Dynojet power commander III User manual

i213-411 2004 Kawasaki ZX6RR - PCIII USB - 1
2004 Kawasaki ZX6RR
Installation Instructions
Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89031 [phone] www.powercommander.com
Parts List
1 Power Commander
1 USB Cable
1 CD-ROM
1 Installation Guide
1 Power Adapter
2 Power Commander Decals
2 Dynojet Decals
1 Velcro®Strip
1 Alcohol Swab
You can also download the Power
Commander software and latest maps
from our web site at:
www.powercommander.com
The ignition MUST be turned
OFF before installation!
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
Button Adjustment Display
Faceplate Buttons
Expansion Port USB Port

1. Remove the tail section by
removing the six push pins
on the underside of the tail
section.
2. Remove the two bolts that
hold the tail section to the
subframe (Fig. A).
3. Pull the tray out of the tail
section. To remove the tray
remove the screw in the cen-
ter of the tray (Fig. A).
Route the PCIII harness
under the frame crossover
and thru the cutout in the
tray (Fig. B).
4. Remove the bolt shown in
Fig. C. This allows the inner
rear fender to be flexed
downwards to allow clear-
ance for the routing of the
PCIII harness.
Fig. AFig. B
Fig. C
2004 Kawasaki ZX6RR - PCIII USB - 2i213-411 www.powercommander.com
Remove these bolts
Remove this bolt
Tray
Frame Crossover

5. Route connectors from the
PCIII one at a time between
the frame and inner fender
(Fig. D).
6. Route the PCIII harness
under the frame crossover
(Fig. E). The battery may
need to be removed to allow
clearance for the connectors
and harness.
7. Lift the front of the fuel tank
up. Remove the air box. To
remove the air box loosen
the the two 3mm allen
screws at the rear of the
air box (Fig. F). Also
disconnect the hoses and
electrical connector as
shown in Fig. F.
Fig. DFig. E
Fig F
2004 Kawasaki ZX6RR - PCIII USB - 3i213-411 www.powercommander.com
Frame Crossover
3mm Allen Screws
Electrical Connector
Hose
Hose

8. Unplug the throttle body
connector (Fig. G). This
connector is located under-
neath the throttle bodies.
9. Plug the connectors that are
closest to the PCIII unit in-
line of the stock throttle
body connector (Fig. H).
10. Unplug the Throttle Position
Sensor connector. This
connector is located in front
of the throttle bodies on top
of the valve cover and is
the grey colored connector
(Fig. I).
Fig. GFig. H
Fig. I
2004 Kawasaki ZX6RR - PCIII USB - 4i213-411 www.powercommander.com
Connector
Stock
PCIII
Unplug This Connector

11. Plug the other connectors
from the PCIII in-line of
the stock TPS connectors
(Fig. J).
12. Connect the ground wire
from the PCIII to the
negative side of the battery
(Fig. K).
13. Make sure all connections
are secure and that the
wiring harness will not get
pinched or chaffed.
14. Reinstall the air box.
15. Reinstall the tail section.
16. Bolt the fuel tank down into
position.
Fig. JFig. K
2004 Kawasaki ZX6RR - PCIII USB - 5i213-411 www.powercommander.com
Stock
PCIII
Connect PCIII Groundwire to Negative