2001-2006 HARLEY DAVIDSON SOFTAIL MODELS INSTALLATION INSTRUCTIONS PARTS LIST quantity description 1 power commander EX 1 USB cable 1 cd-rom 1 installation guide 1 power adapter 2 power commander EX decal 2 dynojet decal 2 velcro strip 1 alcohol swab 1 tray 2 zip tie expansion port USB port PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION DOWNLOAD THE POWER COMMANDER SOFTWARE AND LATEST MAPS FROM OUR WEBSITE: WWW.POWERCOMMANDER.COM Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 1
remove bolts The ignition must be turned OFF before installation. Figure A 1 Remove the seat. 2 Remove the four bolts securing the stock ECM and remove the stock ECM as shown in Figure A. remove bolts retaining plate 3 Remove the three bolts securing the ECM tray as shown in Figure B. Lift the retaining plate up to remove the tray. Figure B remove bolts ECM tray retaining plate 4 Lift straight up on the retaining plate enough to expose the zip ties that hold the wiring harness to the plate. Cut these zip ties. zip tie Figure C i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 2
retaining plate 5 Pull upwards on the retaining plate, which holds the relays, enough to clear the battery. Note: It may be necessary to remove the brake light and datalink connectors from the retaining plate. Figure D retaining plate 6 Rotate the retaining plate forward. Locate the relay retaining tabs as shown in Figure E. Bend these tabs so they are flush with the plate. This allows the relays to sit lower in the slots. Figure E relay retaining tabs 7 Using the stock bolts, secure the supplied ECM tray to the rear fender as shown. Figure F i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 3
relay cover 8 Push down on the relay cover so the cover is flush with the retaining bracket as shown in Figure G. Figure G retaining bracket 9 Plug the PCIII USB EX into the ECM. Note: It is recommended to use dielectric grease on this connection. Figure H ECM velcro, loop side 10 Using the stock bolts, secure the ECM to the new tray. 11 Attach velcro in the areas shown in Figure I. Note: Be sure to first clean these areas with the alcohol swab provided. Figure I velcro, hook side ECM i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 4
Figure J 12 Plug the connector from the stock wiring harness into the PCIII USB EX. Attach the PCIII USB EX connector and the PCIII USB EX to the velcro areas as shown in Figure J. Note: It is recommended to use dielectric grease on this connection. 13 Verify all bolts are secure and the wiring will not interfere with the installation of the seat. 14 Reinstall the seat. solo seat bolt hole If you are not using the optional alarm siren or aftermarket accessories, it is possible to mount the PCIII USB EX to the rear fender with the velcro. Mount the PCIII USB EX two inches from the rear of the solo seat bolt hole as shown in Figure K. Figure K i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 5
Figure L remove bolts SOFTAIL DEUCE MODEL INSTALLATION INSTRUCTIONS Use the following instructions if you have a Softail Deuce model. 1 Remove the seat. 2 Remove the two bolts securing the relay bracket as shown in Figure L. retaining plate 3 Lift straight up on the retaining plate enough to expose the zip ties that hold the wiring harness to the plate. Cut these zip ties. zip tie Figure M retaining plate 4 Pull upwards on the retaining plate, which holds the relays, enough to clear the battery. Note: It may be necessary to remove the brake light and datalink connectors from the retaining plate. Figure N i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 6
retaining plate 5 Rotate the retaining plate forward. Locate the relay retaining tabs as shown in Figure E. Bend these tabs so they are flush with the plate. This allows the relays to sit lower in the slots. Figure O relay retaining tabs relay cover 6 Push down on the relay cover so the cover is flush with the retaining bracket as shown in Figure P. Reinstall the bolts for the relay bracket. Refer to Figure L. Figure P retaining bracket Figure Q black connector grey connector ECM tail light connector 7 Attach the grey connector from the PCIII USB EX to the ECM. Attach the black connector from the PCIII USB EX to the stock wiring harness as shown in Figure Q. Note: It is recommended to use dielectric grease on this connection. Install the PCIII USB EX and connectors with the velcro supplied in the locations show in Figure Q. Note: If you are not using the optional alarm siren or additional accessories, go to step 9. 8 Relocate the taillight connector (Figure Q) to the right hand side of the PCIII USB EX. Attach the connector to the PCIII USB EX with a piece of velcro. i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 7
9 If you are not using the optional alarm siren or additional accessories, it is easier to mount the PCIII USB EX to the rear fender in the location shown in Figure R. Mount the PCIII USB EX so the edge of the PCIII USB EX touches the first rubber bumper. 10 Reinstall the seat. Make sure the seat does not interfere with the wiring harness or the tail light connector. Figure R Figure S wiring harness ECM SCREAMIN EAGLE SOFTAIL DEUCE OR 2006 MODEL INSTALLATION INSTRUCTIONS Use the following instructions if you have a Screamin Eagle Softail Deuce or 2006 model. 1 Remove the seat. 2 Remove the battery, negative side first. 3 Disconnect the wiring harness from the ECM as shown in Figure S. i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 8
relay bracket remove bolts 4 Remove the two bolts securing the relay bracket to the frame as shown in Figure T. 5 Cut the three zip ties securing the harness to the relay bracket as shown in Figure T. 6 Remove the relay bracket. This part will not be reused. Figure T zip ties 7 From the left side of the bike, remove the two bolts that hold the mudguard in place. 8 Remove the mudguard as shown in Figure U. Figure U mudguard Figure V PCIII USB EX connector 9 Route the PCIII USB EX connectors from the bottom of the bike into the battery tray area through the hole in the left rear as shown in Figure V. 10 Run the harness from the PCIII USB EX in between the frame and the stock wiring harness. i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 9
Figure W black connector stock wiring harness grey connector 11 Attach the grey PCIII USB EX connector to the ECM. Attach the black PCIII USB EX connector to the stock wiring harness as shown in Figure W. Note: It is recommended to use dielectric grease on this connection. 12 Reinstall the battery. 13 Push the stock wiring harness and relays down between the frame and battery. ECM 14 Attach the connectors to the top of the frame using the supplied velcro as shown in Figure X. Figure X Figure Y 15 Install the PCIII USB EX in the location show in Figure Y. Use the supplied zip ties to hold the PCIII USB EX in place. Verify the PCIII USB EX does not interfere with the swingarm movement or drive belt. 16 Reinstall the mudguard. 17 Reinstall the seat. PCIII USB EX i805-511ex 2001-2006 Harley Davidson Softail Models - PCIII USB EX - 10