Two Brothers Racing 650 User Manual

2012 Kawasaki EX650

PARTS LIST

Installation Instructions

1 Juice Box Pro™
1 USB Cable
1 Top Tune CD-ROM
1 Installation Guide
2 Velcro strip
1 Alcohol swab

THE IGNITION MUST BE TURNED

OFF BEFORE INSTALLATION!

DOWNLOAD THE TOPTUNE SOFTWARE

AND LATEST MAPS FROM OUR

WEBSITE:

www.twobros.com

PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION

401 S. Grand Ave. Santa Ana, CA 92705

[phone] www.twobros.com

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Selecting the Map Position

S electing the M ap Pos ition

U s ing the R PM R ange Dials

U s ing Top Tune

Installing the Top Tune S oftware

Loading Additional M aps

Altering Maps U sing Top Tune

The J uice Box Pro co mes loaded w ith up to ten m aps. U s ing a #1 Phillips
screwdriver, turn the map select dial to toggle be tween the loade d m aps. R efer to
the map position table below for the maps included in your Juice Box Pro.

Using the RPM Range Dials

The Low, Mid, and High RPM Dials refer to the RPM range, in thirds, of your
vehicle. Each dial allows +/- 10% fuel adjustment on top of what fuel changes are
done in the map. With the dial facing straight up, there is no additional fuel change.
For example, if your vehicle revs to 15,000 RPM:

• the low RPM dial will adjust 0-5000 R PM

• the mid RPM dial will adjust 5001-10000 RPM

• the high RPM dial will adjust 10001-15000 RPM

Using Top Tune

Take y ou r tuning to the next level w ith the Top Tune softwar e.

Position 0 Zero map

Position 1 Stock exhaust

Stock air fi lter

Position 2 Two Brothers full exhaust

Stock air fi lter

USB Port

High RPM Dial

Mid Dial RPM

Low Dial RPM

Map Select
Status Light

(Power to Unit)

2012 Kawasaki
EX650

2012 Kawasaki
EX650

I ns t a l li n g t h e Top Tu ne S o ft w a r e
1 Insert the CD provided into your computer’s cd-rom drive. The launch program

will run automatically.
If auto-run is disabled, double-click the My Computer icon then double-click the
CD drive icon. Double-click TBR Top Tune.exe to manually start the CD.

2 Click Install S oftware and follow the on-screen instructions to install the Top

Tune software. The Top Tune software and maps will be stored in C:\Program
Files\T BR Top Tune.

3 C lick M ap Databas e. All m aps will a uto matically be ins talled to the C:\Program

Files\TBR Top Tune\maps folder.

Loading Additional Maps
1 Connect the US B cable from the computer to the Juice Box Pro. Verify the cable

is fully seated in the J uice B ox Pro.

2 Run the Top Tune software by double-clicking the program icon installed on your

desktop or on your start menu.
3 Click Open Map File and select a map file.
4 C lick Send M ap. You can send the m ap to a ny of the ten m ap positions.

A ltering M aps Us ing Top Tune
The values in the map represent a percentage of fuel change over stock. A value of
10 in the map indicates at that throttle position a nd RPM range the v ehicle w ill be
10% richer than stock. If the value is -10, then it would be 10% leaner than stock. You
ha ve the ability to fine tune y our fuel curve by altering these values . Th e Top Tune
software allows a value of +250 to -100 in each cell.

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FIG.A

FIG.B

harness

1. Remove the seat.

2. Remove the fuel tank.

3. Place the Juice Box Pro in the tail section and route the harness towards the front
of the bike.

4. Route the Juice Box Pro harness under the frame crossover as shown in Figure A.

5. Route the Juice Box Pro harness under the fuel tank bracket as shown in Figure B.

6. Remove the bolts in the air box lid as shown in Figure C.

FIG.C

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FIG.D

FIG.E

7. Remove the four bolts securing the air box to the throttle bodies as shown in
Figure D.

8. Disconnect the air box temp sensor and hoses leading to the air box.

9. Remove the air box from the bike.

10. Unplug the stock wiring harness from the injectors as shown in Figure E.

11. Attach the connectors from the Juice Box Pro to the stock wiring harness and the
fuel injector for both cylinders as shown in Figure F.

FIG.F

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Connect the orange wires from the Juice Box Pro to the left hand cylinder.

FIG.G

FIG.H

12. Locate the Throttle Position Sensor (TPS) connector as shown in Figure G.

The TPS connector is located on the left hand side of the throttle bodies.

13. Unplug the TPS connector from the throttle bodies.

14. Attach the connectors from the Juice Box Pro to the TPS and the stock wiring
harness.

15. Attach the ground wire from the Juice Box Pro to the negative side of the battery
as shown in Figure H.

16. Reinstall the air box.

17. Reinstall the fuel tank.

18. Reinstall the seat.

ground

19. Using the stock rubber band, secure the Juice Box Pro in the tail section.

FIG.I

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