ECU Re-flashing - To Flash or Not to Flash

As you will see in some of my other blog posts I'm preparing a ZX6R to race in the 2018 No Limits Newcomers Championship. As part of these preparations I wanted to remove the Power Commander 5 that came with the bike in favour of an ECU reflash courtesy of Woolich and Parkitt Racing.

So what is an ECU reflash?
ECU re-flashing allows you to tune the various maps and settings available in the stock ECU. You're probably thinking well how is this beneficial, well; The system eliminates the need for other boxes and modules such as Power Commanders and ignition modules which merely modify the signals coming from the ECU, with ECU re-flashing you can directly modify the ECU for things like Fuel Maps, Ignition Maps, Secondary Throttle Maps and RPM Limiters. It opens up several options that aren't available using the other boxes whilst also getting a finer degree of tuning. So what does this really mean? It varies from bike to bike but this is what you can do on the ZX6R's:
The simple stuff...

• Disabling the pair valve
• Disabling the exhaust servo (this will remove the FI light if you have a race system or prevent the need to trick the bike into thinking it has one)
• Disabling the Immobiliser (Allows you to go keyless)
• Disable Stock O2 Sensor
• Disable Tip Over Sensor (TOS)
• Adjust RPM Limiters
• Adjust Fan Temperature

The technical stuff...

• IAP Fuel Maps
• TPS Fuel Maps
• Ignition Timing Maps
• Secondary Throttle Plate (STP) Opening Maps
• Injector Balance Maps
• Ram Air Maps

I'm a big advocate of ECU re-flashing, I've used Power Commanders and Bazzaz units before but the freedom it gives you to disable sensors and systems only really required for road along with the finer tuning of maps results in better throttle response, smoother power curves and in the case of my ZX6R, bigger power gains.

How do you go about doing it?
Once you've decided you want to go for a re-flash there are two options to choose from:

1. Buying the full kit
This option includes the full package you will require to flash your ECU and inherently the most expensive (~ £375 Plus £150 for a dyno re-map)
The package includes:
- USB (Denso or Mitsubishi) v3 (Used to to connect your computer to your ECU)
- USB Cable
- Manufacturer specific harness
- Bin File Definition in the Woolich Racing Tuned software

This option will allow you to flash your ECU on the bike at any time using your computer. It's very useful if you're constantly re-mapping your machine and want the ease of just being able to plug straight in at the circuit or at home. Most of the time this isn't the case so for many of you, option 2 is the best.

2. Woolich Dealer re-flash

This is the option I went down, mainly due to the lower cost and I didn't have the desire to do my own re-mapping. Firstly, you'll need to find yourself a tuner which owns the flashing equipment for your bike. I used Parkitt Racing in Tuxford for my 2009 ZX6R, they've been around since 2000 and have extensive experience in both road and racing machines, double check with them that they have what you need but they do stock equipment for most modern machines. It's as simple as dropping off your bike and leaving it with them. (There is a postage option where you can send in your ECU, they will flash it with a generic map and post it back, it's £150 for this service but it's not recommended as every bike is different and you'll never have a perfect map)

So what do they do while they have it?
To start with they will hook up your ecu and flash in a known good map, this will give a base for the dyno tune. The guys will do a run on the dyno and identify improvements to be made, this will be repeated until they're done, it's really that simple.

Add ons

Race Tools
Race tools is the real highlight of the Woolich products. The Race Tools package allows you to enable Quickshifter, Launch Control and Pit Speed Limiter in the Stock ECU.
It includes:

• High quality strain gauge Quickshifter with digitally controlled pressure sensing that can be used in regular or race shift pattern. Quickshifter Kill times are configurable per gear and kills both fuel and ignition directly from the ECU. These are Cordona quickshifters and rebranded for Woolich, having tried the dynojet QS and a few others I can honestly say this is the best quickshifter I've used, it's incredibly smooth and the ability to control pressure sensitivity means you get a real positive gear change.
• Race Tools ECU Key to enable Launch Control and Pit Limiter.
• Launch Control allows you to modify Delay, Launch RPM, Ramp Time and Ramp RPM
• Pit Speed Limiter allows you to set the RPM to limit the speed while riding through the pits
• Auto blipper for clutchless downshifts is available on some models as well

The cost of the Race tools package is around £370, this may seem steep but you get a quality quickshifter with the added benefits of Launch Control and Pit Limiter. Stand alone QS such as the HM SS come in at £350+ so you're getting much more for your money. Parkitt can also add a 2 button switch which will give you the pit limiter button and an on/off switch for rain lights.

Getting a License - A Novices Guide to Starting Racing

Trackday's are a growing trend amongst the biking community; there's really no other feeling like getting out on track for the first time to test the limits of yourself and your machinery without the threat of a lamp post or car drivers. Trackdays are great fun, rewarding amongst a long list of other perks, but like myself many seek greater things the "Holy Grail of motorcycling" you could call it. I remember sitting there watching Superbike Sunday as Marc Marquez duelled with Jorge Lorenzo at 200 mph, on the edge of human and mechanical possibilities. Crutchlow pinging himself skyward (again), thinking, "I really want to try this, how hard can it really be?" So I set out on a long, tiring, money sapping, time consuming, life changing journey that led me to the start line of an actual race, with people watching!

If you find yourself reading this, it's not because you can't decide whether you want to race or, it's in your head and nothing is going to stop you (apart from the money, that stops us all!). This guide won't be about helping you chose to race or not, just give you the tools that will allow you to start your journey; it will give you all the information about how to get going in Road Racing. (ACUs term for Short Circuit track racing)

What License Can I apply for? Firstly you need to know what license you're going to apply for. The two available for first timers are: Novice & Intermediate Novice. Below is a extract from the ACU guidelines outlining the requirements for each license.

https://members.acu.org.uk/2016-Road-Race-Notes.pdf

REMEMBER: If you have a Full UK "A" License, apply for the Intermediate Novice License. This will allow you to enter races on any capacity machine.


Step 1: Filling out the forms
So now you know which license to apply for, there are two options: Online or Paper Form, the good old paper method is probably the best option for new license applications as there are a number of things you need to do before you can send off the form.

A. Download a copy of the ACU Competition License application form and print out a copy.
2017 ACU Competition Road Race License Application Form
(If you don't have a printer you can call the ACU on 01788566400 and they will post a copy to you)

B. Fill out all the relevant sections (guidance file link)

C. You will need 4 additional items before the ACU will accept your application
     i.    A nice pretty picture of you - Passport photo is ideal. It'll go on your license so make it a good            one!
     ii.   An eye test - Take page 2 of the form to any optician and they should be able to complete this              for you. Most will charge a fee but if you're lucky some are free. They will test you, sign it and            stamp the form to say you've passed.
     iii.  An affiliation code (See Step 2)
     iv.  CTC & Basic Rider Assessment Course Pass (See Step 3)

D. Complete Steps 2 & 3 and get your License!

Step 2: Join a Club
To get a Road Race License you must join an ACU affiliated club. In this guide I won't cover or suggest clubs to join, that's completely up to you based on what class of bike you have and what championship you want to race in. Joining a club will not tie you to this club permanently it's just a requirement for the application.  I myself, joined 1 club and raced with them throughout the year, I felt this was best as you got to know the people and the way that club runs their race weekends. Others feel trying different rounds with different clubs gave them a better understanding of which club they preferred, do what you feel is best for you. There is no limit to the amount of clubs you can join but you will need a membership to enter that specific clubs events. (Ie. A membership to No Limits Racing will not allow you to race with Thundersport)
Most clubs now allow you to apply online, the cost is around £30 and this will allow you to enter all of that clubs events throughout the calendar year.
IMPORTANT: Once you've joined a club, you will get sent a 9 digit ACU affiliation code, make sure you fill this code out in Section 6 of your ACU Application Form (See Step 1 item C. iii) as it is one of the mandatory requirements.

Step 3: Do the Course
This is the final stage of the application process and requires you to complete 2 courses, most if not all providers will do them both in one day:
Competitor Training Course (CTC) - Classroom session where you will be tutored on various aspects of racing, such as flags, safety, etc. At the end of the sessions you will need to answer a multiple choice test, it's nothing to worry about, just make sure you pay attention to to teacher!
Basic Rider Assessment (BRA) - This is an on-track course (so you'll need your bike), it will cover a range of practical exercises that will introduce you to all aspects of on-track race craft. It will assess your competency to ride and give you the chance to experience attending the assembly area > coming onto the grid > the warm-up lap > the lights and the best bit...the start!

 You can find a list of 2017 courses here

Finally, the course leader will stamp Section 7 of your application form and in most cases be responsible for sending off your form to the ACU for processing, approval and eventually a brand new shiny Road Race Licence card through the post! It can take a couple of weeks to come through so don't worry if it doesn't arrive before your first race, you can call the ACU and they will give you your license number so the club you race with can cross reference it with their records.
IMPORTANT: Remember to take your application form with you to the CTC/BRA course, ensuring you have attached a photo, passed your eye test and filled out your affiliation code in Section 6 (See Step 2).

That's it, just one of the stages complete towards doing your first race. The next section will cover your bike and how to prepare it for racing. Below are some useful links to the ACU and some major clubs.

Useful Links
ACU (Auto Cycle Union)
2017 ACU Competition Road Race License Application Form
License Form Guidance Notes
ACU CTC/BRA Training Courses 2017
No Limits Racing Race School
Thundersport GB
North Gloucester Road Racing Club (NGRRC)