PowerTRONIC Installation Manual- Kawasaki ZX10R (2008-2018)

Document Version 1 Release Date 05 March 2019

Application information Vehicle Specific

Vehicle Kawasaki

Model ZX 10 R

Year of manufacture 2008-2018

PowerTRONIC application All PowerTRONIC ECUs, from firmware version F.3.x onward

Note:

● Read through all instructions before installation and use.

● Ensure that the bike is switched off and the key is out of the ignition before proceeding with the
installation.
● Some parts of the bikes might be hot/sharp and may cause burns/cuts. Proceed with extreme
caution or wait until the bike has cooled down. Always wear safety gloves.
● When the installation is complete, make sure to secure the wiring loom away from the movable parts
or components which tends to heat up during the normal operation of the vehicle at any chance.
● PowerTRONIC is intended for motorsport use on a closed course, please check with your local laws
before using this product. Race Dynamics / PowerTRONIC is not liable for consequences arising out
of using the product.

Call/Whatsapp: +919916229292 / +918040929292

E-Mail: [email protected]
Official Website: www.powertronicECU.com
Social: www.facebook.com/PowertronicECU/
www.instagram.com/powertronic_ecu/

Table of Contents
1
 1. Parts list
2. Tools required
3. Installation procedure
3.1 Removing panels, fairing etc
3.2 Routing the harness
3.3 Fuel Injector connectors
3.4 Ignition coil connectors
3.5 Throttle position Sensor connector
3.6 Ground terminal
3.7 Securing the routed harness
3.8 Testing with Stock Coupler
3.9 Plugging in the PowerTRONIC
3.10 Attaching the panels, fairing, etc

1. Parts list
1 PowerTRONIC Piggyback ECU
2 Stock Coupler Stand by unit
● Can be connected in place of the PowerTRONIC to run the bike in stock
mode if need be.
● Used for the verification of the connectors involved.

3 Harness Bike specific harness contains the following connectors

● Fuel injector connectors
● Ignition coil connectors
● Throttle position sensor connector (TPS)
● Crank position (CKP) sensor * if applicable
● Map selection connector
● Quick shifter connector
● Ground terminal
4 USB cable Can be used to connect the PowerTRONIC to a laptop for throttle calibration or
changing maps
5 Nylon Tags To secure wiring harness
6 User guide and Warranty card Instructions

2. Tools required
Serial No Item with description
1 3, 4, 5, 6 mm Allen T handle
2 M8, M10, M12 Hexagonal socket
2 Phillips-Head screwdriver
3 Wire cutter

2
3. Installation procedure
3.1 Removing panels, fairing
Park the bike using the centre stand on a level surface (Or a paddock stand).
Begin at the left side of the bike.

Image 1

Image 2

3
3.1.1 Locate the pillion rider seat lock shown in Image 3 and unlock the pillion rider seat as shown in Image 4.

Image 3

Image 4

4
3.1.2 Detach the pillion rider seat. Gently detach the rider seat also. Refer Image 5

Image 5

3.1.3 Unscrew the fuel tank bolts using a 4 mm Allen key. Refer Image 6

Image 6

5
3.1.4 Unscrew the pillion rider seat panel bolts using a 4 mm Allen key. Refer the Image 7

Image 7

3.1.5 Gently detach the side panel. Refer Image 8.

Image 8

6
3.1.6 Unscrew the rider seat bolts using a 10 mm T handle. Refer Image 9.

Image 9

3.1.7 Gently detach the rider seats. Refer Image 10

Image 10

7
3.1.8 Unscrew the bracket bolts using a 5mm hex bit. Refer Image 11

Image 11

3.1.9 Unscrew the tank cover bolts using 4 mm Allen key and 8 mm hex socket. Refer Image 12

Image 12

8
3.1.10Gently remove the tank cover. Refer Image 13

Image 13

3.1.11 Gently lift the front end of the tank. Refer Image 14

Image 14

9
3.1.12 Disconnect the two vacuum hoses. Refer Image 15

Image 15

3.1.13 Disconnect the fuel line. Refer Image 16

Image 16

10
3.1.14 Disconnect the fuel pump/float connector. Refer Image 17

Image 17

3.1.15 Disconnect the fuel injector connectors. Note: Connect the PowerTRONIC connectors after connecting the ignition
coil connectors and the air box). Refer Image 18 and Image 19

Image 18

11
3.1.16 . Refer Image 19

Image 19

3.1.17 Locate and carefully disconnect the sensor connector. Refer Image 20

Image 20

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3.1.18 Disconnect the relays and Fuel line. Refer Image 21

Image 21

3.1.19 Using a Phillips head screw driver, unscrew the screws on the air box cover. Refer Image 22

Image 22

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3.1.20 Detach the top of the air box. Refer Image 23

Image 23

3.1.21 Unscrew the bracket bolts using a 10mm Hex socket. Then remove the bracket. Refer Image 24

Image 24

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3.1.22 Unscrew the bolt using a 5 mm Hex bit. Refer Image 25

Image 25

3.1.23 Unscrew the air box mounting bolts using a 5 mm allen key. Refer Image 26

Image 26

15
3.1.24 Gently detach the vacuum tubes from air bo. Refer Image 27

Image 27

3.1.25 Gently detach the air box. Refer Image 28

Image 28

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 3.2 Routing the harness
3.2.1 Starting from the glove compartment, route each connector terminal between the welded plate and the mud guard.
Refer Image 29.

Image 29

3.2.2 Start from the glove compartment, route each connector terminal between the mudguard and seat centre panel.
Refer to Image 30.

Image 30

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3.2.3 Route each connector through the panel carefully and route the entire harness. Refer Image 31 and Image 32

Image 31

Image 32

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3.2.4 Route the Injector connectors and Ignition coil connectors to their respective positions. Refer Image 33

Image 33

Important Note: There are 4 fuel injector connectors and ignition coil connectors. Fuel injectors are labelled as
INJ1, INJ2, INJ3, INJ4, and Ignition coil connectors are labelled as SPK1, SPK2, SPK3, SPK4. Before proceeding
with the installation, understand the order and then do the installation in the same order for fuel injector and
ignition coil connectors. Ie Connect the same number of INJ and SPK to connectors that go to the same
cylinder.

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 3.3 Fuel Injector Connector This can be installed at the last after SPK and TPS connectors.
3.3.1 Locate the stock injector connector of your bike. Refer Images 34.

Image 34

3.3.2 Identify the fuel injector connector in the PowerTRONIC wiring harness. The connectors are labeled 'INJ'

3.3.3 Disconnect the injector connector on your bike. Refer Image 35

Image 35

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3.3.4 Connect the PowerTRONIC female injector connector harness to the stock male injector connector. Refer Image 36

Image 36

3.3.5 Connect the PowerTRONIC male injector connector to the stock female injector connector. Refer Image 37

Image 37

3.3.6 Repeat the above steps for the other 3 Injector connectors

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 3.4 Ignition Coil Connector
3.4.1 Locate the stock Ignition coil connectors. Refer Images 38

Image 38

3.4.2 Identify the Spark/Ignition coil connector in the PowerTRONIC wiring harness. The connectors are labelled 'SPK'.

3.4.3 Disconnect the stock ignition coil connectors. Refer Image 39

Image 39

22
3.4.4 Connect the PowerTRONIC Ignition coil female connector to the stock ignition coil male connector. Refer Image 40.

Image 40

3.4.5 Connect the PowerTRONIC Ignition coil male connector to the stock ignition coil female connector. Refer Image 41.

Image 41

3.4.6 Repeat the above steps for the other 3 ignition coils.

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 3.5 Throttle position sensor connector
3.5.1 Locate the TPS connector of your bike. It is generally located on the throttle body, parallel to the throttle cable return
springs. Refer Image 42

Image 42

3.5.2 Identify the Throttle Position sensor connector in the PowerTRONIC wiring harness, labeled as 'TPS'

3.5.3 Disconnect the stock TPS connector. Refer Image 43

Image 43

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3.5.4 Tap the purple wire of the TPS connector to the wire labelled as TPS on the PowerTRONIC harness. Refer Image 44

Image 44

3.5.5 For wire position, Refer Image 45. After the tapping procedure, plug the Connector back into the TPS connector.

Image 45

3.5.6 We advise you to perform a TPS calibration after the installation of PowerTronic ECU.
Refer the detailed TPS calibration document.

25
 3.6 Ground Terminal Connector
3.6.1 Unscrew the battery negative terminal and Identify the Ground terminal connector labelled as GND and connect it to
the negative terminal of the battery. Refer Image 46

Image 48

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 3.7 Securing the harness using ties
3.7.1 Secure the harness away from general heating areas by attaching it to the chassis or frame using the zip
ties provided wherever necessary. Refer Image 47

Image 47

Important note: The PowerTRONIC harness contains a Quick shifter connector. If you have bought the Quickshifter please
attach the connector to it. [Please refer Quick shifter installation manual]

If you have not bought the Quickshifter, you can leave it disconnected but make sure the harness is secured using zip ties
provided.

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 3.8 Testing with the stock coupler
3.8.1 Attach the fuel tank.
3.8.2 You can verify the connections by attaching the stock coupler. Refer to the detailed Stock coupler test
document.
3.8.3 DO NOT proceed with PowerTRONIC ECU without verifying the connections with stock coupler. Refer
Image 48

Image 48

Note: If the PowerTRONIC injectors connectors are connected to the secondary set of
Injectors, then INJ LEDs will pulse at higher RPMs only.

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 3.9 Plugging in the PowerTRONIC
Connect the PowerTRONIc to the harness by connecting the 24 pin connector. Secure it in the glove box. Refer
Image 49

Image 49

3.10 Attaching the panels fairing etc

Attach the panels, fairing as removed from the bike.

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