888 / St4 Hybrid Project

brad black

the screw in thing is a one way return valve, so that is always the return from the pressure regulator to the tank.

one will be the cap recess drain, blow air through that to confirm.

D4RKO

Thanks Brad, Diagram updated below

D4RKO

Well, yesterday was a big day. After getting the ST4S loom rerouted and with extending a few cables all the electrical bits are now in the tail. I've added a shido lithium battery in there too and it all fits nicely.

I have a standard Hypermotard 1100 ECU so I plugged it in and sure enough with ignition on, the fuel pump primed. A press of the starter and she turned over. A few quick checks, another press and she started!

Quite an amazing feeling after such a long journey.

I now need to work out what to do with the ECU... I was hoping to get the Hypermotard 5AM ECU flashed with an ST4S map but I'm not sure that's possible? Or, I guess I need a 59M ECU suitable for a 996 engine without an immobiliser?

D4RKO

Also had a leak from the fuel tank, theres a bolt at the back underneath and it seems to be leaking from there. What is that bolt for ? Maybe I can remove it and add some kind of sealant around the thread ?

stafford

Just a drain plug

seven4nineR

...

D4RKO

Mmmm, tank leak just became more serious, whats the best way to fix this?

D4RKO

I suspect the Hypermotard map will be too far out of spec for a power commander to fix ? Its such a different engine.

I have found some threads on another forum where people managed to get a 5AM ECU loaded with an ST4S map, I have sent messages seeing if they can help

seven4nineR wroteThe thing is running so all you need to do is tune it? A simple PClll or such like should be fine? Then just add the appropriate push/pull gear lever sensor for a plug in quick shifter.

seven4nineR

...

brad black

the hm had a canbus dash with the air pressure sensor in it, and a idle valve so it'll have a few faults i would think on what you're running it on. plus it's a dual spark 2v motor with probably a fairly inappropriate spark map.

the only 5am file that works 100% in the single fan 01 - 03 st4s is the one i had a fellow fix for me - it's an s4r base file with the second fan turned off. if you can handle the second fan issue (one fan will run continuously if second is missing) an s4r file will work. not sure if it will have the shits if you remove the fan control from it that will actually have an impact on use. later 04> 5am st4s file will work, but again has canbus dash so will miss the air pressure sensor input. you'll need to disable the immo on them all to work too.

it will log a fault about fuel trim i think, but it's actually the different starter logic. ignore it.

D4RKO

I sent some messages to guys on another forum who have ST4S bikes and have managed to port over maps to run on the 5AM ECU

Seems a number of them are running these maps successfully although as Brad points out, without the air pressure sensor input (and also apparently the neutral light will not work either)

As a bonus they have managed to write these files without the immobiliser, but the fans working correctly etc. I have been sent two options, a standard map and a Ducati Performance map (for open pipes)

I'm just waiting for the correct cable from Lonelec to turn up and will give it a go...

D4RKO

Today was the day to sort out the map on the bike. To summarise:
ST4S Loom - modified to extend some connections (inc ECU) under the seat Hypermotard 1100 (2008) 5AM ECU - chosen as I was told they do not run an immobiliser and the 5AM is easier to map later (thanks Brad!)

I managed to speak to some guys on the .ms forum who had successfully swapped out the original ST4S ECU (Marelli 59M) for the later ECU used on Hypermotards / 1098s etc (Marelli 5AM) They had suffered with failing ECUs so did the hard work to make the later ones work!

Using the correct cables form Lonelec, a Macbook Pro and some free (!) software called :
IAW5xReader_V0.28_x64 IAW5xWriter_V0.24

I was able to talk to the Hypermotard ECU and download the original map (in case things went wrong..) and then upload the map the guys sent me from the other forum.

To be certain the new map was on there I connected and downloaded again the map I had uploaded and the text file confirmed this was a different map to the original Hypermotard map.

Holding my breath a little I started the bike and... it ran perfectly, ticks over nicely and responds crisply to the throttle - super pleased with this result !

D4RKO

A couple of fault codes read with GuzziDiag_V0.47 to sort out but otherwise all good

The map is lacking input for the air pressure sensor so I suspect one of the codes is that

TPS probably needs a reset too as I 'think' 3.20 is a little low..

D4RKO

Ok, so I guess the next step is the exhaust silencers.

Does anyone know (I've searched) if it's possible to get any kind of link pipes to be able to run 888 high level silencers? I think someone used to make them but I can't find any info

brad black

tps should be 2.6 degrees on an st4s. don't do the electronic reset, it doesn't apply to that ecu.

D4RKO

Thanks Brad, will leave for now (as its running!)

D4RKO

Does anyone know if the regulator cover is shared with other bikes or does anyone have the part number?

I can't find it online, I see there are carbon versions available but not sure I need to spend money on those

D4RKO

Worked on the clocks / dash today, managed to convince a set of 750SS clocks to work with the ST4S loom (thought they were a slightly better match visually than the ST4S clocks)

D4RKO

Also test fitted the single race seat on the Biposta subframe to check it cleared the grab handles etc (race subframe will come later)

ST4S Exhaust silencers are now fully fitted but don't look good (in my opinion) so the search continues for some alternatives..

econti

Dash looks good. Some high level pipes would be nice

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