Sorry, no pictures… but this is pretty straight forward, and should be easy to follow/understand.
This DIY is intended to address - how to enable the gear selection option in the PCV so that you can ultimately have a separate map for each gear and if you’re running the AutoTuner, you will/can be producing trims for each gear’s map along with having separate target AFR tables for each gear. If you decide to perform this modification to your bike, I take no responsibility if you jack up your schit! The following is what I did to my bike and it worked fine in doing so. Dusty over at DynoJet helped tremendously in determining where to tap into for the speed signal (ABS Model Only) as well as other suggestions (AFR related). With this setup, you can now control fueling (similar as you did before) but for each gear independently. My main goal was to use my AutoTuner in such a way that at higher speeds (i.e. higher gears) I would be AutoTuning with the Ram Air affect on my map… and at lower speeds, less ram air affect, therefore (in theory) less fuel needed. You can also play around with responsiveness/acceleration and fuel mileage (through modifying your target AFRs). For example, you might change your AFR table in 6th gear in your cruising RPM range (of the table) to something leaner for better fuel mileage. The options are endless. You might note that the true performance of this setup would not necessarily be recognizable on a Dyno... it would take real world riding to realize (due to the ram air affect)... traps/times/etc. could be used to see the difference but a dyno might not. In other words, a dyno is just one tool in your bag - there are others too.
Perform mod at your own risk.
NOTE: My bike has ABS, so if yours doesn’t, you’re gonna have to find where to pull the speed signal since mine is being pulled from the ABS module/pump (and yours won’t have it).
Tools/items needed:- Assume you already have a PCV and AutoTuner hooked up
- Wire Cutters/strippers
- piece of 16-18ga wire
- Posi-tap for tapping into the speed sensor wire – if you prefer another method, substitute accordingly. This is what DynoJet uses so this is what I used… it’s also less evasive. Some feel that this type of connection is less dependable, I’ve had good luck w/them, but again – you can substitute another method of tapping in if you desire.
Step 1: Tapping into the Speed Sensor Wire (ABS Model Only!):
Locate the 3” long plug underneath the rider’s seat that plugs into the ABS Module/Pump. The plug is located on the right side (exhaust side) of the ABS module/pump. There is a tie wire securing the wires from moving that will need to be released. The plug has a “slide” mechanism located on the top side of the plug when looking down on it; it locks the plug into place. Pull up on the top piece of plastic on the plug… this will release the plug from being plugged in. Next pull the plug out, up and away from the pump so you can have access to the wiring. This is a very tight spot, so you’re gonna have to work a little to get it out. Once you have visual and physical access to the wiring, you will find a WHITE wire with a PURPLE stripe on it. This wire is located 2nd from the bottom of the plug (orientation would be if it were still plugged in and you were looking down on the plug). This is the speed signal wire that you need to tap into. I used a posi-tap (similar to what DynoJet supplies with their PCV for tapping into the TPS). You’ll run a wire from there over to your PCV.
Step 2: Tying the wire tap from the Speed Sensor into the PCV:
Best to pull out your PCV install instructions as it will have a diagram of which hole on the PCV the wire should go into for the speed sensor. If you’re looking at the holes, it’ll be the 3rd hole from the right side.
Step 3: Enabling your PCV software (on your laptop) to have multiple fuel and AFR tables (one for each gear):
Launch the PCV software. Go to the “Map Tools” drop down menu. Click on “Advance/Demote Map”. Change the setting next to “Fuel Tables” and next to “Target AFR Tables” from “Basic” to “Gear Advance”. Click “OK”. Now you will see multiple tables for AFRs, Trims, and Fuel based on Gears (1-6). If you only see multiple tables for fuel and not for AFRs and Trims (and you’re not hooked up to the bike), it means you need to change your Environment Options. Accordingly, go to the “Options” drop down menu and click on “Environment Options”. Then make sure the box for “Show auto tune tables even if the power commander is not auto tuned enabled” is ‘checked’.
Step 4: Creating your initial map/table for each gear:
You will need to create your baseline map from your last map you’ve used/saved. You can do this by opening up your last map and copying the entire fuel table (highlight the whole table, then copy) and then opening up your new map (that you will need to save along the way – as you create it) and pasting it in for each Gear’s fuel table (6 maps/tables). Then go back to the original/last map and copy the AFR table… now paste it into your new map for each gear’s Target AFR table (again 6 tables, one for each gear). Save your map! At this point, if you didn’t want to use a different AFR table for each gear and you'd rather use one AFR table for all gears, you’d go back to Step 3, and change the options accordingly.
Step 5: Calibrate the Speed Sensor/Signal from your bike to the PCV:
You will need to do this before you can calibrate the PCV for Gear Calibration (next step). This step is performed with your bike running and your laptop's USB hooked up to the PCV. DynoJet recommends using a Dyno (safety reasons); I used a rear stand and tried to ensure the bike couldn’t move around much… make sure your rear tire is safely OFF the ground. With the PCV hooked up to your laptop and the PCV software launched, click on the “Power Commander Tools” drop down menu and choose the calibrate speed option. When the popup window appears, you will enter a target speed (I used 25mph). Then you will rev your bike up to the target speed you entered - 25mph in this example (1st gear is fine, but gear selection doesn’t matter), once your dash/speedometer reads exactly what you entered as your target, you will click calibrate. Now the PCV software should read the same speed as your dash. Click OK and proceed to next step.
Step 6: Calibrate the Gear Selection for the PCV:
If you haven’t calibrated your speed sensor at this point, STOP – do that prior to proceeding. Now click on the “Power Commander Tools” drop down menu and click on Calibrate – Gear Calibration option. This will bring up the Gear Calibration popup. You will do similar to what you did in the previous step (with your bike running), except speed is not a big issue, just steady throttle. I used my throttle lock in both cases (this step and the previous) but you can do it with a steady hand too. You’re going to put the bike in 1st gear and hold the throttle steady (speed isn’t a concern, just hold the throttle steady); I think I only had the rear wheel spinning around 15-20mph. Once you’re steady on the throttle, click “Calibrate” for Gear 1 on the popup that came up. Now put the bike in 2nd gear and hold the throttle steady again, click “Calibrate” for Gear 2. Continue sequentially switching into the remaining gears until this process is complete for all 6 gears. When finished, click OK.
Step 7: Final Check
Check and ensure you’ve loaded the map you created in Step 4 above into your PCV. Just because you created it and saved it, doesn’t mean it’s loaded into the PCV. All of your Target AFR tables should be populated with values, and all of your fuel tables should be populated with values. Make sure you open it, then click “Send Map”. You might also start your bike with the PCV plugged into your laptop, and you should be able to see speed and gear selection now on the software interface. The gear selection will only appear if you're in gear
with the clutch out.
All done! Go ride! Have fun!
EDIT - if you change sprockets after you have done the speed and gear calibrations, you will need to go back into the software and do the calibrations
again - this is due to the speed signal changing due to the sprocket changes (going up or down in teeth).
#77 Race/Track Bike
Domn8er
Jeep Rubicon
S1000RR
DIY: PCV - Enabling the Gear Selection Option for Custom Fuel Maps for Each Gear
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Linear Mode
