• 4-123 www.powercommander.com • IgnitionQuickShifter-StandAloneUnit-1

• PLEASEREADALLDIRECTIONSBEFORESTARTINGINSTALLATION

• 2191MendenhallDriveNorthLasVegas,NV89081(800)992-4993www.powercommander.com

08-12 Kawasaki EX250

I ns ta l l a t i on I ns t ruc t i ons

PartsList

• 1IgnitionQuickshifterUnit• 1ShiftSensor(push)• 1ShiftRod• 1InstallationGuide• 2DynojetDecal• 4CableTies• 1Velcrostrip• 1AlcoholSwab• 1Posi-tap

(CarburetedModelsOnly)

• 4-123 www.powercommander.com • IgnitionQuickShifter-StandAloneUnit-2

• Removethekneepanelsunderbothsidesoftheriderseat,bothriderandpassengerseats,andbothsidefairings.

• UsingthesuppliedVelcromountthecontrolboxinthetailsection(Fig.A).• CleanbothsurfaceswiththesuppliedalcoholswabpriortoapplyingtheVelcro.

Fitting the Control Unit

TheIgnitionQuickshiftercontrolunitshouldbepositionedsoitdoesnotexceedanoperatingtemperatureof160°Fandmustbeinstalledwhereitisprotectedfromexcessivevibrationandharshenvironmentalelements.

• Routethewiringharnessdowntheleftsideofthebiketowardstheignitioncoilswhilefollowingthestockwiringascloselyaspossible.RoutethewiringharnessbranchwiththeGREY2-pinconnectortowardstheshiftlinkage(Fig.B).

Figure A: Mounting Unit

Figure B: Harness Routing

• ConnecttheIgnitionQuickshifterharnessin-lineofthestockwiringharnessandtheLeftIgnitioncoil(Fig.C).

• ORANGEwiregoestothespadeterminalofthecoilthatismarkedBLACK• GREENwiregoestothestockBLACKcoilwire.

Figure C: Left Coil Connection

• ConnecttheIgnitionQuickshifterharnessin-lineofthestockwiringharnessandtheRightIgnitioncoil(Fig.D).

• WHITEwiregoestothespadeterminalofthecoilthatismarkedBLACK• BLUEwiregoestothestockGREENcoilwire.

Figure D: Right Coil Connection

• 4-123 www.powercommander.com • IgnitionQuickShifter-StandAloneUnit-3

Fitting the Control Unit (cont.)• TheBLACKwirefromthecontrolunitcanbeconnectedtothe

groundingsideoftheclutchsafetyswitch.WhenthiswireisconnectedtheunitwillnotKILLwhiletheclutchispulledin.

• RoutethesingleBLACKwireuptothebike’sclutchswitch.• UsethesuppliedPosi-taptoattachthesingleBLACKwireto

theBLACKwireoftheclutchswitch(Fig.E).

Figure E: Connecting Cluth Input

• Removetheplastictreycoveringcoveringthetopofthebike’sbattery.• ConnectthepowersupplyharnessoftheIgnitionQuickshiftertothebike’sbattery

(Fig.F).• REDwiregoestothePositivebatteryterminal.• BLACKwiregoestotheNegativebatteryterminal.

Figure F: Connecting the Power Supply

Fitting the Shift Sensor• Removethestockshiftrodfromtheshiftlinkage• Screwthesensorallthewayintotherearheimjointuntilitbottomsout.• Installthesuppliedshiftrodinbetweenthesensorandfrontheimjoint.Adjust

leverpositionandthentightenthelocknuts(Fig.G).• RoutethesensorwiringupwardsandconnectittotheGREY2-pinconnectorof

theIgnitionQuickshifterharness.

Figure G: Sensor Mounting

• Reinstallthebatterycover,thesidefairings,theseats,andkneepanels.

• 4-123 www.powercommander.com • IgnitionQuickShifter-StandAloneUnit-4

Quickshifter System Operation

TousetheIgnitionQuickshifter,makeafullandpositivegearshiftwithyourfootinanupshiftdirectionwithoutusingtheclutchorrollingthethrottle.

Note:Thegearlevermustreturnfullytotherestpositionbeforethesystemresetsitselfforthenextgearselection.

ThestatusLEDwillilluminatesolidgreenwhenevertheQuickshiftersensorisinthetriggerposition.ThisstatusLEDwillflashinunisonwiththeenginewhenevertheengineisrunningandifthereisanignitioncoil/RPMsignalwhichisrequiredforrunningmode.

Therewillbenointerrupt/quickshiftbelow2500RPM.

Theunitcomeswithasetshiftkillinterrupttime.

Troubleshooting

Nopowerup Checkforincorrectconnections,blownfuses,poorbatteryterminalconnections,andseveredortrappedwires.

Noquickshifterinterrupt CheckforcorrectIgnitionQuickshifterpowersupply.Verifythesensoroutputsignalandthequickshifterparametersandprogramminghasbeencarriedout.Checkforlossoftacho/RPMsignal.Checkforseveredortrappedwires.

Noquickshifteroperation Verifythequickshifterparametersandprogramminghavebeencarriedout.Checkforlossoftacho/RPMsignal.Checkforseveredortrappedwires.

Enginemisfire Verifythecontrolunitmountingpositionandcheckforisolationfromvibration.Checkplugandplayconnections.Verifyignitioncoiltypeandsuitabilityandiftheignitioncoiladapterconnectorsrequirefitting.Verifysensoroutputsignal.

Tuner Mode/Setting the Base Interrupt Duration

• ToenterTunerMode,pulltheclutchleverinorholdtheblackclutchswitchlock-outwiretoground/chassis.

• MovethegearleverintoatriggerpositionwherethestatusLEDilluminatessolidgreenandholdinthispositionforsixsecondsuntilthegreenstatusLEDchangestoredtoindicateyouhaveenteredTunerMode.

• Releasetheclutchleverorblackclutchswitchlock-outwirefromground/chassisandreleasethegearlever.

• Onceyouhavefinishedyoursetting,theblackclutchswitchlock-outwireshouldbetapedupandsecuredifitisnotabletobeconnectedtothevehicleclutchswitchitself.

• FactoryDefaultInterruptDurationissetto66ms(milliseconds)andisequaltotenredstatusLEDflashes.Itshouldbenotedthatthisisjustthebasesettingandcanbeadjustedifdesired.ThisadvancedQuickshifterSystemwillvaryinterruptdurationsdependingonengineparameters.

• Toalter/increasethebaseinterruptdurationby2ms,momentarilymovethegearlevertothetriggerpositionwhichcanbeseenbytheflashingredstatusLEDchangingtolightingsolidredwhileinthetriggerposition.

• TheflashingredstatusLEDwillnowflasheleventimesoncethegearleverhasbeenreleasedtoindicatethe2msincreasefrom66msto68ms.

• Eachtimethegearleverismomentarilymovedtothetriggerpositiontheinterruptdurationwillincreaseby2msuptoamaximumof20redstatusLEDflashesor86ms.Afterthispoint,furthermomentarytriggerswilltaketheinterrupttimebackdowntooneredstatusLEDflashor48msinterruptduration.Theinterruptdurationcanbeincreasedagainandsoonuntilthedesiredbaseinterruptdurationisreached.

• ToexitTunerMode,holdthegearleverinthetriggerpositionforfoursecondstosaveandauthenticatethesettingswheretheflashingredstatusLEDwillrevertbacktogreen.

General Product Warranty and Servicing

AswithanytechnicalequipmentofthisnatureitisstronglyrecommendedthattheexposedproductitemssuchastheIgnitionQuickshifterandGP/LSsensorsshouldbekeptcleanandcheckedregularly.Theseunitsshouldbecleanedbyremovingexcessdustwithaclothorsmallnylonbrush.Avoidusingajetwashwithinthevicinityoftheseunits.

Productsfittedtomotocross,supermoto,kart,andoffroadbuggyapplicationsarenotcoveredbythewarranty.

• ThisDynojetproductiscoveredbya12monthwarrantyfromthedateofpurchaseagainstanydefectsinmaterialsorworkmanship.

• IfanydefectshouldoccurduringthewarrantyperiodtheproductshouldbereturnedtoDynojetResearch,oralternativelytotheplaceofpurchasealongwithproofofpurchase.Thiswarrantydoesnotcoverreturnshippingcosts.

• DynojetResearchwillexaminetheproductandifitisfoundtobedefectiveduetofaultymaterialsorbadworkmanshipwill,withoutcharge,repairorreplacetheproductattheirdiscretion.

• Iftheproductcoveredbythiswarrantyisdamagedduetoaccidents,misuse,modificationorunauthorizedrepair,shorteningofcables,brokenweatherproofsealsduetocableexitbending/pullingorincorrectelectricalconnectionsthenthiswarrantybecomesvoid.

• Thiswarrantyispersonaltothepurchaserandisnottransferable.

• ProductsreturnedtoDynojetResearchshouldbepackedcarefullytoavoiddamageintransit.Pleaseincludedetailsofthefaulttogetherwithyourname,addressandcontacttelephonenumbers.