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2012-2016 KTM 250/350/450/500 XCW - PCV - 1I18-022.01 www.powercommander.com
Installation Instructions
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
THE IGNITION MUST BE TURNED
OFF BEFORE INSTALLATION!
YOU CAN ALSO DOWNLOAD THE
POWER COMMANDER SOFTWARE AND
LATEST MAPS FROM OUR WEB SITE AT:
www.powercommander.com
2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 www.powercommander.com
FUEL AND IGNITION
FUEL AND IGNITION
PARTS LIST
1 Power Commander
1 USB Cable
1 Installation Guide
2 Power Commander Decals
2 Dynojet Decals
2 Velcro Strips
1 Alcohol Swab
3 Zip Ties
2012-2016 KTM
250/350/450/500 XCW
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I18-022.01 www.powercommander.com 2012-2016 KTM 250/350/450/500 XCW - PCV - 2
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I18-022.01 www.powercommander.com 2012-2016 KTM 250/350/450/500 XCW - PCV - 3
1 Remove the seat as shown in Figure A.
2 Remove the left side panel covering the air filter as shown in Figure B.
3 Temporarily position the PCV module in the battery box compartment while
routing the PCV wiring harness down the left side of the bike, following along
the underside of the left frame rail as shown in Figure C.
4 Using the supplied velcro, secure the PCV to the inside of the rear fender as
shown in Figure C.
Make sure to clean both surfaces with the alcohol swab before attaching.
5 Using the supplied zip ties, secure the PCV harness to the factory cables.
6 Attach the ground wire ring lug from the PCV harness to the negative (-)
terminal on the battery.
FIG.A
FIG.C
FIG.B
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I18-022.01 www.powercommander.com 2012-2016 KTM 250/350/450/500 XCW - PCV - 4
7 Remove the left and right side radiator shrouds.
8 Loosen the fuel tank by removing the bolt at the location shown in Figure D.
9 Prop the fuel tank upward so you can access the throttle body.
WARNING: Be very careful not to over stretch the fuel line.
10 Locate and unplug the stock wiring harness from the fuel injector as shown in
Figure E.
The fuel injector is located at the front of the throttle body. This connector is
difficult to reach and is not clearly visible in Figure E. Using a curved pair of
needle-nose pliers may help to unplug it from the fuel injector.
11 Attach the PCV connectors to the fuel injector and the stock wiring harness.
12 Locate and unplug the stock wiring harness from the Throttle Position Sensor
(TPS).
The TPS is located on the left side of the throttle body. This connector has
a rubber boot covering it that will need to be peeled back to unplug the
connector.
13 Attach the PCV connectors to the bike’s TPS and the stock wiring harness as
shown in Figure F.
FIG.D
remove
FIG.E
FIG.F
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I18-022.01 www.powercommander.com 2012-2016 KTM 250/350/450/500 XCW - PCV - 5
14 Locate and unplug the stock Crank Position Sensor (CPS) connectors as
shown in Figure G.
This is a blue 2-pin connector pair located inside the left frame rail near the
hydraulic clutch line.
15 Attach the PCV connectors to the stock CPS connectors as shown in
Figure H.
16 Locate the Ignition Coil Spade connection under the tank near the front of the
frame as shown in Figure I.
17 Attach the PCV wiring harness spades in between the stock connectors as
shown in Figure I.
18 Using the supplied zip ties, secure the PCV wiring harness so it is free and
clear of any hot or moving parts.
19 Reinstall the fuel tank, the radiator shrouds on both sides, the left side panel,
and the seat.
FIG.I
FIG.G
FIG.H
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