fish_antlers
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posted May 26, 2004 03:32 PM
 Edited By: fish_antlers on 27 May 2004 07:54
Powercommander install with Photos... bring an ounce or two of patience
Okay.. so I finally got around to installing the Power Commander on the 10R.
First thing to note.... *many people who have never purchased or installed one do NOT realize is that they need a computer within close proximity to the bike so they can program it.... You really cant just "buy the box and put it in".. you need a computer NEXT to your bike to adjust it.
off topic, first thing I noticed when I took the seat off was that the nuts that were supposed to be holding the power valve servo on were gone!! .... bastards!
Anyways... There are some tricky bits to remove.. .this bike is tight... someone who is an origami fanatic must have had a hand in the design. Removing the airbox is easy once you know the trick... It's width is greater than the distance between the frame rails it sits under! Once you have disconnected the air pressure sensor and the drain hose and PCV hose, carefully (without snapping off any of the spigots on the bottom of the air box) rotate the airbox COUNTERCLOCKWISE... eventually it frees itself and slides out backwards...
Another side note.... inspect your air filter! I cant believe how much dirt this thing caught.... most crap I've ever seen in a filter with only 1500miles of city/ street riding...
Once you have wrestled off the air box, take a deep breath before you try to undo the TPS and FI harnesses... they are very tight and hard to undo...
Here's a nice shot of how easy  the FI connector is to access...
There isn't much if anything mentioned about cable routing in the install docs from DJ... I chose my own route, not wanting any ZX-12R repeats with a pinched or damaged harness... I ran the cable alongside the left side of the bike frame rail (outside of it) but behind the fuel pump connector.. This gives you a nice clean route with no pinching or obstructions. It lets you pick up the negative battery terminal and lines you up with the places you need to access in the stock harness.
Then I tucked in behind and underneath the bracket that holds on the left side of the tail section (undo the allen, slide cable under, replace)
The black bodywork panel on the bike needs to be trimmed to run the cable this way... Remember, none of this is in the manual... it just seemed logical to me... I notched the panel like below (this notch isn't visible with the panel installed) and smoothed the edges.. this gives you a very nice exit into the rear of the bike...
Now, where I am stuck is what to do with Powercommander itself. The damn thing just sits in the trunk.. right now it just flops around... nowhere to mount it... Guess I'm waiting on Dino for a solution to this one... perhaps a hinge and under mount ala 12R is the solution... certainly what DJ suggests in their install doc isn't the right answer IMHO...
Now... an important tip, which was also left out of ANY documentation.
When you attempt to connect to the Powercommander with your computer, the bike has to be running or it looses its connection. This makes it impossible (or damn frustrating) to set the TPS values etc.
To overcome this (as in the photo above) use a 9 volt battery and the adapter supplied with the unit. Connect it to the Powercommander and then turn the ignition to the ON position, but do NOT start the engine. You will be able to upload etc and set the TPS as normal. (BTW, TPS adjustment to several attempts to achieve a solid "zero" value). Although this isn't mentioned in any manuals, our contact at DJ says it's safe to do and will not harm the unit.
So, I haven't had a chance to ride the thing... all I can say is that it took me about 2 hours to install.. . Certainly longer than I had expected. Maybe I need smaller hands...
and more beer.
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beansbaxter
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posted May 26, 2004 04:19 PM
Definitely more beer haha.
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Michael Lee
Zone Head
Purchase Ivy
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posted May 26, 2004 04:25 PM
Thanks for the play by play, I did not know the computer had to be close to the bike to make it happen. Appreciate . . .
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fish_antlers
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posted May 26, 2004 04:32 PM
There's a break in the rain... I'm out fer a quick test-thrash with the Powercommander... will report back shortly.
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What business is it of yours where I'm from, Friendo?
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frEEk
Administrator
ummm... yeah
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posted May 26, 2004 04:36 PM
to expand a touch on the point about needing a computer near the bike, this is only needed to the TPS adjustment and a couple other things i think? You should be able to upload and download maps from the PC without having it connected to the bike.
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fish_antlers
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posted May 26, 2004 05:08 PM
sort of.. but once it's hooked up to the bike it's 2 hours to unhook it.. and there's not much point at all in using it without setting the TPS values or else the refernce points for the map are all wrong.
BTW that was a lame ride.. rode out.. .poured rain... made it 2 blocks.. came back home 
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k bryant
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posted May 26, 2004 05:09 PM
Yikes! Look forward to reading what you think. The KMC box took all of 2 minutes to install (yea, yea, no argument that it's priced sky high). After all the adjustments, we had a beautiful fuel curve that ended up adding hp from about 3500 rpm on up to redline. Close to + 4 hp at peak.
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Rubber Pants
Zone Head
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posted May 26, 2004 07:11 PM
You must live in a dirty city!!
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D
Needs a job
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posted May 26, 2004 07:30 PM
Prolly due to the pretty open intake.
I had the monster snorkel on the 12 and was cleaning the filter every 1500 miles.
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DB
Pro
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posted May 26, 2004 08:15 PM
Thanks fish, I put my pipe on 2 weeks ago but haven't gotten around to installing the PC yet either. Just doesn't seem like enough time in the day. Hey, maybe DKET can come over and install it for me. NOT!!!!!!!
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Dan
04 ZX10r (Track only)
08 Concours14
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fish_antlers
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posted May 26, 2004 08:23 PM
rubber... air in Canada is guaranteed to be cleaner than socal! 
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D
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posted May 26, 2004 08:24 PM
I thought we "exported" that up to ya?
Or is it the other way around?
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fish_antlers
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posted May 26, 2004 08:25 PM
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What business is it of yours where I'm from, Friendo?
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Michael Lee
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posted May 26, 2004 08:41 PM
Thanks K Bryant for the input on the KMC box. The 4 hp was on a bike with a slip-on or f/s?
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D
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posted May 26, 2004 08:44 PM
Edited By: D on 26 May 2004 21:56
He could tell ya but then he'd hafta .......
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DB
Pro
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posted May 26, 2004 09:07 PM
quote:
Thanks K Bryant for the input on the KMC box. The 4 hp was on a bike with a slip-on or f/s?
Jardine is not making a full system for the 10r.
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Dan
04 ZX10r (Track only)
08 Concours14
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guamaniac
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posted May 26, 2004 09:40 PM
Yeah fish, the PCIII was a pain to install....can't get over how tight everything is laid out in there...all about the weight baby! Yup, my air filter was as dirty.... Funny how the manual says to turn counterclockwise....but I guess either way is fine....still a PITA though. Oh and excuse my ignorance but what is TPS?
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SMBowen
Novice Class
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posted May 26, 2004 10:03 PM
quote:
rubber... air in Canada is guaranteed to be cleaner than socal!
Yeah but it's not raining here....:-D
thanks for the play by play am going to have to have this page open when I install mine next weekend.
[shawn]
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marco383
Expert Class
Posts: 145
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posted May 27, 2004 03:04 AM
The PC can be mounted sideways (90 degrees to the long axis of the bike) in what passes for a storage compartment in the tail. Use the sticky tape provided and position it to allow future USB cable access for dyno tuning. I really wanted to remove the exhaust valve motor and use that space for the PC (I installed a full exhaust system in the same wrench session), but an earlier post indicated that doing this throws the computer into a fit.
BTW, I thought that I was the only one who had difficulty with those damn electrical connectors.
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swft
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posted May 27, 2004 05:40 AM
Great pics Fish - Now I know that I won't buy a PC. Will be the KMC box if anything. 
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fish_antlers
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posted May 27, 2004 06:44 AM
Hmmm.... I turned clockwise... I'll edit my post if the factory manual says counterclockwise..
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bovinespongiformencephalo
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posted May 27, 2004 06:53 AM
quote:
...in what passes for a storage compartment in the tail...
The ringers they gave the mags had bigger storage areas.
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worm~hole
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posted May 27, 2004 08:42 AM
...what's a the part # for the KMC box and how much of my arm and leg will it cost?...also could you list the PC vs KMC pros & cons?...thank you...
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worm~hole
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Miles to go before I sleep....
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posted May 27, 2004 08:43 AM
...and how'bout a ride review of PK's 6RR? 
____________
“We sleep safe in our beds because rough men
stand ready in the night to visit violence on those
who would do us harm.”
-George Orwell
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D
Needs a job
Posts: 3365
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posted May 27, 2004 09:23 AM
quote:
...what's a the part # for the KMC box and how much of my arm and leg will it cost?...also could you list the PC vs KMC pros & cons?...thank you...
$1600 for ECU and Cable
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