PARTS LIST - RevZilla · 2015 5KK K aaawskaiEXk33-PCiEwXk3 2015 Kawasaki EX300 - PCV - 1 PARTS LIST...
Transcript of PARTS LIST - RevZilla · 2015 5KK K aaawskaiEXk33-PCiEwXk3 2015 Kawasaki EX300 - PCV - 1 PARTS LIST...
17-060 www.powercommander.com 2015 Kawasaki EX300 - PCV - 1
PARTS LIST
1 PowerCommander1 USBCable1 InstallationGuide2 PowerCommanderDecals2 DynojetDecals2 Velcrostrips1 Alcoholswab1 O2Optimizer
THE LATEST POWER COMMANDER SOFTWARE AND MAP FILES CAN BE
DOWNLOADED FROM OUR WEB SITE AT:www.powercommander.com
2015 Kawasaki EX300
I ns ta l l a t i on I ns t ruc t i ons
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
THE IGNITION MUST BE TURNED OFF BEFORE INSTALLATION!
2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 www.powercommander.com
FUEL AND IGNITION
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EXPANSION PORTS 1 & 2
OptionalAccessoriessuchasPOD-300unitorAuto-tunekit.
POWER COMMANDER V INPUT ACCESSORY GUIDE
Map - (Input1or2)ThePCVhastheabilitytohold2differentbasemaps.YoucanswitchontheflybetweenthesetwobasemapswhenyouhookupaswitchtotheMAPinputs.Youcanuseanyopen/closetypeswitch.Thepolarityofthewiresisnotimportant.WhenusingtheAutotunekitonepositionwillholdabasemapandtheotherpositionwillletyouactivatethelearningmode.Whentheswitchis“CLOSED”Autotunewillbeactivated.(SettoSwitchInput#1bydefault.)
Shifter- (Input1or2)TheseinputsareforusewiththeDynojetquickshifter.InsertthewiresfromtheDynojetquickshifterintotheSHIFTERinputs.Thepolarityofthewiresisnotimportant.(SettoSwitchInput#2bydefault.)
Speed- Ifyourapplicationhasaspeedsensorthenyoucantapintothesignalsideofthesensorandrunawireintothisinput.ThiswillallowyoutocalculategearpositionintheControlCenterSoftware.Oncegearpositionissetupyoucanalteryourmapbasedongearpositionandsetupgeardependentkilltimeswhenusingaquickshifter.
Analog- Thisinputisfora0-5vsignalsuchasenginetemp,boost,etc.Oncethisinputisestablishedyoucanalteryourfuelcurvebasedonthisinputinthecontrolcentersoftware.
Crank- DoNOTconnectanythingtothisportunlessinstructedtodosobyDynojet.Itisusedtotransfercranktriggerdatafromonemoduletoanother.
ACCESSORY INPUTS
Wire connections:
ToinputwiresintothePCVfirstremovetherubberplugonthebacksideoftheunitandloosenthescrewforthecorrespondinginput.Usinga22-24gaugewirestripabout10mmfromitsend.PushthewireintotheholeofthePCVuntilisstopsandthentightenthescrew.Makesuretoreinstalltherubberplug.
NOTE:Ifyoutinthewireswithsolderitwillmakeinsertingthemeasier.
CRANK
ANALOG
SPEED
INPUT 1 (Grnd)
INPUT 1
INPUT 2 (Grnd)
INPUT 2
USB CONNECTION
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1 Removetheseats.
2 Removethefueltank.
3 Removetherightandleftsidemid-fairings.
4 LaythePCVinthetailsectionandroutetheharnesstowardsthefrontofthebike,followingalongsidetherightsideframerailascloselyaspossible.
Cross-member brackets may need to be loosened or removed to route the wiring harness beneath them.
5 Movethejunctionboxoutofthewayandremovetheboltforthebatterycover(Fig.A).
6 SecurethegroundwireofthePCVwiringharnesswiththe6mmringlugtothenegativeterminalofthebike’sbattery(Fig.A).
7 Reinstallthebatterycoverandjunctionbox.
8 Unplugthestockwiringharnessfrombothfuelinjectors(Fig.B).
9 PlugthePCVwiringharnessin-lineofthestockwiringharnessandthefuelinjectors(Fig.C).
The pair of PCV connectors with ORANGE colored wires go to the left-most cylinder (cylinder #1).
The pair of PCV connectors with YELLOW colored wires go to the right-most cylinder (cylinder #2).
FIG.A
FIG.B
PCV harnessGround
Unpl
ug
Unpl
ug
FIG.C
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10 LocatetheThrottlePositionSensorontherighthandsideofthethrottlebodies(Fig.D).
This is the GREY 3-pin connector.
This picture was taken with the coolant bottle moved out of the way.
FIG.D
11 PlugtheconnectorsfromthePCVwiringharnessin-lineoftheTPSandthestockwiringharness(Fig.E).
Make sure you do NOT plug the PCV in-line of the stock BLACK connector.
FIG.E
Unplug
FIG.F
STK
PCV
PCV
TPS
12 LocateandunplugtheCrankPositionSensorfromthestockwiringharness(Fig.F).
This is a BLACK 2-pin connector inside of a rubber boot on the left hand side of the engine head.
Unplug
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15 PlugthePCVwiringharnessleadswithGREENcoloredwiresin-lineofthestockwiringharnessandtheleftignitioncoilstick(coilstick#1)(Fig.I).
13 PlugthePCVin-lineofthestockwiringharnessandtheCrankPositionSensor(Fig.G).
FIG.G
FIG.H
FIG.I
14 Unplugthestockwiringharnessfromtheleftignitioncoilstick(coilstick#1)(Fig.H).
The coil sticks are located directly on top of the engine’s valve cover.
STK
PCVSTK
PCV
Unplug
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FIG.J
FIG.L
18 LocatethestockO2sensorconnectionandunplugit(Fig.L)
This is a BLACK 4 pin connector located on the left side of the bike next to the crank sensor connection.
16 Unplugthestockwiringharnessfromtherightignitioncoilstick(coilstick#2)(Fig.J).
17 PlugthePCVwiringharnessleadswithBLUEcoloredwiresin-lineofthestockwiringharnessandtherightignitioncoilstick(coilstick#2)(Fig.K).
FIG.K
Unplug
Unplug
17-060 www.powercommander.com 2015 Kawasaki EX300 - PCV - 7
FIG.N 20 UsingthesuppliedVelcrosecurethePCVunitinthetailsection(Fig.L).
Be sure to clean both surfaces with the supplied alcohol swab prior to applying the Velcro.
21 Reinstallthefueltank,bodywork,andseats.
Optional inputs:
Speed - GREEN/REDwire(pin#5)ofthelargeECUconnector
Engine Temperature - ORANGEwire(pin#17)ofthelargeECUconnector
19 PlugthesuppliedO2Optimizerintothestockwiringharness(Fig.M).
The stock O2 sensor will no longer be connected and can be removed from the exhaust if desired..
FIG.M
O2 Optimizer