KAWASAKI 1500 VULCAN CLASSIC INSTALLATION INSTRUCTIONS

Transcription

1 KAWASAKI 1500 VULCAN CLASSIC INSTALLATION INSTRUCTIONS PARTS LIST quantity description 1 power commander EX 1 USB cable 1 cd-rom 1 installation guide 1 power adapter 1 wire tap 1 ground wire 2 power commander EX decal 2 dynojet decal 2 velcro strip 1 alcohol swab expansion port USB port PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION DOWNLOAD THE POWER COMMANDER SOFTWARE AND LATEST MAPS FROM OUR WEBSITE: Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV (800) i ex Kawasaki 1500 Vulcan Classic - PCIII USB EX - 1

2 Figure A The ignition must be turned OFF before installation. 1 Remove the seat. 2 Remove the left side cover. 3 Remove the speedometer assembly. 4 Unbolt the fuel tank. Note: It is not necessary to remove the fuel tank; however, it does make the installation easier. If you do remove the tank, pay attention to the vent hose routing. Pressing the tabs on the black fuel line connector will allow the fuel line to be disconnected as shown in Figure A. 5 Remove the two bolts securing the battery/ecu hold down bracket as shown in Figure B. Remove the battery/ecu hold down bracket. Figure B remove these bolts 6 Unbolt and move the bank angle (tip over) sensor out of the way as shown in Figure C. bank angle sensor Figure C i ex Kawasaki 1500 Vulcan Classic - PCIII USB EX - 2

3 7 Loosen the bolts holding the plastic tray on the left side of the bike (under the left side cover) as shown in Figure D. Figure D loosen these bolts 8 Route the PCIII USB EX harness between the plastic tray and under the frame side rail as shown in Figure E. 9 Tighten the bolts holding the plastic tray. Figure E route the PCIII USB EX harness between the plastic tray and frame route wires under frame 10 Continue routing the wires from the PCIII USB EX under the frame near the lower fuel tank mount and up toward the throttle body area as shown in Figure F. Figure F i ex Kawasaki 1500 Vulcan Classic - PCIII USB EX - 3

4 Figure G throttle body PCIII USB EX connectors stock connectors 11 Disconnect the injector connector from the rear injector as shown in Figure G. 12 Attach the female PCIII USB EX connector with the orange/white wire to the rear injector as shown in Figure G. 13 Attach the male PCIII USB EX connector with the orange wire to the stock injector connector as shown in Figure G. 14 Disconnect the injector connector from the front injector as shown in Figure G. 15 Attach the female PCIII USB EX connector with the yellow/white wire to the front injector as shown in Figure G. 16 Attach the male PCIII USB EX connector with the yellow wire to the stock injector connector as shown in Figure G. Figure H wire tap attaches to the yellow wire with the white stripe 17 Locate the wires coming from the throttle position sensor as shown in Figure H. The throttle position sensor is located on the right hand side of the throttle body between the frame and engine. 18 Attach the supplied wire tap to the yellow wire with the white stripe as shown in Figure H. Firm pressure is required to close the connector. 19 Attach the grey wire with the spade terminal from the PCIII USB EX to the wire tap as shown in Figure H. It is recommended to seal this connector with silicone. wire from PCIII USB EX harness 20 Install the auxiliary ground wire in the location shown in Figure I. 20a Unscrew the bolt that secures the stock ground wire and install the auxiliary ground wire supplied. 20b Route the wire along the right hand side of the frame towards the battery location. Figure I i ex Kawasaki 1500 Vulcan Classic - PCIII USB EX - 4

5 Figure J 21 Disconnect the stock ground wire (black with yellow stripe) from the negative battery lead. Attach the wire with the male bullet connector from the PCIII USB EX to the female end of the stock connector as shown in Figure J. Attach the female end of the auxiliary ground wire to the male end of the stock connector as shown in Figure J. Figure K 22 Attach the PCIII USB EX module to the plastic tray (or the charcoal canister on California models) under the left side cover as shown in Figure K. 23 Reinstall the speedometer assembly. 24 Reinstall the side cover. 25 Reinstall the seat. 26 Insert the cd provided into your computer s cd-rom drive. 27 Follow the on-screen instructions to install the PCIII USB EX software. Visit to download software tutorials and the latest maps. i ex Kawasaki 1500 Vulcan Classic - PCIII USB EX - 5