Two Brothers Racing Versys650 User Manual

2006-10 Kawasaki ZX650, ER6n,

and Versys

PARTS LIST

Installation Instructions

1Juice Box Pro

TM

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

FOR RACE USE ONLY

DOWNLOAD THE TOPTUNE SOFTWARE

AND LATEST MAPS FROM OUR

WEBSITE:

www.twobros.com

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PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION

401 S. Grand Ave. Santa Ana, CA 92705

[phone] www.twobros.com

2006-10 Kawasaki ZX650, ER6n, and Versys - 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 Two Brothers slip-on

Stock or aftermarket air filter

Position 3 Stock exhaust

Stock air filter

Position 4 Two Brothers slip-on

Stock or aftermarket air filter

USB Port

High RPM Dial

Mid Dial RPM

Low Dial RPM

Map Select
Status Light

(Power to Unit)

2006-2010
Kawasaki ZX650,
ER6n

2006-2010
Kawasaki ZX650,
ER6n

2006-2010
Kawasaki Versys

2006-2010
Kawasaki Versys

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.

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2006-10 Kawasaki ZX650, ER6n, and Versys - 2

Figure AFigure BFigure C

Juice Box Pro

harness

The ignition must be turned OFF before installation.

1 Remove the seat.
2 Remove the fuel tank.
3 Lay 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.

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remove

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

remove

2006-10 Kawasaki ZX650, ER6n, and Versys - 3

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.

Figure DFigure EFigure F

remove

unplug

remove

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

unplug

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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.

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

2006-10 Kawasaki ZX650, ER6n, and Versys - 4

12 Locate the throttle position sensor (TPS) connector.

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.

Figure GFigure HFigure I

TPS

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.

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2006-10 Kawasaki ZX650, ER6n, and Versys - 5