17-060 www.powercommander.com 2015 Kawasaki EX300 - 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

2015 Kawasaki EX300

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

FUEL AND IGNITION

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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

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1 Removetheseats.

2 Removethefueltank.

3 Removetherightandleftsidemid-fairings.

4 LaythePCVinthetailsectionandroutetheharnesstowardsthefrontofthebike,followingalongsidetherightsideframerailascloselyaspossible.

Cross-member brackets may need to be loosened or removed to route the wiring harness beneath them.

5 Movethejunctionboxoutofthewayandremovetheboltforthebatterycover(Fig.A).

6 SecurethegroundwireofthePCVwiringharnesswiththe6mmringlugtothenegativeterminalofthebike’sbattery(Fig.A).

7 Reinstallthebatterycoverandjunctionbox.

8 Unplugthestockwiringharnessfrombothfuelinjectors(Fig.B).

9 PlugthePCVwiringharnessin-lineofthestockwiringharnessandthefuelinjectors(Fig.C).

The pair of PCV connectors with ORANGE colored wires go to the left-most cylinder (cylinder #1).

The pair of PCV connectors with YELLOW colored wires go to the right-most cylinder (cylinder #2).

FIG.A

FIG.B

PCV harnessGround

Unpl

ug

Unpl

ug

FIG.C

17-060 www.powercommander.com 2015 Kawasaki EX300 - PCV - 4

10 LocatetheThrottlePositionSensorontherighthandsideofthethrottlebodies(Fig.D).

This is the GREY 3-pin connector.

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

FIG.D

11 PlugtheconnectorsfromthePCVwiringharnessin-lineoftheTPSandthestockwiringharness(Fig.E).

Make sure you do NOT plug the PCV in-line of the stock BLACK connector.

FIG.E

Unplug

FIG.F

STK

PCV

PCV

TPS

12 LocateandunplugtheCrankPositionSensorfromthestockwiringharness(Fig.F).

This is a BLACK 2-pin connector inside of a rubber boot on the left hand side of the engine head.

Unplug

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15 PlugthePCVwiringharnessleadswithGREENcoloredwiresin-lineofthestockwiringharnessandtheleftignitioncoilstick(coilstick#1)(Fig.I).

13 PlugthePCVin-lineofthestockwiringharnessandtheCrankPositionSensor(Fig.G).

FIG.G

FIG.H

FIG.I

14 Unplugthestockwiringharnessfromtheleftignitioncoilstick(coilstick#1)(Fig.H).

The coil sticks are located directly on top of the engine’s valve cover.

STK

PCVSTK

PCV

Unplug

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FIG.J

FIG.L

18 LocatethestockO2sensorconnectionandunplugit(Fig.L)

This is a BLACK 4 pin connector located on the left side of the bike next to the crank sensor connection.

16 Unplugthestockwiringharnessfromtherightignitioncoilstick(coilstick#2)(Fig.J).

17 PlugthePCVwiringharnessleadswithBLUEcoloredwiresin-lineofthestockwiringharnessandtherightignitioncoilstick(coilstick#2)(Fig.K).

FIG.K

Unplug

Unplug

17-060 www.powercommander.com 2015 Kawasaki EX300 - PCV - 7

FIG.N 20 UsingthesuppliedVelcrosecurethePCVunitinthetailsection(Fig.L).

Be sure to clean both surfaces with the supplied alcohol swab prior to applying the Velcro.

21 Reinstallthefueltank,bodywork,andseats.

Optional inputs:

Speed - GREEN/REDwire(pin#5)ofthelargeECUconnector

Engine Temperature - ORANGEwire(pin#17)ofthelargeECUconnector

19 PlugthesuppliedO2Optimizerintothestockwiringharness(Fig.M).

The stock O2 sensor will no longer be connected and can be removed from the exhaust if desired..

FIG.M

O2 Optimizer