Race Dynamics PowerTRONIC User manual

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PowerTRONIC Installation Manual- KTM Duke 390 (2012-2016)
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Document Version
1
Release Date
02 March 2020
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Application information
Vehicle Specific
Vehicle
KTM
Model
Duke 390
Year of manufacture
2012-2016
PowerTRONIC application
All PowerTRONIC ECUs, from firmware version F.3.x onward
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Note:
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●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.
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Call/Whatsapp:
[phone] / [phone]
E-Mail:
[email protected]
Official Website:
www.powertronicECU.com
Social:
www.facebook.com/PowertronicECU/
www.instagram.com/powertronic_ecu/
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Table of Contents
1. Parts list
2. Tools required
3. Installation procedure
3.1 Removing panels, fairing etc
3.2 Routing the harness 
3.3 Fuel Injector Connector
3.4 Crankshaft position sensor
3.5 Ignition coil connector 
3.6 Throttle Position Connector
3.7 Ground terminal
3.8 Securing the routed harness
3.9 Testing with Stock Coupler
3.10 Plugging in the PowerTRONIC
3.11 Attaching the panels, fairing etc
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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 connector
●Spark/Ignition coil connector
●Throttle position sensor connector (TPS)
●Crankshaft position sensor connector(CKP)
●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
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2. Tools required
Serial No
Main tools
Optional tools
1
M8, M10, M12, M17 Hexagonal socket
Spinner handle
2
M10 T bar Hexagonal Socket wrench
Ratchet handle
3
Wire cutter
Extension bar or Sliding T bar
4
Phillips head screwdriver
4,5,6 mm Allen T handle
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2

3. Installation procedure
3.1 Removing panels, fairing
Begin at the left side of the bike.
Park the bike using the centre stand on a level surface (Or a paddock stand). Refer Image 1
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Image 1
Note the position of the connector/hoses/wires to be removed. Refer Image 2
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Image 2 
3

3.1.1 Detach the pillion seat by inserting the key into the keyhole shown in Image 3 and unlock the pillion seat. Image 4
shows the pillion seat detached.
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Image 3
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Image 4
4

3.1.2 Locate and unscrew the rider seat bolts using M 10 Hexagonal T handle. Refer Image 5.
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Image 5
3.1.3 Image 6 shows both the seat detached.
. 
Image 6
5

3.1.4 Locate and unscrew the side panel screws 1, 2 and 3 using Phillips head screwdriver and side bolt 4 using M10
hexagonal socket . Refer Image 7.
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Image 7
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3.1.4 Locate and unscrew the tank rear screws using a Phillips head screwdriver. Refer Image 8.
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Image 8
6

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3.1.5 Carefully detach the side panel locks. Refer to Image 9.
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Image 9
3.1.5 Carefully unscrew the tank front bolts using 5 mm Allen T handle. Refer to Image 10.
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Image 10
7

3.1.6 Unscrew the tank lid bolts using 4 mm Allen T handle. Refer Image 11.
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Image 11
3.1.7 Carefully detach the tank lid. Refer Image 12
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Image 12
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3.1.8 Carefully detach the coolant tank cap. refer Image 13.
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Image 13
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3.1.9 Carefully detach the fuel tank cover. Refer Image 14.
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Image 14
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3.2 Routing the harness
3.2.1 Place the harness on the bike. Note that the TPS and Ignition coil connectors go to the right side of the bike. All
other connectors go to the left. Refer Image 15.
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Image 15
3.2.2 Route the TPS connector on the right side of the bike. Refer Image 16.
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Image 16
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3.2.3 Route the INJ and CKP connectors to the left side of the bike. Refer Image 17
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Image 17
3.2.4 Route the Ground terminal connector to the battery negative. Refer Image 18
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Image 18
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3.3 Fuel Injector Connector (Left side of the bike)
3.3.1 Locate the stock injector connector of your bike. Refer to Image 19 below.
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Image 19
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 the zoomed view (Image 20) below.
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Image 20
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3.3.4 Connect the female PowerTRONIC injector connector to the stock male injector connector. Refer Image 21
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Image 21
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3.3.5 Connect the stock female injector connector to the PowerTRONIC male injector connector. Refer Image 22
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Image 22
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3.4 Crank position sensor (Left side of the bike)
3.4.1 Locate the stock crankshaft position sensor connector on the bike. Usually located right above the engine. Refer
Image 23.
To identify the CKP connector, locate the connector which includes red-white striped wire.
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Image 23
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3.4.2 Disconnect the stock CKP connector. Refer Image 24.
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Image 24
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3.4.3 Connect PowerTRONIC male CKP connector to the stock female CKP connector. Refer Image 25
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Image 25
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3.4.4 Connect the PowerTRONIC female CKP connector to the stock male connector. Refer Image 26
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Image 26
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3.5 Ignition Coil Connector
3.5.1 Locate the stock Spark/Ignition coil connector on the ignition coil. Refer Images 27.
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Image 27
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3.5.2 Identify the Spark/Ignition coil connector in the PowerTRONIC wiring harness. The connectors are labelled 'SPK'
3.5.3 Disconnect the stock ignition coil connectors. Refer Image 28 below.
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Image 28
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3.5.4 Connect the PowerTRONIC Ignition coil male connector to the stock ignition coil female connector. Refer Image 29
below.
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Image 29
3.5.5 Connect the PowerTRONIC Ignition coil female connector to the stock ignition coil male connector. Refer Image 30
below.
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Image 30
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3.6 Throttle position sensor connector (Right side of the bike)
3.6.1 Locate the TPS connector of your bike. It is generally located on the throttle body, parallel to the throttle cable return
springs. Refer Image 31 and Image 32.
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Image 31
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Image 32
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3.6.2 Identify the Throttle Position sensor connector in the PowerTRONIC wiring harness, labeled as 'TPS'
3.6.3 Disconnect the stock TPS connector. Refer Image 33
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Image 33
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3.6.4 Connect the PowerTRONIC male TPS connector to stock female connector. Refer Image 34.
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Image 34
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3.6.5 Connect the PowerTRONIC female TPS connector to stock male connector. Refer Image 35.
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Image 35
3.6.6 We advise you to perform a TPS calibration after the installation of PowerTRONIC ECU.
Refer to the detailed TPS calibration document.
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