Race Dynamics PowerTRONIC Installation Manual
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Race Dynamics PowerTRONIC Installation Manual

For ktm duke 390
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PowerTRONIC Installation Manual- KTM Duke 390 (2012-2016) 
 
 
 
Document Version 
 
 
 
Application information 
Vehicle 
Model 
Year of manufacture 
PowerTRONIC application 
 
 
Note: 
 
● Read through all instructions before installation and use. 
● Ensure that the bike is switched off and the key is out of the ignition before proceeding with the 
installation. 
● Some parts of the bikes might be hot/sharp and may cause burns/cuts. Proceed with extreme 
caution or wait until the bike has cooled down. Always wear safety gloves.  
● When the installation is complete, make sure to secure the wiring loom away from the movable parts 
or components which tends to heat up during the normal operation of the vehicle at any chance.  
● PowerTRONIC is intended for motorsport use on a closed course, please check with your local laws 
before using this product. Race Dynamics / PowerTRONIC is not liable for consequences arising out 
of using the product. 
 
 
Call/Whatsapp: 
E-Mail: 
Official Website: 
Social: 
 
1 
Vehicle Specific 
KTM 
Duke 390 
2012-2016 
All PowerTRONIC ECUs, from firmware version F.3.x onward 
+919916229292 / +918040929292  
support@powertronicECU.com  
www.powertronicECU.com 
www.facebook.com/PowertronicECU/  
www.instagram.com/powertronic_ecu/  
   
Release Date 
02 March 2020 
1

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Summary of Contents for Race Dynamics PowerTRONIC

  • Page 1 ● PowerTRONIC is intended for motorsport use on a closed course, please check with your local laws  before using this product. Race Dynamics / PowerTRONIC is not liable for consequences arising out ...

  • Page 2: Table Of Contents

    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 connectors involved.  3 ...

  • Page 3: Installation Procedure

    3. Installation procedure  3.1 Removing panels, fairing  Begin at the left side of the bike.  Park the bike using the centre stand on a level surface (Or a paddock stand). Refer ​ I mage 1    Image 1  Note the position of the connector/hoses/wires to be removed. Refer ​ I mage 2   ...
  • Page 4 3.1.1​ Detach the pillion seat by inserting the key into the keyhole shown in ​ I mage 3​ ​ a nd unlock the pillion seat. ​ I mage 4  shows the pillion seat detached.     Image 3    Image 4 ...
  • Page 5 3.1.2​ ​ L ocate and unscrew the rider seat bolts using M 10 Hexagonal T handle. Refer ​ I mage 5​ .     Image 5  3.1.3​ ​ I mage 6​ shows both the seat detached.    Image 6 ...
  • Page 6 3.1.4​ Locate and unscrew the side panel screws 1, 2 and 3 using Phillips head screwdriver and side bolt 4 using M10  hexagonal socket . Refer ​ I mage 7​ .     Image 7    3.1.4​ Locate and unscrew the tank rear screws using a Phillips head screwdriver. Refer ​ I mage 8​ .    ...
  • Page 7   3.1.5​ Carefully detach the side panel locks. Refer to ​ I mage 9.    Image 9  3.1.5​ Carefully unscrew the tank front bolts using 5 mm Allen T handle. Refer to ​ I mage 10.      Image 10 ...
  • Page 8 3.1.6 ​ U nscrew the tank lid bolts using 4 mm Allen T handle. Refer ​ I mage 11​ .     Image 11  3.1.7​ Carefully detach the tank lid. Refer ​ I mage 12    Image 12 ...
  • Page 9 3.1.8​ Carefully detach the coolant tank cap. refer ​ I mage 13​ .      Image 13    3.1.9​ Carefully detach the fuel tank cover. Refer ​ I mage 14​ .      Image 14 ...

  • Page 10: Routing The Harness

    3.2 Routing the harness  3.2.1​ Place the harness on the bike. Note that the TPS and Ignition coil connectors go to the right side of the bike. All  other connectors go to the left. Refer ​ I mage 15​ .    ...
  • Page 11 3.2.3​ Route the INJ and CKP connectors to the left side of the bike. Refer ​ I mage 17      Image 17  3.2.4 ​ R oute the Ground terminal connector to the battery negative. Refer ​ I mage 18     Image 18 ...

  • Page 12: Fuel Injector Connector

      Image 19  3.3.2 ​ I dentify 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 (​ I mage 20​ ) below.   ...
  • Page 13 3.3.4​ Connect the female PowerTRONIC injector connector to the stock male injector connector. Refer ​ I mage 21     Image 21    3.3.5​ Connect the stock female injector connector to the PowerTRONIC male injector connector. Refer ​ I mage 22  ...
  • Page 14 3.4 Crank position sensor (Left side of the bike)   3.4.1​ Locate the stock crankshaft position sensor connector on the bike. Usually located right above the engine. Refer  Image 23​ .   To identify the CKP connector, locate the connector which includes red-white striped wire.   ...
  • Page 15 3.4.3​ Connect PowerTRONIC male CKP connector to the stock female CKP connector. Refer ​ I mage 25    Image 25    3.4.4​ Connect the PowerTRONIC female CKP connector to the stock male connector. Refer​ Image 26    Image 26 ...

  • Page 16: Ignition Coil Connector

    3.5.1​ Locate the stock Spark/Ignition coil connector on the ignition coil. Refer ​ I mages 27​ .     Image 27    3.5.2​ Identify the Spark/Ignition coil connector in the PowerTRONIC wiring harness. The connectors are labelled 'SPK'  3.5.3​ Disconnect the stock ignition coil connectors. Refer ​ I mage 28​ below.    Image 28 ...
  • Page 17 3.5.4​ Connect the PowerTRONIC Ignition coil male connector to the stock ignition coil female connector. Refer ​ I mage 29  below.    Image 29  3.5.5​ Connect the PowerTRONIC Ignition coil female connector to the stock ignition coil male connector. Refer ​ I mage 30 ...
  • Page 18 3.6 Throttle position sensor connector (Right side of the bike)  3.6.1​ Locate the TPS connector of your bike. It is generally located on the throttle body, parallel to the throttle cable return  springs. Refer ​ I mage 31​ and ​ I mage 32​ .    ...
  • Page 19 3.6.2​ Identify the Throttle Position sensor connector in the PowerTRONIC wiring harness, labeled as 'TPS'  3.6.3​ Disconnect the stock TPS connector. Refer ​ I mage 33    Image 33    3.6.4​ Connect the PowerTRONIC male TPS connector to stock female connector. Refer ​ I mage 34​ .     Image 34 ...
  • Page 20 3.6.5​ Connect the PowerTRONIC female TPS connector to stock male connector. Refer ​ I mage 35​ .     Image 35  3.6.6​ We advise you to perform a TPS calibration after the installation of PowerTRONIC ECU.   Refer to the detailed TPS calibration document. ...

  • Page 21: Ground Terminal

    3 .7 Ground Terminal Connector  ​ ​   3.7.1​ Identify the Ground terminal connector labelled GND. Refer ​ I mage 36    Image 36    3.7.2​ Connect the ground terminal connector to the negative terminal of the battery. Refer to ​ I mage 37​ and ​ I mage 38​ .    ...
  • Page 22   Image 38     ...
  • Page 23   Image 39  Important note:​ The PowerTRONIC harness contains a Quick shifter connector. If you have bought the  Quickshifter please attach the connector to it.  If you have not bought the Quickshifter, you can leave it disconnected but make sure the harness is secured ...

  • Page 24: Testing With Stock Coupler

    3.9.1​ Attach the fuel tank.  3.9.2​ You can verify the connections by attaching the stock coupler. Refer to the detailed Stock coupler test document.  3.9.3 DO NOT proceed with PowerTRONIC ECU without verifying the connections with stock coupler. Refer​ Image 40   ...

  • Page 25: Plugging In The Powertronic

    3.10 Plugging in the PowerTRONIC ECU.  Connect the PowerTRONIC to the harness by connecting the 24 pin connector. Secure it in the glove box. Refer ​ I mage 41​ .     Image 41      3.11 Attaching the panels/fairing etc ...

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