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Sunday, 19 November 2017
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Home arrow Modifications arrow Yellow Box Installation

Yellow Box Installation Print
 

Yellow Box Installation


I've created this page to post some information on the "Yellow Box" Speedo recalibrator. I purchased my Yellow Box Speedo recalibrator from YellR (Black Robotics) manufacturer of the Yellow Box. Service was second to none and I highly recommend them and the product. Delivery included the Yellow Box, well written instructions with a ratio chart, wiring loom and a plug that plugs into the Yellow Box Loom that allows complete by-passing of the Yellow Box for whatever reason. (The Yellow Box has a 10 year guarantee.) Visit YellR by clicking here. They have a recalibrator to suit most bikes and cars with an electronic speedo.


My installation of the Yellow Box

Here are some pictures and explanations of my installation. It was a pretty straight forward job and took me under an hour to complete. I just followed the instructions that came with it, they were easy to follow and included the colour coding for Suzuki wiring which was accurate and worked.

Here is a list of tools and equipment I needed / used for the whole installation.

  • Allen key to remove the speedo sensor
  • A knife to strip the cables
  • Pliers
  • Soldering iron and solder
  • Heat shrink tubing to cover the supplied loom.
  • Electrical insulation tape
  • An inch of double sided tape to mount the Yellow Box

 

Yellow Box
Here is the Yellow box,
the removed speedo sensor
and the supplied loom
covered with heatshrink.

The only bits of the bike I had to remove for the whole job was the seat, the hump and the speedo sensor.


Removing the Speedo Sensor

First off I located the speedo sensor plug and unplugged it. On the TLS it is located on the left hand side of the bike just near the two airbox drain plugs. I pulled the front drain tube out of the way to allow a bit more room to work with. Then I removed the complete sensor to make it easier to work on the cables.

Yellow Box
The Speedo sensor plug.
Speedo Sensor
The Speedo sensor removed.

Splicing the looms

Next I stripped the speedo sensor loom as per the instructions and soldered the Yellow Box loom to it and taped it all up. The instructions included the colour coding for Suzuki bikes (I double checked it with the wiring diagram in my manual and the instructions were correct.) I "ring barked" the tubing around the speedo sensor cables taking care not to nick any of them, then did the same to the sensor cables.

Yellow Box Connections
Click for a larger image (24kb).
Yellow Box
The looms taped together.

Installation

With the looms soldered and and taped up it was time to remount the speedo sensor, run the Yellow Box loom and mount the Yellow Box. I ran the Yellow Box loom up from the speedo sensor and followed the OEM loom to where I decided to mount the Yellow box, right next to the ECU.

Yellow Box
The Yellow box mounted.
Yellow Box
Sensor back on the bike.

Testing

Now that everything is in place, it was time to test the unit. I powered it up with all the switches in the off position and read the LED, the self check was performed and it then displayed the switch settings.

Next I selected the switch positions to put the unit into its' "Output Test" mode which sends a 100hz signal to the speedo, the TLS speedo read approximately 75km/h (46mph). Then came the "Input Test". I had the bike on the race stand so I just span the rear wheel and watched the LED flash.

Yellow Box

Settings

All was OK so it was time for a test ride, but what setting to set the Yellow Box to? Below is a chart with some kilometres logged with standard gearing versus the altered gearing compared to my BC800 digital pushbike speedo. It gave me an average of 1.0437 (4.37%). BUT the gearing change from 17/38 standard to 17/40 modified = 5.26%. So what I did for the time being was use the supplied chart that came with the Yellow Box and set it to 5.25% as at least this will get me back to the standard speedo error, if any.

I've done a few kilometres with the Yellow Box fitted now and have gone for a 4.50% setting after digging up some more readings I found I had recorded. Two of the new results are as follows. Bike trip meter 126.0km versus BC800 trip meter 126.22km. (0.17%) Another set are, Bike trip meter 171.9km versus BC800 trip meter 172.21 (0.18%) Which is very close.

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