17-001 www.powercommander.com 2008-2012 Kawasaki EX250 (EFI) - PCV - 1

PARTS LIST

1 PowerCommander1 USBCable1 InstallationGuide2 PowerCommanderDecals2 DynojetDecals2 Velcrostrips1 Alcoholswab1 O2Optimizer

THE LATEST POWER COMMANDER SOFTWARE AND MAP FILES CAN BE

DOWNLOADED FROM OUR WEB SITE AT:www.powercommander.com

2008-2012 Kawasaki EX250(FuelInjectedModelsOnly)

I ns ta l l a t i on I ns t ruc t i ons

PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION

THE IGNITION MUST BE TURNED OFF BEFORE INSTALLATION!

2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 www.powercommander.com

17-001 www.powercommander.com 2008-2012 Kawasaki EX250 (EFI) - PCV - 2

EXPANSION PORTS 1 & 2

OptionalAccessoriessuchasPOD-300unitorAuto-tunekit.

POWER COMMANDER V INPUT ACCESSORY GUIDE

Map - (Input1or2)ThePCVhastheabilitytohold2differentbasemaps.YoucanswitchontheflybetweenthesetwobasemapswhenyouhookupaswitchtotheMAPinputs.Youcanuseanyopen/closetypeswitch.Thepolarityofthewiresisnotimportant.WhenusingtheAutotunekitonepositionwillholdabasemapandtheotherpositionwillletyouactivatethelearningmode.Whentheswitchis“CLOSED”Autotunewillbeactivated.(SettoSwitchInput#1bydefault.)

Shifter- (Input1or2)TheseinputsareforusewiththeDynojetquickshifter.InsertthewiresfromtheDynojetquickshifterintotheSHIFTERinputs.Thepolarityofthewiresisnotimportant.(SettoSwitchInput#2bydefault.)

Speed- Ifyourapplicationhasaspeedsensorthenyoucantapintothesignalsideofthesensorandrunawireintothisinput.ThiswillallowyoutocalculategearpositionintheControlCenterSoftware.Oncegearpositionissetupyoucanalteryourmapbasedongearpositionandsetupgeardependentkilltimeswhenusingaquickshifter.

Analog- Thisinputisfora0-5vsignalsuchasenginetemp,boost,etc.Oncethisinputisestablishedyoucanalteryourfuelcurvebasedonthisinputinthecontrolcentersoftware.

Crank- DoNOTconnectanythingtothisportunlessinstructedtodosobyDynojet.Itisusedtotransfercranktriggerdatafromonemoduletoanother.

ACCESSORY INPUTS

Wire connections:

ToinputwiresintothePCVfirstremovetherubberplugonthebacksideoftheunitandloosenthescrewforthecorrespondinginput.Usinga22-24gaugewirestripabout10mmfromitsend.PushthewireintotheholeofthePCVuntilisstopsandthentightenthescrew.Makesuretoreinstalltherubberplug.

NOTE:Ifyoutinthewireswithsolderitwillmakeinsertingthemeasier.

CRANK

ANALOG

SPEED

INPUT 1 (Grnd)

INPUT 1

INPUT 2 (Grnd)

INPUT 2

USB CONNECTION

17-001 www.powercommander.com 2008-2012 Kawasaki EX250 (EFI) - PCV - 3

1 Removetheseats.

2 Removethefueltank.

3 LaythePCVinthetailsectionandroutetheharnesstowardsthefrontofthebike.RoutethePCVharnessdowntherightsideofthebike(Fig.A).

4 Movethejunctionboxoutofthewayandremovetheboltforthebatterycover(Fig.A).

5 AttachthegroundwireofthePCVtothenegativesideofthebattery(Fig.B).

6 Reinstallthebatterycoverandjunctionbox.

7 Unplugthestockwiringharnessfromeachinjector(Fig.C).

FIG.A

FIG.C

Remove

Ground wire

FIG.B

PCV harness

Remove bolt

PCV harnessUn

plug

Unpl

ug

17-001 www.powercommander.com 2008-2012 Kawasaki EX250 (EFI) - PCV - 4

8 PlugthePCVharnessin-lineofthestockwiringharnessandinjectors(Fig.D).

ORANGE-cylinder#1

YELLOW-cylinder#2

FIG.D

9 LocatethePrimaryThrottlePositionSensorontherighthandsideofthethrottlebodies(Fig.E).ThisistheGREY3-pinconnector.

This picture was taken with the coolant bottle moved out of the way

10 PlugtheconnectorsfromthePCVin-lineofthePrimaryTPSandthestockwiringharness.

Make sure you do NOT plug the PCV in-line of the BLACK 3-pin connector and the bike’s Secondary TPS.

FIG.E

Unplug TPS

11 Usingthesuppliedvelcro,securethePCVunitinthetailsection(Fig.F).

CleanthesurfaceareawiththesuppliedalcoholswabpriortoapplyingtheVelcroadhesive.

FIG.F

17-001 www.powercommander.com 2008-2012 Kawasaki EX250 (EFI) - PCV - 5

12 Removetherighthandfairing.

13 LocatethestockO2sensorconnection.UnplugtheO2sensorfromthewiringharness(Fig.G).

14 PlugtheDynojetO2Optimizerintothestockwiringharness.

The stock O2 sensor will not be connected to anything at this time. It can be removed from the exhaust if desired.

15 Reinstallthefueltank,bodywork,andseats.

Optional inputs:

Speed -GREEN/REDwire(pin#5)ofthelargerECUconnector

Engine Temperature - ORANGEwire(pin#17)ofthelargerECUconnector

FIG.G

FIG.H

Unplug

O2 Optimizer