The following instructions cover the installation of the six accessory button paddle upgrade for 6000 series wheel units equipped with the USB HD Ultra interface. If you do not have this interface, the additional buttons will not work. Begin with removing your existing paddle set from the wheel unit. This is accomplished by loosening the five wheel screws holding the wheel and paddles to the hub. Make sure to disconnect the paddle wire connection before removing the wheel.

The next step is to put together the disassembly fixture. Examine the above images for how the screws and washers fit into the steel triangular plate of the disassembly fixture. First turn a nut down onto each screw as shown to the left, then thread the screws into the plate such that the heads of the screws are about 1-1/2 inch (40mm) from the plate. Try to turn each screw in an equal distance and then lock each into place by tightening the lock nuts against the plate. The plate should stand level when placed on the screw heads.

 DISASSEMBLY

Place the disassembly fixture on a flat surface with the screw heads facing down. Pick up your existing paddle set and pull out the wheel mounting screws from the 12, 7, and 5 o’clock positions. Gently lower the paddle set onto the fixture screws until it rests as shown above.

Using a Philips screwdriver, loosen the two screws that hold the “sandwich” of the paddle set components together as shown above left. Lift the top-most plate of the assembly with both screws and set aside for later reassembly. Next lift the paddle lever plate with the spacers, foam ring, and springs to the side as shown above right. Once the plate is lifted free, these parts may fall loose and will need to be gathered in their proper position when re-assembling. If unsure, take a few photos of these parts in place before taking the paddle set fully apart.

Now lift the two-button plate from the fixture and replace it with your new six-button unit as shown above.

EXCEPTION:

When upgrading some paddle sets, particularly the Pocono set, replacing the paddle arms may be necessary. If needed, your upgrade kit will include these new parts. If not, just skip this step.

To replace the paddle arms, just remove the Philips screws fastening your existing arms to the hinge plate (as shown left) and replace with the new parts provided. Make sure to note the orientation of the paddle arm bends and install the new arms in the same orientation as the originals. 

Please use this link for important additional Pocono details:

POCONO UPGRADE DETAILS

 REASSEMBLY

On top of the six-button plate, lower your old paddle lever plate as shown above left. Place three of the cylindrical spacers over the disassembly fixture studs. Next place the foam cushion using the three spacers as locators as shown above right. Make sure the two small holes for the assembly screws align with their respective holes in the plate below.

Place the remaining two spacers in their positions at 10 and 2 o’clock as shown above left. Then place the two paddle springs over their locating washers on each paddle. Next mount the top plate of the assembly as shown above right. Center the corresponding locating washers for each paddle spring and set the plate over the fixture studs.

EXCEPTION:  When upgrading 6000 MOMO paddle sets, it is necessary to use the MOMO adapter ring to complete the paddle assembly as shown above. For all other paddles sets, skip this step.

Next place the two remaining wheel mounting screws into their 10 and 2 o’clock positions, making sure that the cylindrical spacers they pass through remain in position. Gently press down the top plate compressing the paddle springs. Next thread the two screws that hold the sandwich together into their respective holes at 12:30 and 6:30 positions as shown above left. Make sure that no wires are pinched as you gradually tighten them down.  When the screws are snug you are ready to pull the paddle set from the disassembly fixture. Before doing so, make sure you have the remaining three wheel mounting screws ready at hand. Once the paddle set is pulled from the fixture, these three screws should be placed into the holes where the fixture screws once were, as shown above right.

 PADDLE TRAVEL SETUP

Prior to using the paddle unit it will be necessary to set the preload and travel limit adjustments to tune the response of paddle movement.  Ideally this would be performed with the paddle unit secured to the steering unit hub with the 5 mounting bolts lightly tightened.  The button indicator lights in the Windows joystick utility are used as references.  In some situations it may not be possible to perform the adjustment while assembled to the steering unit.  In these situations the operation can be performed with the paddle unit removed from the steering hub.  It is still necessary to install the 5 mounting bolts through the paddle unit and lightly tightened with #10-24 nuts on the back side.  Off-steering unit adjustment typically requires the use of a multi-meter electronic tool connected to the pins of the paddle unit plugs.

If using the Windows joystick utility button lights as a reference, start the utility and be sure to first fully calibrate the controller before attempting paddle unit adjustment.  If using a multi-meter connect the multi-meter to the pins of the paddle set and set to the continuity setting.

      

The preload setting must be set up first. The preload is the static at-rest position of the paddle as measured relative to the point where paddle movement registers an electronic input. This amount of movement should be very short so paddle input is registered with a minimum of movement. The correct amount of preload can be set by the rotation of the set screw on which the paddle rests when it is fully released. Refer to the above left illustration for how the adjustment screws limit paddle travel.

Turn in the travel limit set screw until paddle input is triggered. When input is reached, slowly back out the screw 1/4 to 3/8 turn and tighten the nut locking the set screw in place. Make sure to continue to hold the set screw in its backed-out position as the lock-nut is tightened. Once tight, operate the paddle lever a few times and make sure that input is reliable and has a small amount of tolerance from rest. If response lags or the paddle actuates as a hair-trigger, redo the adjustment until operation is correct.

The travel limit adjustment limits how far the paddle can move after it actuates the control switch. For some models of paddle sets this is not adjustable. In cases where a travel limit adjustment screw is available, the following procedure is recommended. Pull the paddle against its stop.  Look down behind the paddle lever at the red switch plunger.  On some paddle units this is only visible from the bottom edge of the paddle unit.  There should be a gap between the plunger and the back face of the paddle lever.  The gap should be 1/64" to 1/32" (.015" to .030" , in mm this is .4mm to .75mm).  If required loosen the locknut and gradually turn the adjustment screw as is necessary to achieve the proper gap.  Lightly tighten the locknut when complete.  This adjustment is critical for proper operation of the paddle shifter.  Please take the time to do it correctly.

Next mount the wheel and paddle set using the steps described in your original owner’s manual. Then connect the button wires to the hub connectors. Wire colors do not matter, the paddles will function any way they are plugged in. Carefully arrange the wires within the hub cavity such that none are pinched when the center logo button is installed. The center logo button is installed by engaging the four prongs of the button through the button retaining ring that sits behind the wheel. Push the button firmly until flush to the wheel.

When upgrading from a two-button to a six-button paddle set one needs to change a jumper on the ECCI HD USB board to enable full button function. Refer to the above diagram for the new jumper position. Reboot and enjoy your new paddle set buttons.