Installation Guide

This guide walks you through the complete process of building and installing your Moto32 control unit, from ordering PCBs to final motorcycle installation.

Prerequisites

Before you begin, ensure you have:

• Basic soldering skills (SMD experience recommended)
• Multimeter for testing
• Soldering iron with fine tip (or hot air station)
• Basic hand tools for motorcycle installation
• Computer with USB-C cable for programming
• Understanding of motorcycle electrical systems

Step 1: Order PCBs

Option A: PCBWay (Recommended)

The easiest way to get started is to order through PCBWay, our manufacturing sponsor:

1. Visit the Moto32 PCBWay Project Page
2. Click "Add to Cart"
3. Choose your options:
   • Quantity: Minimum 5 PCBs (standard for prototypes)
   • PCB Thickness: 1.6mm (recommended)
   • Surface Finish: ENIG (best for durability) or HASL
   • Copper Weight: 1 oz (standard)
4. Optional: Add PCB Assembly Service
   • Upload BOM and Pick & Place files from the repository
   • PCBWay will source and solder all components for you
5. Complete checkout and wait for delivery (typically 7-14 days)

Option B: Other PCB Manufacturers

You can also use any PCB manufacturer:

1. Download Gerber files from the GitHub repository
2. Upload Gerber_Canarin_MUX_PCB.zip to your chosen manufacturer
3. Select PCB specifications:
   • Layers: Multi-layer (check Gerber files)
   • Dimensions: Auto-detected from Gerber
   • Thickness: 1.6mm
   • Color: Your choice (black/blue recommended)
   • Surface Finish: ENIG or HASL Lead-Free

Popular alternatives:

• JLCPCB
• OSH Park
• Eurocircuits
• PCBWay (without assembly)

Step 2: Source Components

Download BOM

Get the complete Bill of Materials from the repository:

# Clone the repository
git clone https://github.com/jaksatomovic/motogadget-clone.git
cd motogadget-clone

# BOM file location
BOM and Pick N Place/BOM_Canarin_MUX.csv

Key Components

The most critical components are:

Where to Buy

Recommended Suppliers:

Step 3: PCB Assembly

Tools Required

• Soldering iron with fine tip (or hot air rework station)
• Solder paste (for SMD components)
• Tweezers (fine point, ESD-safe)
• Magnifying glass or microscope
• Flux (no-clean recommended)
• Isopropyl alcohol (IPA) for cleaning
• Multimeter
• ESD mat and wrist strap

Assembly Process

Assembly Order:

1. Small passives first (0402 resistors and capacitors)
   • Apply solder paste with stencil or syringe
   • Place components with tweezers
   • Reflow with hot air or hot plate
2. Larger passives (0603 capacitors)
3. ICs and active components
   • ESP32 module (careful with alignment)
   • MOSFETs (watch orientation)
   • Buck converter IC
   • USB-UART chip
4. Connectors and mechanical parts
   • USB-C connector
   • Pin headers
5. Inspection and cleaning
   • Check for solder bridges under microscope
   • Clean with IPA
6. Initial testing (see Step 4)

Assembly Tips

• Work in a well-lit, static-free environment
• Apply flux generously for better solder flow
• Use hot air at 350°C for reflow (adjust based on solder paste)
• Double-check ESP32 module orientation before soldering
• Verify polarity of diodes and MOSFETs
• Take breaks to avoid fatigue-induced mistakes

For detailed assembly instructions with photos, see the Hardware Assembly Guide.

Step 4: Initial Testing

Before installing on your motorcycle, thoroughly test the unit:

Visual Inspection

• No solder bridges between pins
• All components properly oriented
• USB-C connector securely attached
• No cold solder joints or lifted pads

Power-Up Test

1. Connect USB-C cable to computer
2. Measure voltages:
   • 3.3V rail: Should be stable at 3.3V ±0.1V
   • ESP32 power pins: 3.3V present
3. Check for excessive heat on any components
4. LED indicators (if populated) should light up

Programming Test

1. Install ESP32 support in Arduino IDE (see Firmware Guide)
2. Select ESP32-S3 Dev Module as board
3. Upload a simple "Blink" sketch
4. Verify code uploads successfully
5. Check serial output at 115200 baud

Output Test

Test each MOSFET channel:

1. Connect LEDs with resistors to each output
2. Upload test firmware (available in repository)
3. Verify each output can switch on/off
4. Check for proper logic levels (LOW = active)
5. Measure output current capability
Do NOT connect to motorcycle battery yet! Complete all bench testing with USB power or a current-limited 12V supply first.

Step 5: Motorcycle Installation

Pre-Installation Planning

Before installing, plan your wiring:

1. Choose mounting location
   • Under seat (most common)
   • Behind headlight nacelle
   • In side panel
   • Protected from water and vibration
2. Measure wire lengths needed
3. Plan wire routing to avoid moving parts
4. Select connectors for easy removal
5. Document your wiring for future reference

Wiring Connections

Power Input:

12V+ (Battery) ────[Fuse 10A]────> Moto32 12V Input
Ground (Frame) ──────────────────> Moto32 GND

Typical Output Assignments:

Output	Function	Notes
OUT1	Headlight	High beam
OUT2	Headlight	Low beam
OUT3	Tail light	Running light
OUT4	Brake light	Brake switch input
OUT5	Turn signal	Left
OUT6	Turn signal	Right
OUT7	Horn	Momentary
OUT8	Ignition coil	Kill switch input

Customizable: These are suggestions only. Configure outputs to match your specific motorcycle requirements.

Installation Steps

1. Disconnect battery (negative terminal first)
2. Mount Moto32 unit with vibration-damping mounts
3. Run power wires with appropriate gauge (14-16 AWG)
4. Install inline fuse (10A recommended) near battery
5. Connect ground to clean frame ground point
6. Route signal wires for switches and sensors
7. Connect output wires to loads (lights, horn, etc.)
8. Secure all connections with heat shrink or connectors
9. Double-check all wiring against your diagram
10. Reconnect battery (positive first, then negative)

First Power-Up on Motorcycle

1. Turn ignition to ON position (don't start engine)
2. Check for smoke or unusual smells (if any, disconnect immediately)
3. Verify Moto32 powers up (LED indicators if present)
4. Test each function individually:
   • Lights (headlight, tail, brake)
   • Turn signals
   • Horn
5. Check for proper ground connections
6. Verify no voltage drop under load
7. Test with engine running for electrical noise immunity

Final Testing

Before riding:

• All lights function correctly
• Turn signals flash at proper rate
• Horn sounds clearly
• Kill switch cuts ignition
• No flickering or dimming under load
• All connections are secure
• No loose wires or sharp edges
• Emergency stop procedures tested

Step 6: Configuration & Tuning

Upload Production Firmware

Replace test firmware with your final configuration:

1. Connect USB-C cable
2. Open Arduino IDE or PlatformIO
3. Configure pin mappings for your setup
4. Set input debounce times
5. Configure auto-cancel timers (if used)
6. Upload firmware

See Firmware Configuration for detailed instructions.

Fine-Tuning

Adjust settings based on real-world use:

• Turn signal flash rate
• Auto-cancel sensitivity
• Brake light delay
• Headlight modulation
• Custom sequences

Troubleshooting

Unit Won't Power Up

• Check 12V input voltage at connector
• Verify ground connection
• Test buck converter output (should be 3.3V)
• Check for reverse polarity damage

Outputs Don't Work

• Verify MOSFET orientation during assembly
• Check gate drive signals with oscilloscope
• Test MOSFET with known good component
• Verify firmware output pin configuration

USB Not Recognized

• Install CH340 drivers for your OS
• Try different USB cable (must support data)
• Check USB-C connector solder joints
• Verify 3.3V present on CH340 chip

ESP32 Won't Program

• Hold BOOT button while connecting USB
• Select correct board in Arduino IDE
• Check serial port selection
• Verify ESP32 module is properly soldered

For more help, see the Troubleshooting Guide or ask on GitHub Issues.

Next Steps

Configure Firmware

Customize pin mappings and behaviors for your motorcycle

Hardware Details

Learn more about the PCB design and components

User Guide

Learn how to use and maintain your Moto32 unit

Join Community

Share your build and get help from other users

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Congratulations! You've successfully built and installed your Moto32 control unit. Share your build on GitHub and help others in the community!