Tourmaster synergy electric jacket

[Dusty Boots]

I find during cold riding conditions(<40*), my W&S gloves are not warm enough, when plugged into my TourMaster Jacket Liner, unless I crank the jacket liner way up, which is then too hot.
I bought a small Y splitter and plug the TM pants heat controller into that and then run the Y harness through the jacket liner to my gloves, giving me ample heat to the gloves. Hope that TM pant heat controller doesn't crap out, like the jacket liner one did.
I run the mod and a W&S single potable heat troller now and plug that into the other connection on the Y splitter. If the TM pants heat troller dies, guess I'll go with a W&S dual portable heat troller to comfortably control both the TM jacket/pant liners and the W&S gloves

[Mark 42]

Anyone know the wiring schematic for the jacket?

If I can find out how it's wired I can short out the controller plug
(remove the big heavy cable) and set it up so that it is always
on high. The I could use an external controller to adjust the jacket
and I would only have two or three of the smaller cords (one for the
main jacket power, one for the gloves, and another for the pants, with
the glove and pant cords tucked away for now since I don't need them)

Basically, I want to create three separate circuits that are always
on full current if hooked up directly to a 12V source. Then I can
put a 3-way controller in between and mount it on the bike.

The Tourmaster controller takes a beating hanging off of my jacket
all the time.

It has held up very well though. I broke the clip that attaches it to
the leg strap (I attach it to my pants pocket).

Now that the clip is gone I button it under the flap of the pants pocket,
and I actually like that better because it puts the controller in easy reach.

But I would prefer to have it on the handlebars.

[XPLORZ]

This post is on page 21, but the pics had disappeared some how. This is still working great for me.

Originally Posted by XPLORZ

Against my better judgement, I bought a Tourmaster Synergy heated jacket liner for an up-coming trip. OK, maybe not the most brilliant move, but I did get First Gear/Warm and Safe jacket and pant liner for the spousal unit. Not gonna risk an equipment failure with her. If she's cold and miserable.......

Anyways, I ended up with a spare First Gear heat troller. I plan to take it along as a spare to the Synergy controller for my jacket. First, out of curiousity, I dis-assembled the Synergy controller.

Front of the board:


Back of the board:


Looks like a PWM!

Then I got out the DVM and tested this plug on the jacket to see whats what:


This diagram shows what I found. It also shows how I plan on jumping it so I could use the inline First Gear heat troller.


I dug around until I found some spade terminals that were rounded and would slide over the pin pairs. Some terminals are almost flat and will not work. Here is the jumper:


Notice that when the jumper is plugged in, the pin with straight through to the + side is NOT used:


With the jumper in place, I went direct through with NO controller of any kind to a 12v battery. I was testing to see how many amps it would pull. It buried my ammeter! So I removed the jumper and installed the Synergy controller. It pulled 6.3 amps in high, about 5.3 amps med and 4.3 amps on low. I put the jumper back on and put the First Gear heat troller in line. It pulled the same 6.3 amps on high, but it would go even lower on its variable heat settings.

So with the jumper in place I will be able to use the First Gear inline heat troller (plugs are the same) as a backup.

a word of warning:
DO NOT PLUG DIRECTLY IN TO YOUR MOTORCYCLE WITH THE JUMPER IN PLACE AND NO HEAT TROLLER IN LINE. On the test, it pegged the needle on my ammeter!

[Mark 42]

Now I see the pictures!

I couldn't see them earlier. I printed it before they disappear again!

I saw the schematics after I posted, but as I understand it, they are for the
vest rather than the jacket.

I followed the wires around inside my jacket awhile back, but some I couldn't
get access to so I had to take an educated guess where they go.

I think I will go with First Gear if this jacket ever dies on me.
I hate having the controller on the jacket all the time.

I'll probably remove the whole cable and just solder the wires which the jumper
shorts out together. I'll have to figure out where to pick up the other connections
for gloves and such.

[madmaximum]

There is an adapter out now so you can use a heattroller with it.

[Mark 42]

I'm thinking of modding the jacket and the controller so that I can
completely remove the thick 5 conductor cable and plug the jacket
directly into the controller.

There is really no reason why more than three wires are going into
the controller. If I mount it to the bike with a screw I should only
need two wires... +12V input and Pulsed 12V output. The ground
could be accomplished by the screw (the controller needs Gnd & 12V
to operate its own circuits).

Someone mentioned using a resistor - the problem is the wattage.

I'm thinking maybe a speed controller for the blower fan in the heat & A/C
system for a car might be sturdy enough.

On my heated grips I intend to use a 3 position switch to put the two
heat elements either in series (low heat) in parallel (hi heat) or off.

If I knew the circuit inside the jacket I might be able to do the same.
I wonder how hot the wires in the jacket would get with straight 12V
applied while the jumper is in place.

[SNicky]

Originally Posted by Wistrick

so is everybody still having issues with the Controllers in 2010???

I order an XL I am 5'9" 245 45 chest and 48 belly according to tourmaster web site it should fit fine but seem it might be to small based on what peoplw here are saying..


thanks

Dan

Mine crapped out this morning during my 35F degree commute. I was not happy. I've emailed Tourmaster and talked (to a human, no less) at Competition Accessories (retailer).
I'm just glad I wasn't on a longer ride.

[bmwmc]

I bought the TM Synergy jacket last winter, so it has gone through two winters. I went through several returned controllers and jackets at first. Finally got one that has held up well every since. I am satisfied for the money. I don't like the controller-on-a-stick. That cable is way too heavy, but I have not been inclined to do anything about it. At this price point, I would purchase the jacket again.

[xtphreak]

sigh

my controller finally quit

it's been what, 3 years? 4?

guess I need go PWM, ZZRon sent me one, now where the he!! did I put it

of course it's just getting chilly and I'm going to TN this weekend

[mike toon]

When it gets cold this year I'm going to open up the jacket and move the controller's connection inside with maybe just the controller sticking out of the pocket a little. Could even make it so it would move in and out of the pocket.

[owrstrich]

i gotts the 1st gen synergy jacket...

the controller was intermittent at best...

when it worked the jacket would get freaking hot hot hot...

i scored the warm n safe plug and the warm n safe controller...

now the jacket will only get warm at best... no wheres as hot as with the oem 3 way switch...

anybody have similar experience... what gives...

j o

[Norhasken]

Thanks for this thread. I really wanted to buy a Synergy, but went for a Gerbing.

[Wistrick]

after my second controller bit the dust, shorted out and took the main fuse on the VFR with it and left me stranded on the side of the freeway I bought a Gerbings...My buddy who rdies a Tiger has been though 5 controllers 3 jackets and a blown main fuse on his Tiger 1050...these coats are evil....

Dan

[PLRider]

I was wondering if there is a way to connect this liner to 12v socket.
I have a fuse box and 1 unused sae connector. I would like to connect the liner to it. What i would have to do or if it is possible to do it?
Im planning to get the liner therefore my questions.
Where do you plug 3 (red, black, white) connectors?
thx

[HaChayalBoded]

Originally Posted by PLRider

I was wondering if there is a way to connect this liner to 12v socket.
I have a fuse box and 1 unused sae connector. I would like to connect the liner to it. What i would have to do or if it is possible to do it?
Im planning to get the liner therefore my questions.
Where do you plug 3 (red, black, white) connectors?
thx

It comes with a battery cable, if you however want to use your SAE connector you can buy a converter that converts the SAE connector to coaxial.