Dynojet Power commander V User manual

2009 HD Sportster 1200 PCV - 115-002 www.powercommander.com
FIG.
FIG.
FIG.
2009 HD Sportster 1200 PCV - 115-002 www.powercommander.com
2191 Mendenhall Drive North Las Vegas, NV 89081 [phone] www.powercommander.com
2009HarleyDavidson
Sportster1200
InstallationInstructions
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
TheignitionMUSTbeturned
OFFbeforeinstallation!
PARTS LIST
1 Power Commander
1 USB Cable
1 CD-ROM
1 Installation Guide
2 Power Commander Decals
2 Dynojet Decals
2 Velcro
1 Alcohol swab
1 Zip tie
2 O2 optimizers

2009 HD Sportster 1200 PCV - 215-002 www.powercommander.com
FIG.
FIG.
FIG.
2009 HD Sportster 1200 PCV - 215-002 www.powercommander.com
Map- The PCV has the ability to hold 2 different base
maps. You can switch on the fly between these
two base maps when you hook up a switch to
the MAP inputs. You can use any open/close
type switch. The polarity of the wires is not
important. When using the Autotune kit one
position will hold a base map and the other
position will let you activate the learning mode.
When the switch is “CLOSED” Autotune will be
activated.
Shifter- These inputs are for use with the Dynojet
quickshifter. Insert the wires from the Dynojet
quickshifter into the SHIFTER inputs. The
polarity of the wires is not important.
Speed- If your application has a speed sensor then you
can tap into the signal side of the sensor and
run a wire into this input. This will allow you to
calculate gear position in the Control Center
Software. Once gear position is setup you can
alter your map based on gear position and
setup gear dependent kill times when using a
quickshifter. NOTE: Harley Davidson models
have this feature enabled internally - do
NOT use this input for HD models.
Analog- This input is for a 0-5v signal such as engine
temp, boost, etc. Once this input is established
you can alter your fuel curve based on this input
in the control center software.
Crank- Do NOT connect anything to this port unless
instructed to do so by Dynojet. It is used to
transfer crank trigger data from one module to
another.
SHIFTER
SHIFTER
CRANK
MAP
MAP
ANALOG
SPEED
EXPANSIONPORTS1&2
Optional Accessories such as
Color LCD unit or Auto tune kit.
USBCONNECTION
Wireconnections:
To input wires into the PCV first remove the
rubber plug on the backside of the unit and
loosen the screw for the corresponding input.
Using a 22-24 gauge wire strip about 10mm
from its end. Push the wire into the hole of
the PCV until is stops and then tighten the
screw. Make sure to reinstall the rubber plug.
NOTE: If you tin the wires with solder it will
make inserting them easier.
ACCESSORYINPUTS
POWERCOMMANDERV
INPUTACCESSORYGUIDE

7 Run a zip tie behind the wiring harness (Fig. C).
8 Route the stock wiring harness as shown in Fig. D. Due to the lack of room
on this bike this step needs to be exact or the install will not fit properly.
Make sure that the harness coming from the GREY connector is flush
against the battery box. A couple inches of this harness will be tucked
underneath the frame.
2009 HD Sportster 1200 PCV - 315-002 www.powercommander.com
FIG. A
FIG. C
FIG. B
WARNING! This install is intended to be used with the stock seat.
This install may NOT work with aftermarket seats.
1 Remove the stock seat.
2 Remove the left hand side cover.
3 Remove the battery.
4 Unplug the stock wiring harness from the ECM (Fig. A) .
5 Connect the GREY connector of the PCV to the stock ECM (Fig. B).
6 Route the PCV underneath the left hand side of the frame.
Unplug
PCV connector
Zip tie

2009 HD Sportster 1200 PCV - 415-002 www.powercommander.com
FIG. D
FIG. F
FIG. E
9 Plug the BLACK connector from the PCV into the stock wiring harness.
(Fig. E).
10 Secure these connectors to the stock wiring harness with the zip tie (Fig. E).
Zip tie
11 Reinstall the battery.
12 Relocate the diagnostic connector to the front of the fuse box.
13 Using the supplied velcro attach the PCV to the side of the battery (Fig. E).
Make sure to use the alcohol swab to clean both surfaces before attaching.
Diag plug
14 Locate the front stock O2 sensor connection. This is located in front of the
oil filter. Unplug the O2 sensor from the wiring harness.
15 Plug one of the Dynojet O2 sensor eliminators into the stock wiring harness
(Fig. F).
The stock O2 sensor does not need to be connected to anything. The
sensor can be removed completely from the motorcycle if desired. If using
the Autotune kit remove the stock sensor and install the Dynojet O2 sensor
into the exhaust.
O2 eliminator

2009 HD Sportster 1200 PCV - 515-002 www.powercommander.com
FIG. G
FIG. J
FIG. H
16 Locate the rear stock O2 sensor connection. This is located behind the rear
exhaust pipe. Unplug the O2 sensor from the wiring harness.
17 Plug one of the Dynojet O2 sensor eliminators into the stock wiring harness
(Fig. G).
The stock O2 sensor does not need to be connected to anything. The
sensor can be removed completely from the motorcycle if desired. If using
the Autotune kit remove the stock sensor and install the Dynojet O2 sensor
into the exhaust.
FollowtheseinstructionswheninstallingtheAutotunekit(part#AT-100)
1 Remove the left hand side cover.
2 Using the supplied velcro install the Autotune module on top of the battery.
3 Remove the rubber plug for the diagnostic connector. Plug the lead from the
Autotune kit into the stock diagnostic connector
O2 eliminator
AT module
4 Connect the longer harness to the front O2 sensor. Route the harness along
the front down tube and along the backbone of the frame to Autotune module
AT#1. Wire the harness to the module per Figure J. The harness can be cut
to length if desired
5 Repeat step 4 for the rear cylinder using the shorter harness and connect to
AT#2.
6 Plug the CAN bus cable to the Autotune module and to the PCV. It does not
matter what ports are used.
7 Install the CAN termination plug into the open port of the Autotune module.
8 Secure the harnesses in place as to not contact the exhaust.
9 Reinstall the side cover.
Go to www.powercommander.com for maps and software updates.