INSTALLING THE YELLOW BOX - Yellow Box Speedo Recalibrator
Contents
1. Now you will cover each solder join area with electrical insulating tape or heatshrink Step 4 Wires are laid down flat ready for Nellow Box electrical tape to be wrapped Bike www YELLR com The diagram below shows the wires layed down flat this is why we put 20mm 3 4 inch between each connection so now we can wrap electical insulating tape around this entire bare section to make it neat and safe again Overlap the tape as you wrap it check the other wiring in your vehicle and do it like that Be sure there are no bare wires sticking out from the tape that might touch metal parts of the vehicle and that no wires touch each other where they are not supposed to Feel free to wrap tape around any wire that will make the installation neater and safer www YELLR com Makers of the Yellow Box Speedo Recalibrator This text is reproduced on our web site INSTALLING THE YELLOW BOX Step 5 Secure Yellow Box and route wires a Secure the Yellow Box We recommend you mount secure your Yellow Box in a reasonably dust free dry area Mount it away from high heat sources like the exhaust or engine away from electrical spike generating sources like the ignition system the battery and battery charging system regulator rectifier spark plugs etc Usually the best location is under the passenger seat in motorcycles b Route the Yellow Box harness wires Route the wires away from high heat sources anything that moves and2. any potential electro magnetic generating sources electrical noise interference sources and as described for the Yellow Box above Note Speed sensors with a 5 volt power supply are more susceptible to electrical interference Take extra care where you secure your Yellow Box and harness wiring with a 5 volt system This precaution is recommended due to the very high sensitivity of modern speedometer systems Potential electrical noise may be just strong enough to register in modern speedometer systems if something changes from the factory vehicle ie an aftermarket product Step 6 Testing and take it for a spin Testing and Calibration Refer to Using the Yellow Box for special test modes Refer Calibrating the Yellow Box for how to determine your total speedometer error and set your correction Suggestion for Step 5 above To make testing and calibration easier you may wish to delay the secure step and leave your Yellow Box in a place where you can easily get to the switches needed for calibration After calibration is complete you may seal the switches and move it to a more secure location Optional switches covering The Yellow Box switch contacts are gold plated and weather resistant In some cases you may wish to seal cover the switches for extra protection against the weather and fine dust build up Choose an easy to remove option Switch sealing options include hobby hot melt glue not industrial s
3. trucks Inductive coil speed sensor has 2 wires o z ae Speed Speedo Sensor www YELLR com Page 1 of 3 After the Yellow Box is connected Speed sensor signal now passes through the Yellow Box enabling the Yellow Box to correct the signal in real time After Yellow Box installation PWR o YELLOW BOX ae Cy Speed Black or Green Sensor Speedo www YELLR com Installation of the Yellow Box Steps 1 6 Step 1 Locate the vehicle speed sensor In many motorcycles the speed sensor is located on the top or side of the transmission gearbox crankcase The speed signal pulse is generated from the revolution of the crankshaft gears In other motorcycles the speed sensor is located near the front sprocket As the front sprocket rotates the sensor detects this and sends an electrical pulse to the speedo Many sportscars pickups utes 4WDs 2WDs and cars also use a 3 wire hall effect type speed sensor In these vehicles the speed sensor is usually located on or near the transmission or transfer case toward the rear of the engine There should be a 3 pole connector plug visible Some vehicles will connect the Yellow Box at a location not near the speed sensor Such as into near or after the ECM ECU engine control module or PCM powertrain control module or other connection point Refer to our Vehicle specific installation guides Step 2 Prepare the vehicle wiring To gain access to the s
4. INSTALLING THE YELLOW BOX Background Information Please read this entire installation guide before starting Your Yellow Box package includes e Yellow Box Speedo Recalibrator e YB wiring harness e Jumper plug returns YB wiring to original speedo e Instructions What is needed for the installation Installation is fairly straight forward Most people do the installation themselves usually takes 30 to 60 minutes Soldering forms a better electrical connection and is our recommended method see our Soldering tips guide You will need basic electrical amp other tools Screwdriver allen keys etc Wire cutters wire stripper sharp knife or pliers Soldering iron and fine solder Electrical tape or heatshrink some cable ties Voltmeter or multimeter Vehicle service manual or electrical wiring diagram is also helpful for locating the speed sensor Where does the Yellow Box Connect The Yellow Box connects after your vehicle speed sensor and enables you to correct the speed signal before the speedometer and or other vehicle systems Hall effect speed sensor has three wires Diagram showing before the Yellow Box is connected Hall effect speed sensor has 3 wires PWR 12 v or 5v Signal Ov to 12v to Ov JLSLIL Cy Speed GND Ov Speedo Sensor www YELLR com Inductive coil type speed sensor has two wires The other speed sensor type which is often used in BMW motorcycles some cars and some
5. lean the switches with a spray of total evaporation electrical spray solvent non residue then work the switches forward and back about 20 times repeat Switches are covered under the 10 year warranty The speedo jumps fluctuates sometimes Check where you have secured your Yellow Box and routed the YB harness wires Refer Step 5 above The quality of the power supply may also be a factor see below Check for bad connections on all YB harness wires solder your connections Speedo drops out reads zero sometimes Check your connections solder your connections The power supply quality may also be a factor see below The Yellow Box power supply quality is important It needs to be a clean filtered source that is not subject to voltage fluctuations or electrical spikes The speed sensor power is the best power source for the Yellow Box Any other source may not be filtered If you must use another power source try adding a filter capacitor 25 volt 470 uF across the red and black YB wires into the connector pins at the Yellow Box unit itself This should help to filter any low quality power source www YELLR com Makers of the Yellow Box Speedo Recalibrator This text is reproduced on our web site
6. n your workbench carefully strip back the outer cover sheath to gain access the 3 sensor wires You need about 100mm 4 inches to make it easier Splice the 3 wires of the hall effect speed sensor e Wire 1 power score this wire don t cut e Wire 2 ground score this wire don t cut e Wire 3 speed signal wire cut twice as shown in diagram below leaving a 20mm 3 4 inch gap Note STRIP and CUT EXACTLY as shown below Step 2 100mm 4 inch Sensor Black Red Black White Suzuki colors A Yamaha colors N Orange Red Black White Honda colors R Black Pink www YELLR com The wiring colors indicated above are for some Suzuki Yamaha and Honda motorcycles Your wiring colours may be different Please check the electrical diagram in your vehicle s service manual and then confirm each wire with a voltmeter Page 2 of 3 Step 3 Connect the Yellow Box The Yellow Box wiring harness has four wires YB RED Power speed sensor power 5 or 12 V YB BLACK Ground speed sensor ground YB WHITE speed signal IN comes from sensor YB GRAY speed signal OUT goes to speedo Four wires go to Yellow Box Bike www YELLR com You must connect the Yellow Box wires exactly as shown above or your speedo may not work properly Carefully compare your work to the Step 2 and Step 3 pictures and with the before and after diagrams on page 1 Step 4 Protect your wiring connections
7. peed sensor on motorcycles you may need to remove the left side fairings the seat and lift or remove the fuel tank Other vehicles refer to the vehicle specific install guides or follow the steps below if connecting at the speed sensor a Use voltmeter to check each speed sensor wire Power up your vehicle and measure the voltage on each of the 3 speed sensor wires Push voltmeter probe into the speed sensor coupling 3 pole connector pins Write down or mark with tape texta or draw a schematic indicating what each wire does as below www YELLR com Makers ofthe Yellow Box Speedo Recalibrator This text is reproduced on our web site INSTALLING THE YELLOW BOX Voltage measure the 3 wires of hall effect speed sensor e Wire 1 power constant 12 volt or 5 volt e Wire 2 ground main vehicle earth e Wire3 speed signal wire measures 0 volts then 12 volts or 5 volts as the wheel is rotated square wave b Remove the speed sensor from the vehicle Remove unplug the entire speed sensor coupling sensor and wiring up to the first connector Release the plastic catch locking mechanism of the connector Unscrew the sensor pickup Removal makes it easier to produce good electrical connections c Splicing the speed sensor wires Closely examine the diagrams below showing how to prepare the speed sensor wires See page 1 diagrams showing before and after the Yellow Box is connected With your removed speed sensor coupling o
8. trength silicone sealant store in a plastic bag or zip seal bag or use 3M removable adhesive strips Command brand Page 3 of 3 Problems All Yellow Boxes are tested during and after manufacture Most problems are be caused by an incorrect installation Refer to the Using the Yellow Box for the special test modes you can use to check all your wiring connections Yellow Box never lights up with ignition on This means there is no power to the Yellow Box Check you have the YB power red wire and ground black wire connected properly and the right way around Check for bad connections on these wires The Yellow Box will not be damaged by reverse connection for a few minutes It lights up ok but the speedo doesn t work Make sure it is not in a special test mode Check you have connected the YB harness IN white wire and OUT wire grey or green wire the correct way around Check for bad connections on these wires Incorrect connection will not damage the Yellow Box or damage the speedo The speedo reads way high or way low If the speedo seems normal but reads very low or very high you may have in kph mph conversion mode Check switch setting think some switches don t work Test the switches all On and all Off Flick switches back and forth to clean The Yellow Box has a high quality switch with gold plated contacts but dirt or moisture over a long time may still cause switch malfunction You may c
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