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2002-2003 Kawasaki Vulcan 1500 Mean Streak

Installation Instructions Parts List Power Commander CD-ROM Installation Guide Wire Tap Connector Power Commander Decals Dynojet Decals Velcro® Strip Alcohol Swab 1 1 1 1 2 2 1 1

The ignition MUST be turned OFF before installation! You can also download the Power Commander software and latest maps from our web site at: www.powercommander.com

PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION

Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89031 (800) 992-4993 www.powercommander.com

i205-211 2002-2003 Kawasaki Vulcan 1500 Mean Streak - PCIII - 1

1

Squeeze this connector together to remove

Remove the seat. Remove the left side cover. Remove the indicator light cluster assembly. Unbolt the fuel tank.

2 3

Fig. A

4

Remove this clip to disconnect

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 hold down bracket (Fig. B).

Fig. B

Remove these two bolts to remove bracket

6

Loosen the bolts holding the plastic tray on the left side of the bike (under the left side cover) (Fig. C).

Fig. C

Loosen these 4 bolts

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2002-2003 Kawasaki Vulcan 1500 Mean Streak - PCIII - 2

7

Route the wires from the PCIII behind the plastic tray and under the frame side rail (Fig. D&E). Retighten the bolts holding the plastic tray.

8

Fig. D

Route the PCIII harness between the frame and tray

Fig. E

Route the PCIII harness between the frame and plastic tray

9

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&G).

Fig. F

Route wires under frame

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2002-2003 Kawasaki Vulcan 1500 Mean Streak - PCIII - 3

Fig. G Wires from PCIII

10

Throttle body

Disconnect the injector connector from the rear injector (Fig. H). Plug the male PCIII connector with GREEN/ORANGE wires onto the rear injector (Fig. H). Connect the female PCIII connector with BLUE/RED wires onto the stock injector connector (Fig. H). Repeat steps 11thru 13 for front injector using the PCIII connectors with the PURPLE/BROWN colored wires. Locate the wires coming from the throttle position sensor. (Fig. I). Attach the supplied wire tap onto the YELLOW wire with WHITE stripe. Firm pressure is required to close the connector. (Fig. I). Plug the GREY wire with the spade terminal from the PCIII, into the wire tap (Fig. I). It is recommended to seal this connector with silicone.

11

Fig. H

12

Stock Connectors PCIII Connectors

13

Wire tap connector goes onto the yellow wire with the white stripe

14 15

Fig. I

16

Wire from PCIII harness

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2002-2003 Kawasaki Vulcan 1500 Mean Streak - PCIII - 4

17

Stock auxiliary ground

Reinstall the fuel tank. Plug the ground wire from the PCIII into the auxiliary ground from the stock harness (Fig. J). The auxiliary ground can be found lying next to the battery. It has a double lead on a black wire with a yellow tracer. Attach the PCIII module to the plastic tray (or the charcoal canister on California models) under the left side cover (Fig. M). Reinstall the side cover. Reinstall the seat.

18

Fig. J

19

Battery Ground wire from PCIII

20 21

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Fig. K

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2002-2003 Kawasaki Vulcan 1500 Mean Streak - PCIII - 5

PCIII user's guide.

Adjusting Your Power Commander 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. NOTE: On some models, the injectors are powered down shortly after turning the ignition on. To send a map, adjust the throttle position or adjust the buttons you will need to use the Power Adaptor (#66116001 or 76423001). Plug the power adapter up to the Power Commander. Then plug the 9 pin serial cable to the other side of the power adapter (see figure). s e G u i d

The latest software and maps can be found at www.powercommander.com

To adjust the buttons follow these steps: 1. Hold all three buttons down firmly. 2. While holding the buttons down connect the battery to the power up adapter. 3. Release the buttons.

U

s

e 4. Select the range you wish to adjust: Low, Med, High, by pushing the corresponding button once. 5. At this point holding that button down will move the lights down (leaning out the mixture). Hold these buttons and start the bike to adjust the Power Commander III I I P

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6. Pushing the button repeatedly will move the light up (richening the mixture). 7. When the two center lights are lit up this is the "0" setting.

PCIII User's Guide - 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 20-30 seconds after making adjustments before starting or turning off the bike. i u G ' r P

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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. 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. 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 III. 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.

PCIII User's Guide - B

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