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Cheap Bastard\'s Chop Shop - Taming the beast
author // Bruce Steever
photographer //
Cheap Bastard's Chop Shop

One of the first things I wanted to do to our new Hayabusa is get with the folks over at Bazzaz Performance, and get Suzukus Maximus under control…Traction Control.

I'm a track rider and I drool over the latest race technology. When Ammar Bazzaz introduced the new Z Fi TC unit, he immediately earned a Brappy for 2007's best roadracing product.

Now while the Busa won't be seeing too much track time, the tire spinning power is ripe for a traction control system. The idea is simple: when the tire begins to spin up, sensors cut power to keep the bike pointing in the right direction. Bazzaz Performance is very clear about the fact that this system is for track use only, but the system works just fine on the street, thank you.

By having a dealer install this system, you'd be looking at spending over $1500. Screw that! The install is quite doable for the home tuner, so save the $500 you'd spend in labor for something more important...like rent or a mortgage payment.

This Month's Chops:

Parts: Bazzaz Performance Z Fi TC Engine Control Unit with Traction Control ($999.95, www.bazzazperformance.com) and Traction Control / Map Switch ($249.95)

Tech Level: Again, the pretty plastics make things more difficult than strictly necessary, but once you get the panels and airbox off, the actual installation is pretty straightforward. Call it a Medium difficulty job for the home tuner.

Money Saved: The Bazzaz TC system is so new that many shops in the area didn't even have labor rates for it, but average quotes came to around 6 hours, or about $480. By doing our own installs, our total savings for the Busa thus far is $800.

Result: The Bazzaz unit offers enough adjustments to get you into trouble, but before I even got into the software, the ECU hardware did a fantastic job of curtailing any fishtailing. Rolling burnouts, out. Massive power under control, in. And the quick shifter is just icing on the cake.

STEP 1
Cheap Bastard's Chop Shop

First, curse vividly at the stylized fairings. The lack of external hardware may look clean, but the extra work to peel the panel off is frustrating at best.

STEP 2
Cheap Bastard's Chop Shop

Using the supplied tank prop stand, lift and support the fuel tank (a nearly empty tank makes life easier here). Remove both seats. Remove the negative battery lead (never work on electrical systems with the battery attached!).

STEP 3
Cheap Bastard's Chop Shop

Remove the airbox sensor connectors, airbox bracket and vent hoses, then loosen the throttle body clamps. Then, firmly but gently wiggle and pull the airbox free from the throttle bodies. A rubber mallet can help with the "firmly" part.

STEP 4
Cheap Bastard's Chop Shop

Now things get interesting! We will need to install two separate wiring harnesses, plus a third for the control switchgear. The sheer number of connectors may be daunting, but it’s not as difficult as it appears.

STEP 5
Cheap Bastard's Chop Shop

Directions are your friend. Read them thoroughly before you begin. Then you'll be prepared for each step along the way.

STEP 6
Cheap Bastard's Chop Shop

Well, this part's easy, anyway. The Bazzaz TC system bypasses the oxygen sensor, so simply plug in the bypass on the right side of the bike.

STEP 7
Cheap Bastard's Chop Shop

Start by placing the ECU in the tail and routing the Bazzaz fuel injection harness along the left side of the bike. Then, locate the tagged connectors on the Bazzaz wiring harness for lower injector #1. Remove the stock connector, and plug the Bazzaz connectors into place.

STEP 8
Cheap Bastard's Chop Shop

Continue along the bottom row of injectors, and then repeat for the secondary injectors on the top row. Each connection during the install is inline, meaning that we add the new connections in addition to the stock components rather than replacing them.

STEP 9
Cheap Bastard's Chop Shop

Once all the injector clips are in place, find the Throttle Position Sensor and clip the Bazzaz connector in place. Feel free to make jokes about TPS Reports.

STEP 10
Cheap Bastard's Chop Shop

Buried underneath the left hand frame rail are the connections for the Gear Position Indicator (which allows the Bazzaz system to tune traction control individually for each gear) and the RPM sensor. Connect the Bazzaz harness inline like the rest.

STEP 11
Cheap Bastard's Chop Shop

Power up! Attach the ground lead to the crankcase bolt where the stock electrical system grounds (top of the crankcase, directly under fuel pump) and then using the supplied splice, cut into the stock wiring harness to attach the switch lead for the Bazzaz harness. Gods above, I hate cutting into electrical systems…does it show?

STEP 12
Cheap Bastard's Chop Shop

Yaaay, more wires! Route the Bazzaz ignition harness along the right side of the bike. Just like the injectors, this will connect inline with each spark plug wire. Unlike the injectors, this harness starts at cylinder #4 first.

STEP 13
Cheap Bastard's Chop Shop

Remove the stock shift linkage rod, and install the shift sensor in its place. Connect the shift sensor lead to the Bazzaz ignition harness.

STEP 14
Cheap Bastard's Chop Shop

Finally, bolt the traction control switchgear onto the left clip-on and route the wires along the right side of the bike to connect to the Bazzaz fuel injection and ignition harnesses at the rear of the bike.

STEP 15
Cheap Bastard's Chop Shop

Everything should behave as if the last 6 hours didn't just happen. The software is pretty straightforward, but before you start screwing around with a laptop, take your tweaked bike for a ride. A simple test was full throttle in first gear on cold tires. The system cut power to keep the bike from spinning the rear tire. And the quick shifter worked like a charm.

2WT recommmends proper training before working on your motorcycle. Procedures may vary for each bike. This article is considered a basic guide, use it at your own risk.




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