Convert Saitek X45 Throttle
to Direct USB Connection

For those that might be afraid to attempt this project on their own I have
decided to offer converted throttles
on an exchange basis for $75 plus
shipping. Exchange means you send me a working throttle and I send you
one
already converted. If you would like to do this, contact me at admin AT
brewsterbuffalos.com.

Otherwise, follow the instructions below and do the conversion yourself. It
really isn't hard.

NOTE: The Saitek programming software will no longer work with the
throttle if you do this conversion.
You will have to map all of the buttons
and axis in whatever game you use.

Materials:

1 – BU0836 USB Joystick
Board
Wire (can recycle wires from throttle cable)
Solder
Hot Melt
Glue
2 - IN914 Diodes
1/2 of a Dual IC Board available from Radio
Shack
1 - USB Cable

Tools:

Soldering Iron
Hot Melt
Glue Gun
X-Acto Knife or Razor Blade
Metric Allen Wrench Set
Phillips
Screw Driver

Wiring Diagram:
(Note: Save diagram to your computer for a larger, easier to read
image)

Instructions:

Step 1: Remove the 4 allen head screws from the top of the throttle. NOTE:
These are metric allen head screws.

Step 2: Turn the throttle over and remove the 4 screws as shown below and
remove the base:

STOP! You
need to make a decision at this point. If you can live without Aux 2 and Mode
2
you can proceed to Step 17. Otherwise
continue at step 3.

Step3: Remove the 7 screws holding the cover on the throttle arm and remove
the cover:

CAUTION: When you remove these screws the throttle handle will be separated
from the arm!

Step 4: Remove the 6 screws holding the throttle handle together and
CAREFULLY separate the two halves:

Step 5: Arrange the two halves so the top half with the Aux and Mode switches
is resting on a table or
work bench and remove the items as shown in the
picture below:

Step 6: CAREFULLY remove the switch PC board from it's mount by sliding it up
and away from the
side the LED is on. Then set the board in a position that
you can work with as shown below.

Step 7: Solder the 2 wires at the locations shown above so you wind up with
this:

NOTE: Be sure the wires are long enough. 18 to 20
inches should suffice. It's better to have them to long than not long
enough.

Step 8: Carefully route the wires in the same direction as all of the other
wires and hot melt glue them in place.
The glue acts as a strain relief and
an insulator.

CAUTION: Be sure the wires do not short out on any other terminals when you
route them.

Step 9: Remount the board by sliding it back into it's mounting slots and
replacing the screw. Then put a small dot
of glue where the one was that you
removed in Step 5. Also, slide the button back into position.

Step 10: Glue the wires back down on the throttle handle half. THIS IS
IMPORTANT! If you do not do this
the wires will rub on the rudder actuator
and it will eventually cause the wires to fail.

Step 11: Feed the two wires you connected to the switch PC board through the
throttle arm and into the base.

Step 12: Make sure the throttle handle is in it's correct position, pull the
wires tightly into the base and
glue the wires in place on the throttle
arm.

Step 13: Replace the throttle arm cover, which at the same time holds the
throttle handle in place.

Step 14: Route the two new wires as shown below:

Step 15: Prepare your diodes and wiring, Make sure the wires coming from the
switches
are on the negative side of the diodes. The other two wires are on
the positive side of the
diodes and will connect to two of the Columns on the
BU0836.

Step 16: Remove the screw holding the Saitek circuit board and install your
board as shown below.
Then put some Hot Melt glue over the wire
connections:

Step 17: Cut your original cable about 8 inches from
the strain relief. Using an X-Acto knife
or razor blade carefully remove the
outer cover from the cable as close to the strain relief as you can.
Once the
cover is removed you should be able to slide the strain relief off of the
wires.

BE CAREFUL NOT TO KNICK THE WIRES!! There is a shield around them, so if you
are careful
you should only damage the shield.
ALSO BE CAREFUL NOT TO
DAMAGE YOURSELF! The blade is sharp!

Step 18: Group the wires into bundles for the Analog inputs, Columns and
Rows.
(it's easier to know what your working with that way)

Analog Bundle: Yellow, Orange, Red/Wht, Red, Brown, White, Purple, Shield
(black wrapped for a short distance)
Row Bundle: Green, Blk/Wht, Gray, Lt
Green
Column Bundle: Pink, Brn/Wht, Black, Blue, PLUS the two wires to the
Diode Board that you added.

Step 19: Cut the place where the original wire exited the throttle roughly
into the shape of the USB port
on the BU0836 and trim the housing as shown
below.

Step 20: Remove 1 screw from the Saitek board and use it to mount the BU0386
as shown below.

Step 21: For added stability, add hot melt glue as shown below. Let the glue
flow through the hole.
This will bind it to the back of the throttle.

Step 22: Cut your wires to length and solder them to the appropriate
connectors. The group shown
below is the column connector on the BU0836. I am
not going to take pictures of each connector.

PAY CLOSE ATTENTION TO THE PIN ORDER SHOWN IN MY WIRING
DIAGRAM!

You should end up with these connectors...

1 – 6 pin connector with 6 wires (4 wires if you opted not to
solder in Aux2 and Mode 2) for Columns
1 – 6 pin connector with 4 wires
connected to pins 3 through 6 for Rows
1 – 3 pin connector with 2 wires for
Analog 8
1 – 3 pin connector with 2 wires for Analog 3
1 – 3 pin connector
with 2 wires for Analog 4
2 – 3 pin connectors with 1 wire each for Analog 5
and Analog 6

When finished soldering connect all of the connectors to the
appropriate terminals on the BU0836.
For added strength you can put a little
hot melt glue on the wires before you connect them to the board. This is
optional.

Step 23: Once you connect your
wires, you have an operational throttle. I would connect it to your
computer
and make sure all axis and buttons are functioning. If they aren't,
go back and double check your connections
to the BU0836. (NOTE: I was holding
the hat switch in the up position when this screen shot was taken.)

Step 24: Cut a small notch in the throttle base where the original wire
exited the throttle.
You can judge the amount needed by test fitting the base
onto the throttle.

Step 25: Reassemble the base to the throttle.

Step 26: Calibrate and go play a game!