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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1

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.
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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
9

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
10