Power Commander Install

Power Commander 'Perfect' Install

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WARNING!: The modifications described in these web pages are for INFORMATIONAL PURPOSES ONLY. I will NOT accept any responsibility if you attempt these modifications yourself. These modification can damage/ destroy/ make the bike UNSAFE/ VOID the Warrantee, injure or cause death to the rider & passenger if the modification are done incorrectly! Seek a Professional motorcycle mechanic if you think your unable to do these modifications yourself or if you think your motorcycle is UNSAFE. Do the modifications at YOUR OWN RISK!

Oliver (aka Frankenstein) at RSWarrior.com forums deviated from the recommended Power Commander installation. The biggest difference, was that Oliver installed one of the PCIII ground wires directly to the digital ground wire from the ECU. This was a more precise way of reading the throttle position. He also installed the PCIII TPS (Throttle Position Sensor) wire (GREY wire) closer to the ECU. Details can be found in this thread: PERFECT PCIII Install

I went to a local Electronics store to look for a quick connector for my install. I have the older PCIII serial box and I think I will upgrade to the PCIII USB version sometime in the future. I didn't want to have to re-solder the USB version when I did get it. So, I went with a quick connect to make swapping or removing the PCIII easier.

I found a couple connectors that would work just fine. But, I chose to use this water resistant connector. It costs a little more and was bulkier than the other connectors, but I wanted to try it out. I picked up the male & female connector body and terminal pins, along with the rubber wire seal. The rest of the supplies and tools, I already had.

One tip, don't buy the heat shrink tubing from Radio Shack (I had purchased some long time ago), it's pure garbage. I couldn't find where I had put the good heat shrink tubing, so I used the ones from Radio Shack that I had lying around.

I have had my PCIII installed on the Warrior for a few years already. I had to work around it, while it was still on the bike. I didn't have to uninstall it from the bike to do the "Perfect" install.

First step was to cut one of the PCIII ground wires to hook up to the bikes ECU digital ground from the frame electrical ground. The PCIII ground has two wires going to the ring tongue connector that is grounded near the oil filler cap. I cut the Black ground wire with the White-line at the base of the ring tongue connector. I left the solid Black PCIII ground wire still attached to the ring tongue connector that is still bolted down near the oil filler cap.

Next step was to unwrap the electrical tape from the PCIII wires going to the TPS connector between the cylinders. I unwrapped about 7 inches of the electrical tape. About the same length of wire as the digital ground wire that I had just cut. I then located the Grey wire and cut it about the same length as the Black/White-line ground wire.

I re-wrapped the PCIII wire harness with electrical tape.

I then took the Grey & Black/White-line wires and stripped enough of the end off to crimp some terminals. The green grommet is supposed to make the connector water resistant. After crimping the terminals I soldered the terminals to the wires. I then inserted the terminals into the connector body. Pushed the green grommets in and snapped the back end of the connector over the wires.

I disconnected the ECU from the main wire harness. To prevent damaging the ECU, while cutting and soldering a few wires.

I located the Yellow TPS wire that needed to be hooked up to the Grey PCIII wire. I cut the Yellow wire a few inches from the connector, and stripped the ends. I then cut a piece (5 inches) of 18 gauge White wire from a spool (I didn't have Yellow wire). I slipped a few inches of heat shrink tubing over one of the Yellow wires and then proceeded to solder the two halves of the Yellow Wire with the White wire I had cut. When I was satisfied with the solder joint, I slipped the heat shrink tubing over the joint and shrunk it down with a hair dryer and lighter.

Locate the digital ground wire.

Its the Black/Blue-line wire on the other side of the connector from the Yellow TPS wire. It's near the center of the connector, near a wire plug. I then cut the Black/Blue-line wire a few inches from the connector. Stripped the ends off and cut a 5 inch long Black 18 gauge wire from a spool. I slipped a piece of heat shrink tubing over one end of the Black/Blue-line. I soldered the two halves of the Black/Blue-line wire with the Black wire. Slipped the heat shrink tubing over the solder joint, and shrunk it down with a hair dryer and lighter.

I stripped the ends of the two wires (solid Black and the solid White wire) that I had soldered to the Yellow and Black/Blue-line wires from the ECU connector. I slipped the green grommets over the wires then crimped the terminals onto them. I soldered the terminals to the wires. Then inserted the terminals onto the connector body. I had to make sure and match the correct colored wires into the connector body, to make sure they match up with the correct wires on the other connector. You don't want to cross the wires.

The 2nd photo shows the connector snapped together. I made sure that I had the correct ECU wires going to the correct corresponding wires from the PCIII.

All the components back in place. ECU & PCIII is plugged in. The PCIII in it's neoprene pouch, under the seat bracket. I put the foam cover over the components and strapped the ECU strap over the cover & ECU.

After doing this mod, it's recommended that you recalibrate the throttle position in the Power Commander software.

Connector info:

Manufacturer (.pdf files): Delphi "Weather Pack"

Distributor ('WP Series', bottom of page. Part #s can be seen in the picture next to my tool box): Noble Wire & Terminal Corp.