AIM MXL Plug&Play Kit for Suzuki GSX-R K3

Presentation

AIM is a world leader in data acquisition for the racing environment. Established in 1976, AIM produces high-performance instruments such as dashes, data loggers, digital displays, and lap timers for various motorsports including karting, cars, bikes, dragsters, powerboats, and snowboards. AIM products combine traditional functionalities like tachometers, RPM indicators, temperature, and pressure gauges with compact, user-friendly units, all characterized by innovation. Each AIM system is designed, produced, and tested by their technicians, comprising electronic and mechanical engineers, physicists, and other specialists.

Preface

The MXL Plug & Play kit for Suzuki GSX-R K3 is a dashboard with an integrated data logger (in the Pista version). It is designed for easy and quick installation, allowing a direct connection to the bike's ECU with minimal effort. It displays various information without requiring additional sensors. The logger is powered by the bike's master switch.

MXL Strada Features:

• RPM
• Speed
• Water temperature
• Oil Pressure Signal
• Fuel level
• Turning lights
• High beam
• Engaged gear
• 2 free channels

MXL Pista Features:

• RPM
• Speed
• Water temperature
• Engaged gear
• 6 free channels

The MXL Strada and Pista kits for Suzuki GSX-R K3 are compatible with the following bike models:

Note: Lap times can be displayed/recorded using the optical IR transmitter/receiver (included in MXL Pista kit, optional for MXL Strada).

1 - Kit Description

The contents of the Plug & Play kits differ based on the MXL version. The images show typical components.

MXL Strada Kit:

• MXL Strada unit (1)
• Suzuki GSX-R K3 interface wiring (2)
• USB cable for MXL (6)
• Leaflet MXL Suzuki GSX-R K3 (7)
• Race Studio 2 software CD (8)
• Bracket kit (10) including: 4x Phillips 4*8mm recess screws, 2x Phillips 5*12mm recess screws, 4x Grover washers Ø 4mm, 4x washers Ø 5mm, 4x Phillips threading forming recess screws 40*12.

MXL Pista Kit:

• MXL Pista unit (1)
• Suzuki GSX-R K3 interface wiring (2)
• IR Transmitter (3)
• IR receiver (4)
• Transmitter power cable (5)
• USB cable for MXL (6)
• Leaflet AIM products (7)
• Race Studio 2 software CD (8)
• TPS – throttle position sensor - cable (9)
• Bracket kit (10) including: 4x Phillips 4*8mm recess screws, 2x Phillips 5*12mm recess screws, 4x Grover washers Ø 4mm, 4x washers Ø 5mm, 4x Phillips threading forming recess screws 40*12.

Universal Kit (for existing MXL Strada/Pista users):

• Universal interface cable for Suzuki GSX-R K3 (2)
• Bracket kit (10) with screws and washers.

MXL Strada Optional Components:

• IR transmitter (3)
• IR receiver (4)
• Transmitter power cable (5)
• TPS – throttle position sensor cable (9)

Note: Verify all kit components are present before installation.

1.1 - Part Numbers (see Appendix "A")

The document lists specific part numbers and technical draw codes for various MXL Strada and Pista kits for Suzuki GSX-R models, as well as optional accessories.

2 - Plug & Play Kits Installation

These kits are designed for straightforward installation. WARNING: Kits are developed and tested for maximum compatibility with manufacturer-stock bikes. The anchor plugs allow easy replacement of the stock dash without cutting or modifying any wires. The bracket is made of black anodized aluminum.

General Notes:

• Do not cut any cables; the wiring is Plug & Play.
• Handle stock connectors carefully to avoid damage.
• Avoid installing the system when the engine is hot due to proximity of connectors to hot engine parts.
• Be cautious when plugging/unplugging connectors under the fuel tank due to limited space.
• Do not lose screws and washers.
• Avoid damaging fairings during installation/uninstallation.

2.1 - Removing the lateral mirrors and the front and lateral fairings

The first step involves removing the lateral mirrors and the front and lateral fairings. Lateral mirrors are secured by two hex screws, often covered by plastic caps. The front screen and right lateral fairing are typically fixed with Phillips thread-forming screws. The fairing is attached with four such screws. The wiring will be routed on the bike's right side, requiring the removal of the right lateral fairing, which is held by six hex screws and four plastic pins.

[Image description: Figure 1 shows the removal of plastic covers from mirror screws. Figure 2 shows the hex screws securing the mirrors. Figure 3 illustrates the location of screws for the front screen. Figure 4 indicates screws and pins on the right lateral fairing.]

Additional plastic pins are located on the bottom part of the bike. These pins can be released by inserting a tip into the central hole and pressing until a click is heard. After releasing all pins and hex screws, the right lateral fairing can be removed.

[Image description: Figure 5 shows the pin positions at the junction of right and left fairings. Figure 6 demonstrates releasing the central clip of a plastic pin. Figure 7 shows the removal of a plastic pin.]

2.2 - Removing the bike seat and lifting the fuel tank.

To access connectors located near the engine and under the fuel tank, the fuel tank must be lifted. This requires removing the bike seat, which is secured by two screws. The fuel tank is hinged and fixed with two hex screws near the fork. After unscrewing these, the fuel tank can be lifted.

[Image description: Figure 8 points to a screw for the bike seat. Figure 9 shows unscrewing the bike seat screws. Figure 10 illustrates how to remove fuel tank screws. Figure 11 shows lifting the fuel tank.]

2.3 - Releasing the high beam and the front fairing screws.

This step involves removing screws for the high beam and front fairing to facilitate kit installation. These are self-threading Phillips screws. Once these screws are removed, the front fairing can be gently pulled forward to access the new dash's lateral screws. Care must be taken not to disconnect the high beam wiring.

[Image description: Figure 12 shows the position of front fairing and high beam screws. Figure 13 shows the front fairing and high beam screws released.]

2.4 - Removing the stock dash; unplugging the connectors

The stock dash is removed by first unscrewing the hex screws securing it. It is then rotated and unplugged from the high beam. The 16-pin AMP connector at the back of the dash must be unplugged by releasing a locking tongue. The manual details the default positions of gear and water temperature stock connectors, showing male and female connector types and cable colors.

[Image description: Figure 14 shows the position of stock dash front screws. Figure 15 illustrates stock dash removal. Figure 16 demonstrates unplugging the stock dash connector. Figure 17 shows the default position of gear and water temperature connectors. Figure 18 provides a close-up of the gear connector.]

The water temperature stock connector is a 2-pin green connector. Instructions are provided on how to unplug connectors using a flat screwdriver to release the locking tongue.

[Image description: Figure 19 shows a close-up of the water temperature connector. Figure 20 illustrates how to unplug a connector.]

2.5 - Assembling the kit.

The MXL unit is mounted onto the aluminum bracket using four anti-vibration mountings, four screws, and four Grover washers.

[Image description: Figure 21 shows an anti-vibration mounting. Figure 22 displays the rear view of the assembled MXL and bracket.]

2.6 - Cables connection

The wiring harness, wrapped in a rubber girdle, is routed along the bike's right side. The wiring (except the "Lap" cable) passes between the high beam and front fairing. The AMP connectors and the stock wiring's black aluminum box should remain above the high beam chassis. Cables labeled "Gear", "Water temp", etc., are routed along the bike chassis and secured with plastic wrappers. These connectors are typically found under the fuel tank and should enter the engine compartment. AIM male connectors are connected to the stock female connectors and vice versa. The 16-pin connector is attached to the black aluminum box, and the stock dash plastic cover is used to ensure water resistance.

[Image description: Figure 23 shows general wiring installation. Figure 24 illustrates kit installation. Figure 25 depicts the wiring routing along the chassis. Figure 26 shows a detail of the AMP connector.]

2.7 - Installing the kit

The 26-pin MS connector is connected to the MXL unit. The black aluminum box is placed between the bracket and the high beam. The channels interface box is secured using Velcro or plastic wrappers. The MXL unit is then installed on the high beam. The new dash is fixed at four points: two frontal and two lateral. M5 screws are used for the frontal points, and thread-forming screws for the lateral points. Plastic wrappers can be used to secure the new wiring to the chassis. Before reassembling fairings, seat, and fuel tank, switch on the bike to check system integrity and proper working.

[Image description: Figure 27 shows the position of four screws for mounting. Figure 28 illustrates the position of lateral and bottom wings of the bracket. Figure 29 shows lateral screw fixing.]

2.8 - Installing the TPS cable

Before installing the TPS cable, the fuel tank must be removed. The Suzuki stock cable is unplugged from the TPS sensor and connected to the MXL wiring's TPS male connector. The MXL TPS cable's female connector is then connected to the TPS sensor. The 4-pin Binder connector is plugged into a free channel on the MXL. Configuration of the TPS sensor channel is detailed in later chapters.

[Diagram description: A diagram shows the MXL wiring connector, Suzuki stock wiring, TPS sensor, and the connection path for the TPS cable.]

3 – MXL Connection Inputs

The MXL unit features several connectors for data acquisition:

• Lap connector: For lap time acquisition.
• Expansion modules connector: For connecting CAN expansion modules like GPS or Lambda probes.
• 2 AMP connectors (12 and 16 pins): For communication between the logger and the Suzuki GSX-R K3 ECU.

[Image description: A view of the MXL unit showing the labeled connectors: Lap connector, AMP 12 pins connector, AMP 16 pins connector, and Expansions Modules connector.]

4 - MXL GSX-R K3 Firmware

The MXL firmware for Suzuki GSX-R K3 provides a second virtual dashboard. In "street mode", it displays RPM, speed, engaged gear, battery voltage, odometer, date, and time. On the track, it automatically switches to "track mode" when a transmitter is detected, displaying lap times instead of the odometer.

[Image description: Figure 30 shows the display in street mode with parameters like RPM, Speed, Gear, Battery, and Odometer. Figure 31 shows the display in track mode with Lap time.]

The visualization mode (street/track) is stored by the logger. The default is "show odometer".

5 - Configuration

After installation, the logger uses a default configuration. For custom configurations, use the Race Studio 2 software. Launch Race Studio 2, select "AIM system manager", choose MXL, and then press the "New" button in the system configuration window.

The configuration window requires selecting the Data logger type (MXL Pista or Strada), entering a new configuration name and vehicle name, and choosing units for speed, temperature, and pressure. After these settings, select the "Channels" layer for channel configuration.

[Image description: Screenshots show the Race Studio 2 interface for system management and creating a new configuration, including selecting logger type, vehicle name, and units.]

The channel configuration screen displays sampled channels for both MXL Pista and Strada. Additional analog channels are disabled by default and can be configured via the Race Studio Configuration user manual.

[Image description: Screenshots show the channel configuration screens for MXL Pista and MXL Strada in Race Studio 2.]

Display Configuration

The display configuration involves setting parameters like RPM max value (e.g., 14000), gear sensor calibration (detailed in Chapter 6), and shift light thresholds. For speed, the sensor is on the jackshaft, and the equivalent circumference is calculated using a formula involving pinion and crown teeth numbers and wheel circumference. The default equivalent circumference for a Suzuki GSX-R K3 750 is 801.4 mm (31.55 inches). If gear ratios change, this value needs re-computation.

[Image description: A screenshot of the Race Studio 2 system configuration layer showing display settings, RPM, gear sensor, and speed configuration options.]

Displayed channels include ECT (water temperature) with threshold values (Min 50°, Max 90°), and Odometer. The logger defaults to showing the odometer but switches to "Show lap time" mode on the track with an IR receiver/transmitter. The odometer display returns when switching the MXL on/off.

6 - Gear Calibration

Gear calibration is the final system configuration step, necessary if the default settings do not accurately display the engaged gear. This procedure requires a PC with Microsoft XP or Vista and the Race Studio 2 software. Connect the logger to the PC via USB and switch it on. Run Race Studio 2, select the logger, and press "Calibrate" on the menu bar or "AIM System calibration" button.

[Image description: Screenshots show the Race Studio 2 interface and the sensor calibration window, prompting the user to press the 'calibrate' button.]

The calibration process involves enabling checkboxes for each gear number and pressing "Continue". Progressively engage each gear (with the bike switched off but the master switch on) and press "Continue" after each engagement, following on-screen instructions. The system automatically stores the new values.

[Image description: Screenshots show the gear sensor calibration window with fields for gear number and raw value, and the process of engaging gears and continuing calibration.]

Once calibration is complete, press "End calibration" and then "Transmit calibration" to send the new configuration to the logger.

[Image description: Screenshots show the final calibration confirmation and the sensor calibration window with a "Transmit calibration" button.]

6.1 - Saving the configuration with custom gear calibration

To save the new configuration, activate the "Select configuration" layer in the system configuration window and press the "Receive" button. This reads the logger's configuration and saves it to the Race Studio 2 database.

[Image description: A screenshot of the Race Studio 2 system manager showing the "Select configuration" layer and the "Receive" button.]

7 – Equivalent Circumference Compute

To compute the equivalent circumference for the "Channels" layer in Race Studio 2, use the "Bike.exe" utility found in the "X:\Utilities" folder on the Race Studio 2 software CD. Run "Bike.exe", input the drive gear teeth number, driven gear teeth number, select the unit of measure, and enter the circumference value. Press "Compute" to get the equivalent circumference, which is then entered into the Race Studio 2 configuration window.

[Image description: Screenshots show the "Bike.exe" utility interface for calculating equivalent circumference, with fields for gear teeth numbers, unit of measure, circumference value, and the resulting equivalent circumference. Another screenshot shows the "Speed_1" channel configuration with "Wheel circumference (mm)" and "Pulses per wheel revolution" fields.]

8 – TPS Sensor Configuration

After installing the TPS sensor, calibrate it using Race Studio 2 software on a PC. Connect the logger to the PC, run Race Studio 2, select the logger, and activate the "Channels" layer. Choose a free channel, enable it, set a channel name, select "Zero based Potentiometer" as the "Sensor Type", set the "Measure Unit", and input a high scale value (suggested 110%). Finally, click "Transmit" to send the configuration to the logger.

[Image description: Screenshots show the Race Studio 2 interface for TPS sensor configuration, including selecting channels, sensor type, and measure units.]

To calibrate, click "Calibrate" in the software. The calibration window prompts to press "Get Raw Value" for both the high (gas fully open) and zero (gas closed) positions. Match the acquired values with custom values in the "Measure" box and press OK. The calibration is then transmitted to the logger.

[Image description: Screenshots show the sensor calibration window for TPS, with steps to get raw values for zero and high positions, and to input measure values.]

9 – Channels

The MXL Strada/Pista kits for Suzuki GSX-R come with default channel configurations. These include RPM, Speed, Water Temperature, Oil Pressure, Fuel Level, Turning Lights, High Beam, Engaged Gear, calculated gear, lateral acceleration, datalogger temperature, and battery voltage. Additional channels can be used for external sensors like suspension potentiometers or brake pressure sensors.

[Table description: Lists channel identifiers, names, and functions for MXL Pista Suzuki and MXL Strada Suzuki.]

10 - Data Download and Analysis

Data download and analysis are available on the MXL Pista model after a test session. Refer to the Race Studio Configuration and Race Studio Analysis user manuals for details.

11 – MXL Optional Expansions

The MXL system is modular and expandable. Optional expansions include:

• GPS Module: Allows sampling of brake and suspension analysis, vehicle chassis information, and pilot behavior analysis on track. Data can be exported to Google Earth®.
• LCU-ONE CAN: Optimizes the Air/Fuel stoichiometric ratio using a Bosch LSU 4.9 wide band probe, detecting Lambda values between 0.65 and 1.6 for maximum engine performance.

[Image description: Images show the GPS Module and the LCU-ONE CAN device.]

11.1 – Appendix "A" MXL for Suzuki GSX-R K3 Kit Wirings

This section provides detailed wiring diagrams and connector pinouts for the MXL Pista and MXL Strada Plug&Play kits for Suzuki GSX-R K3. It includes tables for 10-pin Hirose female connectors, Binder 719 connectors, and AMP connectors, specifying pin assignments, cable colors, and lengths.

[Diagram description: Wiring diagrams for MXL Pista and MXL Strada kits, showing connections to various components like Sumitomo connectors, Binder connectors, and AMP connectors. Tables list connector pinouts and cable details.]

11.2 – Appendix "B" TPS Cable

This appendix details the TPS cable used for the MXL Plug&Play kit for Suzuki GSX-R K3-K4. It includes a diagram showing the cable split and pinout details for the 4-pin Binder 719 male connector and 3-pin Yazaki connectors.

[Diagram description: A diagram illustrating the TPS cable for the MXL Plug&Play kit, showing the cable split and pinout for Binder 719 and Yazaki connectors.]