Two Brothers Racing KFX450R User Manual

2008-10 Kawasaki KFX450R

PARTS LIST

Installation Instructions

1Juice Box Pro

TM

1 USB Cable
1 Top Tune CD-ROM
1 Installation Guide
2Velcro
1 Alcohol swab
1Wire tap

FOR RACE USE ONLY

DOWNLOAD THE TOPTUNE SOFTWARE

AND LATEST MAPS FROM OUR

WEBSITE:

www.twobros.com

iTBR001-166

PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION

401 S. Grand Ave. Santa Ana, CA 92705

[phone] www.twobros.com

2008-10 Kawasaki KFX450R - 1

Selecting the Map Position

The Juice Box Pro comes loaded with up to ten maps. Using a #1 Phillips
screwdriver, turn the map select dial to toggle between the loaded maps. Refer 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 RPM

• the mid RPM dial will adjust 5001-10000 RPM

• the high RPM dial will adjust 10001-15000 RPM

Using Top Tune

Take your tuning to the next level with the Top Tune software.

Position 0 Zero map
Position 1 Stock exhaust

Stock air filter

Position 2 Stock exhaust - baffle insert

removed
Stock air filter
Air box lid removed

Position 3 Two Brothers slip-on exhaust

(spark arrestor removed)
Stock air filter

Position 4 Two Brothers full exhaust (spark

arrestor removed)
Stock air filter

USB Port

High RPM Dial

Mid Dial RPM

Low Dial RPM

Map Select
Status Light

(Power to Unit)

2008-2010
Kawasaki KFX450

2008-2010
Kawasaki KFX450

2008-2010
Kawasaki KFX450

2008-2010
Kawasaki KFX450

Installing the Top Tune Software

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 Software 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\TBR Top Tune.

3 Click Map Database. All maps will automatically be installed to the C:\Program

Files\TBR Top Tune\maps folder.

Loading Additional Maps

1 Connect the USB cable from the computer to the Juice Box Pro. Verify the cable

is fully seated in the Juice Box 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 Click Send Map. You can send the map to any of the ten map positions.

Altering Maps Using 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 and RPM range the vehicle will be
10% richer than stock. If the value is -10, then it would be 10% leaner than stock. You
have the ability to fine tune your fuel curve by altering these values. The Top Tune
software allows a value of +250 to -100 in each cell.

iTBR001-166

2008-10 Kawasaki KFX450R - 2

Figure AFigure BFigure C

removed screws

remove bolts

Juice Box Pro

harness

The ignition must be turned OFF before installation.

1 Remove the seat.
2 Remove the two screws securing the side covers to the fuel tank as shown in

Figure A.

3 Remove the two bolts at the rear of the fuel tank as shown in Figure A.

This allows the rear of the fuel tank to be raised up enough to install the Juice Box
Pro.

4 Lay the Juice Box Pro in the tail section.

5 Route the wiring harness from the Juice Box Pro towards the throttle body.
6 Route the harness underneath the cross member of the sub-frame as shown in

Figure B.

iTBR001-166

7 Unplug the stock wiring harness from the injector as shown in Figure C.

This connection is under the rear of the fuel tank.

unplug

2008-10 Kawasaki KFX450R - 3

8 Attach the Juice Box Pro wiring harness to the injector and the stock wiring harness

as shown in Figure D.
9 Remove the bolt securing the stock ground wire to the frame.
10 Attach the ground wire from the Juice Box Pro to this same location as shown in

Figure D.

Figure DFigure EFigure F

ground wire

unplug TPS

11 Locate the stock throttle position sensor (TPS) connector on the left hand side of the

throttle body.
12 Unplug the stock wiring harness from the TPS as shown in Figure E.

This allows access to the wiring harness.

13 Crimp the supplied wire tap to the yellow/white wire as shown in Figure F.
14 Attach the grey wire from the Juice Box Pro to the wire tap as shown in Figure F.

Note:It is recommended to use dielectric grease on both of these connections.

15 Attach the TPS connector to the throttle bodies.

iTBR001-166

2008-10 Kawasaki KFX450R - 4

16 Remove the four bolts securing the tool kit in place as shown in Figure G.

Figure GFigure H

17 Using the supplied velcro, secure the Juice Box Pro to the rear fender as shown in

Figure H.

Make sure to clean both surfaces with the alcohol swab before attaching.

Note:Due to the lack of storage room on this motorcycle, this is the best place to

mount the Juice Box Pro. This will require removal of the stock tool kit.

18 Reinstall the tool kit with the four bolts removed earlier.
19 Lower the fuel tank back into position.
20 Reinstall the two bolts and screws removed earlier.
21 Reinstall the seat.

iTBR001-166

2008-10 Kawasaki KFX450R - 5