Kawasaki Vulcan 1500 Classic

Transcription

1 Floppy Disc Request Form If you do not have a CD-Rom drive and would like to receive the program and the alternate maps for your model on a 3 1/2 floppy disc, please fax this form to Dynojet at or call Bike Model Name Street Town State Zip Kawasaki Vulcan 1500 Classic You can also download the Power Commander software and the latest maps from our web site at : Parts List 1 Power Commander CD-ROM Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV Installation Guide I Wire Tap Connector Ground Wire

2 Installation Instructions for Kawasaki Vulcan 1500 Classic 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. It does however 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 (Fig. A) 5 Remove the battery/ecu hold down bracket (Fig. B). 6 Unbolt and move the bank angle (tip over) sensor out of the way (Fig. C). 7 Loosen the bolts holding the plastic tray on the left side of the bike (under the left side cover) (Fig. D). 8 Route the wire from the PCIII behind the plastic tray and under the frame side rail (Fig. E). 9 Retighten the bolts holding the plastic tray. 10 Continue routing the wires from the PCIII under the frame near the lower fuel tank mount and go up to the throttle body area (Fig. F). 11 Disconnect the injector connector from the rear injector (Fig. G). 12 Plug the male PCIII connector with GREEN/ORANGE wires onto the rear injector (Fig. G). 13 Connect the female PCIII connector with BLUE/RED wires onto the stock injector connector (Fig. G). 14 Repeat steps 11thru 13 for front injector using the PCIII connectors with the PURPLE/BROWN colored wires. 15 Locate the wires coming from the throttle position sensor. (Fig. H). 2

3 16 Attach the supplied wire tap onto the YELLOW wire with WHITE stripe. Firm pressure is required to close the connector. (Fig. H). 17 Plug the GREY wire with the spade terminal from the PCIII, into the wire tap (Fig. H). It is recommended to seal this connector with silicone. 18 Reinstall the fuel tank. 19 Install the auxiliary ground wire in the location shown in Fig. I. Unscrew the bolt that secures the stock ground wire and install the auxiliary ground wire supplied. Route the wire along the right hand side of the frame towards the battery location. 24 Disconnect the stock ground wire (white connector) from the negative battery lead (Fig J). Plug the female end of the auxiliary ground wire into the female end of the stock ground connector (Fig K). Then plug the male end of the ground wire from the PCIII into the female end of the stock ground connector (Fig. L). 25 Attach the PCIII module to the plastic tray (or the charcoal canister on California models) under the left side cover (Fig. M). 26 Reinstall the side cover. 27 Reinstall the seat. 14 3

4 Fig.A Trouble Shooting If you feel that you are having any problems at all with the Power Commander III, disconnect it from your motorcycle. This will allow the motorcycle to run directly off of the stock ECU. The lights don t come on when I turn the ignition switch on. Check to make sure connectors are seated and the kill switch is in the run position. The on-board adjustment buttons do not hold their settings. Be sure to wait seconds after making adjustments before starting or turning off the bike. Can not upload to or download from the Power Commander III. Check to see that the serial cable is firmly in place. Verify that ignition switch is on and the kill switch is in the run position. Fig.B My mouse uses the same serial port. If your computer has a PS/2 port purchase a DB9 to PS/2 adapter for your mouse. Remove these 2 bolts I get a verify failed... message when I upload a map to the Power Commander III. Programs running in the background or fluctuations in supply voltage (from outlet) can sometimes cause this error. In most cases, the information was sent properly to the Power Commander II. Pushing the upload all button again should produce a tables sent and verified message. I typed in notes, but they didn t save. You need to first push the accept button in the notes window and then the save file button. 4 13

5 Adjusting Your Power Commander Fig.C Your Power Commander has been programmed with a base map for your application. You can adjust the base map or install an alternate map using your Computer. Please refer to the supplied CD-Rom for more information. You can also adjust your Power Commander using the face plate buttons as described below. Bank angle sensor (tip over switch) 1. With the ignition off, hold down all three buttons on the Power Commander III unit. 2. While still holding down the buttons, turn the ignition on. 3. Release buttons. 4. Select the range you wish to adjust: Low, Med, High, by pushing the corresponding button once. Fig.D 5. At this point holding that button down will move the lights down ( leaning out the mixture). 6. Pushing the button repeatedly will move the light up (richening the mixture). 7. When the two center light are lit up this is the 0 setting. After making your adjustments wait 20 seconds before starting the bike or turning it off. This allows the settings to be saved to memory. To verify that it is safe to start the bike, move the throttle and watch to see if the lights move up and down the scale. If they do, you may start or turn off the bike. Loosen these 3 bolts 12 5

6 Fig. E Route PCIII harness between plastic tray and frame Fig. F Route wires under frame 6 11

7 Fig. G Fig. M Fig. H Wire tap connector goes onto the yellow wire with the white stripe Wire from PCIII harness 10 7

8 Fig. I Fig. K Fig. J Fig. L 8 9