and electrical connections Easy to route actuator cable to throttle • Disadvantages Most of bike's forward plastic panels must be removed for servicing or adjusting servo I
PAGE 18
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle It is important to avoid tight bends in the actuator cable. The cable has more length than is needed, so it must be routed in such a fashion as to use up some of its length. As the actuator cable leaves the back of the servo, route the cable downward behind the left side body panel. Make certain that the cable will not interfere with the air duct/maintenance lid. Curve the cable back up toward the fuel filler box.
PAGE 19
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Combined Servo & VC Mount Subsequent to the original publishing of these installation instructions, an alternative approach was developed which combined the servo and vacuum canister (VC) on a single mount. The original instructions have been maintained, but this section has been added to describe the alternative approach.
PAGE 20
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle The U-bolt fits around the upper fairing frame brace and through the servo/VC mounting bracket. Make sure that the frame brace does not become crushed or bent from over-tightening the nuts on the U-bolt. The bracket is angled forward so that the servo cable will be angled downward and rearward in order to pass under the left pocket in the dash panel deck. Page 18 Copyright © 2001-2006 by Bruce Pickett.
PAGE 21
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Several Views of the Combined Servo & VC Looking upwards from below the mounted servo/VC. View from in front of the mounted servo/VC. Servo accessible through dash panel left speaker hole. Page 19 Copyright © 2001-2006 by Bruce Pickett. Copying or printing for personal use is permitted. All other rights reserved.
PAGE 22
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Throttle Actuator Cable Anchor The actuator cable must be anchored to a stable mount in which to pull the throttle against. There are two alternative methods for anchoring the cable: to the front, or to the rear. A rearward pulling cable will allow for the use of a longer bellcrank.
PAGE 23
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle The cable anchor itself is bolted to the bracket and should be pointed directly at the throttle bellcrank to minimize friction on the cable exiting the casing end. It is important to avoid tight bends in the actuator cable.
PAGE 24
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Carburetor Connections A connection to the throttle linkage on the carburetor is needed for the servo actuator cable to pull upon. This may be done with a "bellcrank", which is an extension arm attached to the throttle.
PAGE 25
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle On the side of the #1 (left) carburetor, remove the nut that secures the throttle pulley to its shaft. Attach the fabricated bellcrank to the shaft, then use a small amount of Locktite or blue RTV on the threads of the shaft, and secure the nut back in place. (Caution - do not get any thread locking compound on any of the bike's plastic, as this may cause damage).
PAGE 26
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Alternative 2: Upward Bellcrank For Rear Pulling Actuator • • • Advantages Allows for recommended 40-45mm full throw of CC actuator cable Allows full 50º rotation of throttle pulley Cable and chain are not near anything to rub upon • Disadvantages Must be bent around the choke cable, therefore design is somewhat weaker than a straight bellcrank To form the bellcrank, start with a flat piece of metal 3inches long b
PAGE 27
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Upward bellcrank, rear-pulling actuator cable, and anchor: Chain Connections Locate the "bead chain eyelet connector (#25)" and "slotted head shoulder bolt with lock washer and hex nut (#34)" from the CCS100 kit. Attach the eyelet to the bellcrank using the shoulder bolt. Ensure that the bolt, washer, and nut are tightened securely.
PAGE 28
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Electrical System Disconnect the bike's power before making any electrical connections. Handlebar Control Unit The kit's "dash-mounted control switch", as the name implies, is normally mounted on the dash of an automobile, but on the PC, an ideal mounting location is on the right handlebar in the space between the Run switch and the starter button.
PAGE 29
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle The black wire is a ground connection and is required to be connected for the CC to work. The grey wire provides power to illuminate the control switch; if you do not wish to have the control switch illuminated, you can leave the grey wire unconnected.
PAGE 30
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Splice a wire into the parking lights wiring to supply power for the handlebar control switch (grey wire). Make a connection to ground for the control switch, too (black wire). Route these wires through the convoluted tubing up into the handlebar covers. Attach terminals to these wires to mate with those from the handlebar control switch.
PAGE 31
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle Afterwards Reactivate the electrical system. Replace the body parts. Test ride. Each time the ignition switch or the cruise control switch is turned OFF, the system is deenergized. To reenergize the system, the ignition switch must be turned on, and the cruise control switch must be moved to the ON position. The cruise control switch can be left ON at all times without causing any damage to the system.
PAGE 32
Installing the Audiovox CCS100 Cruise Control on the Honda Pacific Coast PC800 Motorcycle RESUME Whenever you use the brakes to slow or stop the vehicle, the cruise control will disengage but retain the programmed SET SPEED. To return to the SET SPEED, accelerate to a speed above 35 mph, then press and release the RESUME/ACCEL switch. The vehicle will automatically accelerate to the programmed SET SPEED, and hold that speed.