Setting up a zeeltronic on a 3XV

[mellorp]

If you are doing this for the 1st time it is quite easy

What I would say is that if your engine is tired you are pretty much wasting your time. Any 250 2 stroke is fickle at best but trying to optimise an engine with pistons that slap a crank that rattles and pipes and airbox that wont let it breath then you are wasting time and money. Anyway assuming you have a spanker of a motor read on.....

I prefer the laptop software over the hand held. It's much easier to use, you can save files screen shot things and still have the monitor option

Check you know how to load and save settings. Do it in the wrong order and it's frustrating. Do it in the correct order and it's a POP

The base setting you get for the 3XVR is quite good. Iginition advance is OK so you probably just want to tackle the PV and air solenoids

If you have a map switch then setting up by riding on the road is simple. You set your 2 extremes on map 1 and map 2 in the garage and simply swap between them whilst you are out on the road.

I have even taken a mini lap top in a rucksack and made adjustments out and about. Get me !!!!!

So the key is the extremes. As the fixed transfer porting has different effects over engine speed, you can tweak the PV's , air solenoids and ignition advance to optimise those fixed settings.

But before you start fiddling balance the carbs and have the oil pump set properly
Calibrate the TPS closed 0% and WOT 100%
Next calibrate the PV's again 0% and and 100% and make sure they are adjusted properly

The 3 fixed jets are the air screw, and pilot jet and main jet. The needle being the only previous variable. But not now

Next get the pilot jet and air screw correct. These affect jetting right thru the range. Things are easier with the zeeltronic as you can go on the rich side and let the air solenoids correct everything. As long as it starts (needing choke), idles evenly and picks up quickly from low revs then you are somewhere close.

If possible get the MJ optimised for WOT with plug chops. At this point I suggest you have the air solenoid fully shut with TPS at 100%

So it's running OK so lets get to the tuning bit

Set the monitor on and see how far out your rev counter is. No point in calibrating the zeel using the rev counter and finding it's 10% out.

Leave the ignition advance as it comes

1 - Set the PV fully open thru the entire rev range and go for a ride
Note when the power really kicks in. Thats your 100% open point
2 - Set the PV fully closed  thru the entire rev range and go for a ride
Note when the power starts to drop off. That's your opening point

The zeeltronic extrapolates the changes between action points. e.g. PV shut at 6k and full open ay 10k then at 8k they are 50% open.To that end if you need the PV to start opening at 8k then you need to tell the zeel to have them full closed at 7900

Doing the air solenoids is a bit more difficult as you need air flow sensors, and to know what you are doing with the jetting etc. That's where a dyno can help, ditto the ignition advance. But if you have the ability to change things on the fly then give it a go

So now rather than messing with needles and clip positions you can bleed air in using the solenoids

If it feels a bit fluffy then you might be a bit rich so open the air solenoid to lean things off. If it feels a bit lean go the other way. If the air solenoid is already shut you need to raise the needle to richen it up Best to ride without ear plugs so you can hear the engine and exhaust

And that's about it. Spend a day riding around and
1 you have fun
2 you get to know the bike
3 you get a faster bike at the end of it
4 you feel like a gimp/tuning guru depending on the results

Just my thoughts. Please feel free to rubbish or support these ideas as you feel necessary

Programming the PV servo

I have been programming the PV's on my RGV500 and discovered an interesting feature that was of massive benefit

When calibrating the PV's the servo sits in it's "at rest" position which you calibrate at say 200 and adjust the cables etc.. However what you can do is set the resting position at say 250 (or 150 or what ever), which places the servo in a slightly different position then adjust the cables to bring the PV to it's closed position.

The advantage here is if you run out of adjustment on the cable, just program the servo to start in a different position, so the cables are never at their limit of adjustment
I also binned the idea of using the alignment marks. If you are smart you scribed your own alignment marks for fully open/closed. If not it's pipes off and feel the position of the PV in the exhaust port.

Then with the exhausts off, or your own alignment marks, you can play with the fully open position setting in the zeeltronic software until you get the PV in the fully open position. 

PV - a word of caution

Get the 1st PV to be working correctly then try to get the cr@ppy linkage to get the other PV into sync. The important setting is getting them fully open at the same time, if they are a bit out at other points in time don't worry too much.  The alternative is a TZ style servo with 4 cables, or adapt one from the RGV250 (VJ21/22/23 are all the same).

[vinny]

Nice work 

[4l04ever]

The air solenoids do not work properly with a Zeel on an R model.  If you compare to what a 3MA Zeel does, it is completely different.  The 3XV Zeel appears to be setup for Powerjet carbs rather than Air solenoids.  I tried to use VJ22 air solenoids, which are duty solenoids, but could not get them working correctly.  Ending up using the powerjet settings with the original £XV solendoids and adjusted as best I could.   This setup was completed on a dyno, so I could see the fuelling as it was adjusted.

[Steveog]

Thanks, Phil. A zeel is in my future. I'm assuming the PC you're referring to is an MS OS. Any version preference?

[scrimsmustang]

Please could you send me a "somewhere close"map ile give you my specs for motor pipes jetting airbox i use, im just not confident to do it setting up powervale programming etc

[ybk]

Nice, I'll sticky this. What file extension does the Zeel use? I'll add it to the attachable extension list then maybe we can add some base config files to the post?

[maccas]

.zee files YBK.

Dan

[thump566]

Great write-up Phil 
It might be easy as you suggest but only with the shared experience imparted by you more knowledgeable guys   

[ybk]

Anybody willing to attach their config file along with a setup description for reference?

[mellorp]

Some screen shots in Open Office text (word) files. They should download automatically

Screen shot ONE

Screen shot TWO

And some zeel files

The 1st two are me messing about and the third one what I settled on. DO NOT THINK THIS SETUP IS RIGHT FOR YOU. I live in freezing cold UK and this was set up for an RS with SP porting SP crank Martin77 pipes SP airbox

Hopefully it gives a good starting point


http://www.characterdata.co.uk/TZR%20Manual/3xvcurveA.zee
http://www.characterdata.co.uk/TZR%20Manual/3xvbaseC1C2.zee
http://www.characterdata.co.uk/TZR%20Manual/3xv%2014%10%09.zee

[4l04ever]

Dave Reynolds said that good gains can be had with fine adjustment of the power valves, but I guess this would need to be done on a dyno to see what is happening in detail.

You also need to be careful with the ignition advance, as it works in combination with compression and exhausts, so one setup may be safe on one bike, but may melt a piston on another....

[Yakuzastyle]

I dont understand abbreviation totally a newbie

[913xvBrian]

The air solenoids do not work properly with a Zeel on an R model.  If you compare to what a 3MA Zeel does, it is completely different.  The 3XV Zeel appears to be setup for Powerjet carbs rather than Air solenoids.  I tried to use VJ22 air solenoids, which are duty solenoids, but could not get them working correctly.  Ending up using the powerjet settings with the original £XV solendoids and adjusted as best I could.   This setup was completed on a dyno, so I could see the fuelling as it was adjusted.

So, we picked up a SP engine for our 3XV. I am under the impression that the Zeel should work just fine with that engine. Your thoughts?

[rz500guy]

Just let Borut know the engine. I saw someone with one of his controllers for sale with an engine and it looked like it had connectors installed from him.

[Steveog]

The PDCI-20V Zeel for the 3xv comes with the proper connectors installed, rz500.