Installation Guide. Thank you for the purchase of our product. You have just unleashed infinite control, power and ability into your hands.

Transcription

1 Installation Guide Thank you for the purchase of our product. You have just unleashed infinite control, power and ability into your hands. This product is for race use only by experienced engine tuners. Note that it is possible to damage your engine by choosing inappropriate tuning or set-up parameters. (ignition timing too advanced, fuel ratio too lean or extremely rich) Be sure to fully read and understand this document, and all associated tuning documents. Always use a good premium fuel. Version 1.1

2 Table Of Contents Section 1: Whats In The Box Section 2: Installation Harness A Harness B Exhaust Sensors Monster Ports Expansion Spare In / Outs Monster Spark Expansion Section 4: Stock Component Location Guide

3 Section 1: In the Box Tune Monster ECM: ECM Harness A, Engine Harness (black connector to ECM and all engine sensor / ATV connectors) Harness B, Expansion & Ground Harness (grey connector to ECM, engine ground eyelet and 4 expansion plugs) Universal Exhaust (O2) Sensor harness (connects to harness B) DVD (contains USB to Serial adaptor driver, Tune Monster tuning software, Data Logging Software and all manuals) USB to Serial Adaptor

4 And if Optionally Purchased Monster Ports Expansion: Micro Relay (to replace stock fan relay) Large Relay (New cooling fan relay) Cooling Fan Harness (connects to harness B, new relay and stock fan) Universal IN / OUT port Harness Monster Spark Expansion: Ignition Module Spark Harness (connects to Harness B, ignition module and stock ignition coil)

5 Section 2: Installation Notes: For novice users, it might be a lot easier to just install and set up the base ECM (fuel only) and harness. Once familiar with everything and the ATV is tuned, then install the Monster Ports and / or Monster Spark expansions. Learning in steps is easier than trying to learn too much at once. If you ride in deep water or mud, we recommend that you use dielectric grease (available at your local auto store) on all the connections. Just as you would on the stock machine. You don't need to pack the connector, the purpose of the grease is to just keep all seals lubricated. We also recommend that you double check every wire seal going into each connector to make sure there are no seals that are not pushed in quite far enough or that they are not pushed in too far exposing a terminal. Do this for both the stock harness and your new harnesses. Instructions: For each connection, unplug the appropriate stock connector and install the new harness inline. Remove plastic to access the stock ECM area. Remove the right side panel that runs by your leg and covers the top of the engine. The harness runs along the right side of the engine. String the harness from one connection location to the next. You can secure it anywhere you want with tie wraps. Find a suitable location up front for your new ECM. We recommend laying it on top of the stock ECM. Other places include in front of the right side of the airbox. Inward of the right shock above the coolant hoses. Behind the fuse box. Up behind the dashboard. Basically anywhere you want to put it. We do not recommend putting it behind the airbox, in front of the seat. This area gets extremely hot from the engine and exhaust. Over heating the ECM can shorten its life.

6 2-1: Starting with Harness A 1) The first connector is a black 12 pin that goes to the Tune Monster. 2) Next is the white 6 pin killswitch connector. Stock Killswitch connector is located in front handle bars on the bracket above the stock ECM. Its the first connector on the left, while sitting on the machine. 3) Next is a black 2 pin connector for the crank sensor. This is located on the right side, just in front of the airbox, below the gear shifter. 4) Next is the grey 2 pin Injector #1 connectors. Located on the end of the intake, on top of the front cylinder. 5) Next are both the MAPTS and TPS at the same branch. The TPS is the black 3 pin connector located in the throttle body. The MAPTS is the flat black 4 pin connector located on the side of the intake. 6) Next is the grey 2 pin Injector #2 connectors. Located on the end of the intake, on top of the rear cylinder. 7) The last connector is the black 2 pin coolant sensor. This is located on the rear cylinder head on the left side.

7 2-2 : Next is the B harness 1) The 12 pin grey connector goes to the Expansion (B) plug of the ECM. 2) The long ground wire, with the eyelet / ring terminal needs to be grounded to the engine block. Connect to the stock engine ground location behind the right engine side cover, between the cylinders. Or with a new bolt, connect it at the front of the engine block, in front of the oil filter cover and above the front drive shaft. There are 2 or 3 empty holes here. You can also remove any block bolt and install. It just needs to be a good connection to the engine block. (not cylinder head or cylinder as these are insulated with gaskets). It must be engine block or direct to battery negative. Clean the block with sand paper before connecting the new ground wire. 3) You are done installing the Tune Monster ECM. Mount ECM, Ignition Module & new fan relay anywhere you want. (With the exception of allowing any unit to be mounted where it could overheat from hot sources like the exhaust and do not mount the ignition module to the stock ignition coil) Secure with tie wraps or electrical tape.

8 2-3: Exhaust Sensors (O2 / Oxygen) The grey 3 pin connector out of harness B connects directly to the Monster Wideband. Optionally it can connect to any 5v analog wideband controller output. If using the Monster Wideband, just connect it. If using a different controller, follow the following pin outs and use the supplied universal jumper harness. Pin 1 = O2 Sensor 1 input (white wire) Pin 2 = O2 Sensor 2 input (blue wire) Pin 3 = Supplied Wideband Controller Ground (brown or grey) You must use the supplied ground to avoid ground offsets and inaccurate sensor readings. If using 2 controllers for 2 sensors the controllers must be the same / provide the exact same volts per AFR specification. Monster Wideband

9 2-4: Monster Ports Expansion 1) Replace stock fan relay with new one supplied. (top left relay & shown on fuse box lid). This relay MUST be used from now on. This relay is in normally closed operation. 2) Plug 1 pin connector to Harness B 3) Plug 2 Pin connectors inline with Cooling Fan. 4) Install new fan relay to harness and mount anywhere convenient.

10 2-5: Spare Port Input / Output harness Pin 1 = Relay #1 output (yellow wire) Pin 2 = Relay #2 output (orange wire) Pin 3 = Triggered Input (green wire) 2-6: Monster Spark Expansion 1) Plug the 3 pin connectors inline with the ignition coil. 2) Plug the single 3 pin connector into harness B. 3) Plug the grey 8 pin connector to the ignition module and mount anywhere convenient.

11 Section 4: Stock Component Location Guide Killswitch Crank Sensor

12 Injector 1 TPS

13 MAPTS Injector 2

14 CTS (Coolant Sensor) Stock Engine Ground

15 Optional Engine Ground Cooling Fan

16 Stock Fan Relay Ignition Coil

17 Accessory / Winch Power