Two Brothers Racing RMZ450 User Manual

2009-2010 Suzuki RMZ450

PARTS LIST

Installation Instructions

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

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

Selecting the Map Position

The J uice B ox Pro com es loaded w ith up to ten m aps . U s ing a #1 Phillips
screw driv e r, turn the m a p select dial to toggle between the loaded m aps . Refer to
the map position table below for the maps included in your J uice Box Pro.

Using the RPM R ange 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. W ith 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 nex t level with the Top Tune s oftwar e.

Position 0 Zero map

Position 1 Stock exhaust

Stock air fi lter

Position 2 Two Brothers M2R slip-on exhaust

Stock air fi lter

Position 3 Two Brothers M2R full exhaust

Stock air fi lter

USB Port

High RPM Dial

Mid Dial RPM

Low Dial RPM

Map Select
Status Light

(Power to Unit)

09-10 Suzuki
RMZ450

09-10 Suzuki
RMZ450

09-10 Suzuki
RMZ450

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 com puter’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 TB R 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\T BR Top Tune.

3 C lick M a p Databas e. All m a ps w ill autom atically be installed to the C : \Progra m

Files\TBR Top Tune\maps folder.

Loading Additional Maps
1 Connect the US B cable from the computer to the J uice B ox 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 S end M a p. You can send the m a p to a ny of the ten m ap pos itions .

A ltering M aps U s ing Top Tune
The values in the map represent a percentage of fuel change over stock. A value of
10 in the map indica tes at that throttle pos ition and R PM r ange 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 v e the ability to fine tu ne your fuel curve by altering these values . The Top Tune
software allows a value of +250 to -100 in each cell.

ITBR001-225 www.twobros.com 2009-2010 Suzuki RMZ450 - 2

Figure A Figure BFigure C

1. Remove the seat.

2. Remove the fuel tank.

3. Remove the front number plate.

4. Using the supplied zip ties, secure the Juice Box Pro to the stock ECU as shown in
Figure A.

5. Route the wiring harness from the Juice Box Pro between the frame and the fork
tube on the right hand side of the bike.

Juice Box Pro

harness

unplug

6. Continue to route the Juice Box Pro harness down the right side of the bike.

7. Route the harness to the inside of the frame and go towards the throttle body as
shown in Figure B.

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

9. Unplug the stock Throttle Position Sensor (TPS) connector as shown in Figure C.

The TPS connector is a grey 3-pin connector.

unplug

ITBR001-225 www.twobros.com 2009-2010 Suzuki RMZ450 - 3

Figure DFigure E

10. Attach the connectors from the Juice Box Pro to the stock injector and the stock
wiring harness as shown in Figure D.

11. Attach the Juice Box Pro harness to the stock TPS connectors as shown in
Figure E.

12. Using one of the mounting bolts for the ignition coil, attach the ground wire from
the Juice Box Pro as shown in Figure F.

The coil is on the right hand side of the bike behind the radiator.

13. Reinstall the front number plate.

14. Reinstall the fuel tank.

15. Reinstall the seat.

Figure F

ground wire

ITBR001-225 www.twobros.com 2009-2010 Suzuki RMZ450 - 4