Powertronic Installation Manual Royal Enfield Himalayan (2017-2020) & 2021 With Choke
Powertronic Installation Manual Royal Enfield Himalayan (2017-2020) & 2021 With Choke
Powertronic Installation Manual Royal Enfield Himalayan (2017-2020) & 2021 With Choke
PowerTRONIC application All PowerTRONIC ECUs, from firmware version F.3.x onwards
Note:
1. Parts list
1 PowerTRONIC Piggyback ECU
2 Stock Coupler Stand by unit
● Can be connected in place of the PowerTRONIC to run the bike in stock
mode if need be.
● Used for the verification of the connections.
2. Tools required
Serial No Main tools Optional tools
1 10mm Hexagonal socket Spinner handle
2 10mm T bar Hexagonal Socket wrench Ratchet handle
3 Wirecutter Extension bar or Sliding T bar
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3. Installation procedure
3.1 Removing panels, fairing
Begin at the left side of the bike.
Park the bike using the center stand on a level surface (Or a paddock stand).
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3.1.1 Detach the pillion seat by inserting the key into the keyhole shown in Image 1 and unlock the pillion seat. Image 2
shows the pillion seat detached.
Image 1
Image 2
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3.1.2 Detach the rider seat. (Gently lift and slide it towards the rear end) - Refer Image 3.
Image 3
Image 4
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3.1.4 Unscrew the tank bolts using the T socket 10mm T bar Hexagonal socket wrench. Refer Image 5.
Image 5
3.1.5 Gently give a little lift to the tank and locate the fuel gauge connector (Blue color) on the left side of the tank. Refer
Image 6.
Image 6
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3.1.6 Detach the fuel gauge coupler. Refer Image 7.
Image 7
3.1.7 Go to the right side of the bike, Locate the fuel line under the fuel tank, after the fuel valve. Gently squeeze and pull
the fuel pipe to detach it from the valve. (There may be some amount of gasoline in the pipe. Make sure it does not fall on
your body or clothes). Refer Image 8.
Image 8
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3.1.8 Right next to the fuel valve, locate the fuel pump connector and detach the connector carefully. Refer Image 9.
Image 9
3.1.9 Lift the tank carefully and locate the two vacuum hoses present (and connected) under the tank. Disconnect both
the hoses and lift away the fuel tank and place it safely. Refer Image 10
Image 10
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3.1.10 Refer Image 11 for the disconnected view of the vacuum hoses.
Image 11
3.1.11 Unscrew the bolts using 10mm Hex T-bar from the casing as shown through Image 12 and Image 13 below.
Note: Use a spinner handle with 10 mm Hex socket and hold the nut below for easy removal.
Image 12
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Image 13
3.1.12 Remove both the screws using 10mm Hex T-bar from the mud guard (adjacent to tail indicators) shown through
Image 14.
Image 14
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3.1.13 Once you unscrew the bolts, there will be enough space to route the wiring harness of the PowerTRONIC. Refer
Image 15.
Image 15
3.1.14 Remove the screws using 10mm Hex T-bar from the casing as shown in Image 16 below.
Image 16
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3.2 Routing the harness
3.2.1 Starting from the glove compartment, route each connector terminals from in-between the welded plate and the
mud guard. Refer Image 17.
Image 17
3.2.2 Apply slight pressure, if needed, (refer Image 18 ) on the mudguard for easy routing.
Image 18
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3.2.3 Once all the connectors are through, secure the harness along the bike’s frame as shown in Images 19 & 20.
Image 19
Image 20
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3.3 Fuel Injector Connector (Left side of the bike)
3.3.1 Locate the stock injector connector of your bike. Refer the Images 21 and Image 22 below
Image 21
Image 22
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3.3.2 Identify the fuel injector connector in the PowerTRONIC wiring harness. The connectors are labeled 'INJ'.
3.3.3 Disconnect the injector connector on your bike. Refer the zoomed view (Image 23).
Image 23
3.3.4 Connect the female PowerTRONIC injector connector to the stock male injector connector. Refer Image 24.
Image 24
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3.3.5 Connect the stock female injector connector to the PowerTRONIC male injector connector. Refer Image 25.
Image 25
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3.4 Ignition Coil Connector (Left side of the bike)
3.4.1 Locate the stock Spark/Ignition coil connector on the ignition coil, located right above the engine. Refer Images 26
and 27.
Image 26
Image 27
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3.4.2 Identify the Spark/Ignition coil connector in the PowerTRONIC wiring harness. The connectors are labelled 'SPK'
Refer Image 28.
Image 28
3.4.3 Detach the stock ignition coil connectors. Refer Image 29.
Image 29
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3.4.4 Connect the PowerTRONIC Ignition coil male connector to the stock ignition coil female connector. Refer Image 30.
Image 30
3.4.5 Connect the PowerTRONIC Ignition coil female connector to the stock ignition coil male connector. Refer Image 31
below.
Image 31
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3.4.6 Refer Image 32 for completed view.
Image 32
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3.5 Throttle position sensor connector (Left side of the bike)
3.5.1 Locate the TPS connector of your bike. It is generally located on the throttle body, parallel to the throttle cable return
springs. Refer Image 33 and 34.
Image 33
Image 34
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3.5.2 Identify the Throttle Position sensor connector in the PowerTRONIC wiring harness, labeled as 'TPS'.
Image 35
3.5.4 Connect the PowerTRONIC male TPS connector to the stock female connector. Refer Image 36.
Image 36
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3.5.5 Connect the PowerTRONIC female TPS connector to the stock male connector. Refer Image 37.
Image 37
3.5.6 We advise you to perform a TPS calibration after the installation of PowerTRONIC ECU for 2017-2020 models..
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3.6 Ground Terminal Connector (Right side of the bike)
3.7.1 Identify the Ground terminal connector labeled as GND and connect it to the negative terminal of the battery.
Refer the Images 38 and 39.
Image 38
Image 39
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3.8 Changing Relays
3.8.1 Locate the stock relays Image 40.
Image 40
3.8.2 Remove the stock relays from the relay kit. Refer Image 41.
Image 41
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3.8.3 Replace the stock relays with provided relays. Refer Image 42.
Image 42
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3.9 Securing the harness using ties
3.9.1 Secure the harness away from hot/moving parts by attaching it to the chassis/frame using the zip ties provided
wherever necessary. Refer to Image 43.
Image 43
Important note: The PowerTRONIC harness contains a Quick shifter connector. If you have bought the Quickshifter please
attach the connector to it. [Please refer to Quick shifter installation manual]
If you have not bought the Quickshifter, you can leave it disconnected but make sure the harness is secured using zip ties
provided.
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3.10 Testing with the stock coupler
3.10.1 Attach the fuel tank.
3.10.2 You can verify the connections by attaching the stock coupler. Refer Image 45 Refer to the detailed Stock coupler
test document.
Image 44
DO NOT proceed with the PowerTRONIC ECU without first verifying the connections with the stock
coupler.
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3.11 Plugging in the PowerTRONIC
Remove the key from the ignition, unplug the stock coupler and connect the PowerTRONIC to the harness by connecting it
to the 32 pin connector. Secure it in the glove box. Refer Image 46.
Image 45
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