Two Brothers Racing EX650R User Manual

Download

Page 1

V.A.L.E.

Two Brothers Racing

V A R I A B L E A X I S L O C K I N G E X H A U S T

Juice Box™ - Fuel Controller

2006-08 Kawasaki Ninja 650R Installation & Operation Manual Part # 0 08-142

Parts Incuded

Installation Instructions

Remove the 4, 5mm Allen bolts, (Fig 6) and while lifting

Thank you for purchasing a genuine Two Brothers Racing JUICE BOX™. This product represents a radical step forward in tuning fuel-injected motorcycles and ATVs for optimal performance using “load-based” technology. We at Two Brothers Racing hope that you will ﬁnd this

6. air box lid you will need to disconnect the crankcase breather hose from the gearbox (Fig 7).

Fig 6

development as exciting and useful as we do. And remember: Proper Fuel = Maximum Power!

the installation. Also, make sure the vehicle is secure and

Make sure the vehicle is completely cool before starting

will not roll around.

Remove seat.

Remove both side panel Philips screws and remove

3. panels. Remove both tank bolts (Fig 1).

Fig 1

Fig 7

The JUICE BOX™ will be placed under the seat so you need to thread the JUICE BOX™ wires towards the front

Lift gas tank up gently just enough to access to the quick

4. disconnect and release the red lock tab and remove fuel line (Fig 2). Remove any and all vent lines from the tank. Gently remove gas tank and set aside.

Fig 2

of the bike under the gas tank support plate towards the throttle bodies. You can remove the tank support plate by removing the 2 10mm bolts (Fig 8). Locate the injector connectors and disconnect the stock connectors and plug the JUICE BOX™ grey connector onto the bikes injector, and then plug the stock connector into the JUICE BOX™ black connector repeat on remaining cylinder (Fig 9).

Fig 8

Qty. Description Part Number

1 Juice Box™ Fuel Control Kit 008-142 3 Zip Ties 1 Adhesive Velcro Square

Tools Needed For Install

- Phillips Screw Driver #2

- 10mm Wrench or Socket

- 5mm Allen Wrench

IMPORTANT - PLEASE READ CAREFULLY

We recommend that this performance part be installed by a qualied motorcycle

technician. If you have any doubts as to your ability to install this performance part,

please consult with your local motorcycle dealer. Read all instructions rst before

starting installation. Make sure the vehicle and exhaust system are completely cool before starting the installation. Also, make sure the vehicle is secure during installation. Be sure to save all stock components for possible use later.

The Juice Box™ is legal ONLY for closed course race vehicles. The Juice Box™ is not applicable, nor inteded for use on EMISSIONS CONTROLLED street, highway or off-road vehicles. The Juice Box™ is not applicable, nor inteded for use on aircraft.

Warranty

Two Brothe rs Racing w arrants tha t this produ ct carries a warranty for 2 years from date of purchase against or iginal defects in materia ls and work manship. S hould this product fai l to perfor m for eithe r of the ab ove reasons , Two Brothers Racing will repair or replace it with an equivalent product at no charge, except for postage, to the origin al retail pu rchaser.

To obtain t he benefits of this wa rranty, the r etail purch aser must r eturn the pr oduct and p roof of pur chase to th e place of origina l purchase.

Disconnect fresh air system hose from the fresh air

5. solenoid then disconnect the black air temp connector (Fig 3). Disconnect the green connector from the solenoid then remove solenoid from air box (Fig 4). Remove all of the air box screws 7 total (Fig 5) and remove lid.

Fig 3 Fig 4

Fig 5

Fig 9

Connect JUICE BOX™ ground lead to the negative post of

8. the battery.

Assembly is the opposite of disassembly.

Continued on page 2

Page 2

Operation Manual

Two Brothers Racing

Juice Box™ - Fuel Controller

2006-08 Kawasaki Ninja 650R Installation & Operation Manual Part # 0 08-142

Installation Instructions continued...

Start the bike. The green LED should scroll left to right and

10. back for about 3-5 seconds and then go to 1-2 steady or slowly ﬂashing green LED’s. If the number 1 green LED and number 8 red LED’s continue ﬂashing after startup or idling, an injector wiring error is indicated. Re-check the wires from the JUICE BOX and make sure they are connected to the proper wire of your bike’s stock harness. MAKE SURE you have the correct wires selected in the stock harness. DO NOT PROCEED UNLESS ABOVE CONDITIONS ARE MET.

NOTE: Re check your wire routing and JUICE BOX™

11. location and make certain that in no way the wires can come into contact with any moving parts or high heat source and that the JUICE BOX™ is mounted in a way as to not cause a handling problem with the machine.

If the unit requir es cleaning , use a clo th that is only lightl y dampened with water or mild det ergent.

Cleaning

It is recommended that the pre-programmed settings of

1. the Juice Box™be used. However, the Juice Box™ can be adjusted to suit different engine modiﬁcations, states of tune and environmental conditions. To begin this process, press the mode button. To enter each successive mode, just press the mode button again. Note that every mode will be identiﬁable by the color(s) of the ﬂashing LED(s) on the LED display. by an LED color or color combination.

as follows, respectively: Green, Yellow, Red, Green-Blue, Yellow-Blue and Red-Blue.

You are now ready to manually program each mode. Consult the base settings supplied with the unit.

To program the Juice Box™, the bike must be running in order to supply power to the Juice Box™.

Simply press the mode button to activate the ﬁrst mode. If at anytime you stay in an adjustment mode for longer than 5 seconds without pressing any buttons, the Juice Box™ will exit the adjustment mode and will return to the operational mode.

To save settings in a particular mode press the MODE button which goes to the next adjustable mode or wait for the Juice Box™ to exit back to the operational mode.

The settings in each mode are adjusted by pressing the (+) and (-) buttons located on the right and left side of the mode button, respectively. For easy reference, the LEDs are numbered 1 through 8. However, the LEDs can be adjusted to the following positions: 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5,

5.5, 6, 6.5, 7, 7.5, 8. For example, in a particular mode, if LED 4 is ﬂashing then the LED display is set to 4 in that mode. If the (+) button is pressed once then LEDs 4 and 5 will ﬂash simultaneously and the LED display is set to 4.5. If the (+) button is pressed once again, only LED 5 will ﬂash and the LED display is set to 5. The LED display can also be set to 0.5 by pressing the (-) button and scrolling the colored LED to position 1 and then pressing the (-) button once more until the LED in position 1 is ﬂashing twice as fast as normal.

I. additional amount of fuel added under cruise conditions. A ﬂashing green LED should appear on the LED display. To add more fuel, scroll the ﬂashing green LED to the right using the (+) button. To add less fuel, scroll the ﬂashing green LED to the left using the (-) button. If you set the ﬂashing green LED to the 0.5 position on the LED display, no fuel will be added to the stock fuel curve.

II. additional amount of fuel added during acceleration. A ﬂashing yellow LED should appear on the LED display. To add more fuel, scroll the ﬂashing yellow LED to the right using the (+) button. To add less fuel, scroll the ﬂashing yellow LED to the left using the (-) button. If you set the ﬂashing yellow LED to the 0.5 position on the LED display,

no fuel will be added to the stock fuel curve.

There are six modes that are distinguished

The 6 modes are

The ﬁrst mode (Green Mode) represents an

The second mode (Yellow Mode) represents an

III. The third mode (Red Mode) represents an additional amount of fuel added during full throttle conditions. A ﬂashing red LED should appear on the LED display. To add more fuel, scroll the ﬂashing red LED to the right using the (+) button. To add less fuel, scroll the ﬂashing red LED to the left using the (-) button. If you set the ﬂashing red LED to the 0.5 position on the LED display,

to the stock fuel curve.

Note: If the ﬂashing green, yellow and red LEDs in modes 1 through 3 (Green, Yellow and Red) are set to the 0.5 position on the LED display then the Juice Box™ will not add any fuel to the bike’s stock fuel curve. This setting will essentially turn off the Juice Box™ even though it is still attached to the bike’s fuel injection system. The bike will run as though the Juice Box™ is not installed. The Juice Box™ LEDs will still operate normally even though no fuel is being added.

IV.

The fourth mode (Green-Blue Mode) - Not Required

for this particular model.

The ﬁfth mode (Yellow-Blue Mode) is an adjustment

to determine the time when the acceleration/Yellow Mode fuel amount turns on. A ﬂashing yellow LED appears on the LED display while at the same time a ﬂashing blue LED appears on the 8th LED. To increase the sensitivity and therefore cause the Yellow Mode fuel to turn on sooner, scroll the ﬂashing yellow LED to the left using the (-) button. To decrease the sensitivity and therefore cause the Yellow Mode fuel to turn on later, scroll the ﬂashing yellow LED to the right using the (+) button.

VI.

The sixth mode (Red-Blue Mode) is an adjustment

to determine the time when the full throttle/Red Mode fuel amount turns on. A ﬂashing red LED appears on the LED display while at the same time a ﬂashing blue LED appears on the 8th LED. To increase the sensitivity and therefore cause the Red Mode fuel to turn on sooner, scroll the ﬂashing red LED to the left using the (-) button. To decrease the sensitivity and therefore cause the Red Mode fuel to turn on later, scroll the ﬂashing red LED to the right using the (+) button.

no fuel will be added

Page 3

Operation Manual - JUICE BOX™ Settings

Pre-set Settings: Ninja 650R baseline settings with stock air ﬁlter and TBR slip-on system. (G=1.5, Y=2.5, R=1, GB=N/A, YB=4, RB=4)

Two Brothers Racing

Juice Box™ - Fuel Controller

2006-08 Kawasaki Ninja 650R Installation & Operation Manual Part # 0 08-142

Mode 1 - Green

Mode 4 - Green/Blue Mode 5 - Yellow/Blue Mode 6 - Red/Blue

Mode 2 - Yellow Mode 3 - Red

For Race Use Only

For additional settings please visit our website at www.twobros.com.

Two Brothers Racing EX650R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual