Race Dynamics PowerTRONIC, Installation Manual

Page 1: ...y cause burns cuts Proceed with extreme caution or wait until the bike has cooled down Always wear safety gloves When the installation is complete make sure to secure the wiring loom away from the movable parts or components which tends to heat up during the normal operation of the vehicle at any chance PowerTRONIC is intended for motorsport use on a closed course please check with your local laws...

Page 2: ...be Used for the verification of the connectors involved 3 Harness Bike specific harness contains the following connectors Fuel injector connector Spark Ignition coil connector Throttle position sensor connector TPS Crankshaft position sensor connector CKP Map selection connector Quick shifter connector Ground terminal 4 USB cable Can be used to connect the PowerTRONIC to a laptop for throttle cali...

Page 3: ...ing panels fairing Begin at the left side of the bike Park the bike using the centre stand on a level surface Or a paddock stand Refer Image 1 Image 1 Note the position of the connector hoses wires to be removed Refer Image 2 Image 2 3 ...

Page 4: ...3 1 1 Detach the pillion seat by inserting the key into the keyhole shown in Image 3 and unlock the pillion seat Image 4 shows the pillion seat detached Image 3 Image 4 4 ...

Page 5: ...3 1 2 Locate and unscrew the rider seat bolts using M 10 Hexagonal T handle Refer Image 5 Image 5 3 1 3 Image 6 shows both the seat detached Image 6 5 ...

Page 6: ... side panel screws 1 2 and 3 using Phillips head screwdriver and side bolt 4 using M10 hexagonal socket Refer Image 7 Image 7 3 1 4 Locate and unscrew the tank rear screws using a Phillips head screwdriver Refer Image 8 Image 8 6 ...

Page 7: ...3 1 5 Carefully detach the side panel locks Refer to Image 9 Image 9 3 1 5 Carefully unscrew the tank front bolts using 5 mm Allen T handle Refer to Image 10 Image 10 7 ...

Page 8: ...3 1 6 Unscrew the tank lid bolts using 4 mm Allen T handle Refer Image 11 Image 11 3 1 7 Carefully detach the tank lid Refer Image 12 Image 12 8 ...

Page 9: ...3 1 8 Carefully detach the coolant tank cap refer Image 13 Image 13 3 1 9 Carefully detach the fuel tank cover Refer Image 14 Image 14 9 ...

Page 10: ...rness on the bike Note that the TPS and Ignition coil connectors go to the right side of the bike All other connectors go to the left Refer Image 15 Image 15 3 2 2 Route the TPS connector on the right side of the bike Refer Image 16 Image 16 10 ...

Page 11: ...3 2 3 Route the INJ and CKP connectors to the left side of the bike Refer Image 17 Image 17 3 2 4 Route the Ground terminal connector to the battery negative Refer Image 18 Image 18 11 ...

Page 12: ...injector connector of your bike Refer to Image 19 below Image 19 3 3 2 Identify the fuel injector connector in the PowerTRONIC wiring harness The connectors are labeled INJ 3 3 3 Disconnect the injector connector on your bike Refer the zoomed view Image 20 below Image 20 12 ...

Page 13: ... female PowerTRONIC injector connector to the stock male injector connector Refer Image 21 Image 21 3 3 5 Connect the stock female injector connector to the PowerTRONIC male injector connector Refer Image 22 Image 22 13 ...

Page 14: ...k crankshaft position sensor connector on the bike Usually located right above the engine Refer Image 23 To identify the CKP connector locate the connector which includes red white striped wire Image 23 3 4 2 Disconnect the stock CKP connector Refer Image 24 Image 24 14 ...

Page 15: ... 3 Connect PowerTRONIC male CKP connector to the stock female CKP connector Refer Image 25 Image 25 3 4 4 Connect the PowerTRONIC female CKP connector to the stock male connector Refer Image 26 Image 26 15 ...

Page 16: ...ion coil connector on the ignition coil Refer Images 27 Image 27 3 5 2 Identify the Spark Ignition coil connector in the PowerTRONIC wiring harness The connectors are labelled SPK 3 5 3 Disconnect the stock ignition coil connectors Refer Image 28 below Image 28 16 ...

Page 17: ...ition coil male connector to the stock ignition coil female connector Refer Image 29 below Image 29 3 5 5 Connect the PowerTRONIC Ignition coil female connector to the stock ignition coil male connector Refer Image 30 below Image 30 17 ...

Page 18: ...sensor connector Right side of the bike 3 6 1 Locate the TPS connector of your bike It is generally located on the throttle body parallel to the throttle cable return springs Refer Image 31 and Image 32 Image 31 Image 32 18 ...

Page 19: ...on sensor connector in the PowerTRONIC wiring harness labeled as TPS 3 6 3 Disconnect the stock TPS connector Refer Image 33 Image 33 3 6 4 Connect the PowerTRONIC male TPS connector to stock female connector Refer Image 34 Image 34 19 ...

Page 20: ...owerTRONIC female TPS connector to stock male connector Refer Image 35 Image 35 3 6 6 We advise you to perform a TPS calibration after the installation of PowerTRONIC ECU Refer to the detailed TPS calibration document 20 ...

Page 21: ...l Connector 3 7 1 Identify the Ground terminal connector labelled GND Refer Image 36 Image 36 3 7 2 Connect the ground terminal connector to the negative terminal of the battery Refer to Image 37 and Image 38 Image 37 21 ...

Page 22: ...Image 38 22 ...

Page 23: ... zip ties provided wherever necessary Refer the Image 39 Image 39 Important note The PowerTRONIC harness contains a Quick shifter connector If you have bought the Quickshifter please attach the connector to it If you have not bought the Quickshifter you can leave it disconnected but make sure the harness is secured using zip ties provided 23 ...

Page 24: ...e fuel tank 3 9 2 You can verify the connections by attaching the stock coupler Refer to the detailed Stock coupler test document 3 9 3 DO NOT proceed with PowerTRONIC ECU without verifying the connections with stock coupler Refer Image 40 Image 40 24 ...

Page 25: ...TRONIC ECU Connect the PowerTRONIC to the harness by connecting the 24 pin connector Secure it in the glove box Refer Image 41 Image 41 3 11 Attaching the panels fairing etc Attach the panels fairing as removed from the bike 25 ...