Bulletin # PS-0409-9 April 2009

New Product

Wiseco Kawasaki KFX450R 2008 Piston Kits
Features Benefits Dedicated forging.. Light weight, superior strength, optimized design Stock Compression. Matches OEM compression ratio High Compression.. Maximum torque and throttle response Dome design... Improved flame travel to maximize air/ fuel burn efficiency Chrome plated piston pin. Reduced friction, improved scuff resistance Horizontal slot pin oiling.. Improved lubrication, better pin oiling, reduced friction Pressure seal groove.. Maximum ring seal Skirt coated... Reduced friction, quieter operation, improved scuff resistance. Dedicated rings.. Optimized for each application, light weight, high perfromance, better oil control Experience.. 68 years as the industry leader in forged piston technology
Piston sold complete with: Rings, piston pin, and circlips. Complete top end kits sold complete with: Piston, rings, piston pin, circlips, and complete top end gasket kit. Prices (USA): Stock Compression 12.4:1: $188.24 96mm, $207.07 98mm High Compression 13.4:1: $227.78 96mm, $250.56 98mm

Years 2008-09

Bore x Stroke (mm) 96 x 62.1
Bore Size (mm) 96.00 98.00

Top End Kit TBA TBA

Top End Kit Piston Kit Number Price TBA TBA 4973M09600 4973M09800
Price Per Piston $188.24 $207.07
Repl. Ring Set 9600XS 3858XS
Repl. Pin & Clips S656 CW21
Top End Gasket Kit 96mm W6651 98mm W6652 96mm W6651 98mm W6652
Kawasaki KFX450R 12.4:1 Stock Compression Skirt Coated Kawasaki KFX450R 13.4:1 High Compression Skirt Coated

2008-09

96 x 62.1

96.00 98.00

TBA TBA

4974M09600 4974M09800

$227.78 $250.56

9600XS 3858XS

S656 CW21
Copyright 2009 Wiseco Piston Co., Inc. 7201 Industrial Park Blvd. Mentor, OH 44060-5396 440-951-6600 Fax: 440-951-6606 www.wiseco.com

Installation Instructions
Thank you for purchasing a genuine Two Brothers Racing JUICE BOX. This product represents a radical step forward in tuning fuel-injected motorcycles and ATVs for optimal performance using load-based technology. We at Two Brothers Racing hope that you will find this development as exciting and useful as we do. And remember: Proper Fuel = Maximum Power! 1. Make sure the vehicle is completely cool before starting the installation. Also, make sure the vehicle is secure and will not roll around. 2. Remove the seat.

Two Brothers Racing

V.A.L.E.
5. Unplug the stock injector connector from the injector. (See Fig.4a) The stock injector connector looks just like the gray connector on the Juice Box. This connection is under the rear of the fuel tank. Plug the Juice Box gray injector connector into the injector, then plug the stock injector connector into the black Juice Box connector. (See Fig. 4b)

Fig 4a

V a r i a b l e

A x i s

L o c k i n g

E x h a u s t

Juice Box - Fuel Controller
2008 Kawasaki KFX450R Installation & Operation Manual Part # 008-166

Fig 4b

3. Remove the 2 screws that hold the side covers to fuel tank. Remove the 2 bolts at the rear of the fuel tank. This allows the rear of the fuel tank to be raised up enough to install the Juice Box without removing the fuel tank. (See Fig.2)
6. Remove the bolt that secures the stock ground wire to the frame. Attach the ground wire from the Juice Box to this location. (See Fig. 5)

Parts Incuded

Description
Juice Box Fuel Control Kit Zip Ties Adhesive Velcro Square

Part Number

008-166

Tools Needed For Install

- #3 PhillipsScrewdriver - 8mm Wrench or Socket - 10mm Wrench or Socket
4. A Good location for the Juice Box is in the tail section. Route the wiring harness from the Juice Box towards the throttle body. (See Fig.3a) Route the harness underneath the cross member of the sub frame. (See Fig.3b)

Fig 3a

7. Remove the 4 bolts that hold the tool kit holder in place. (See Fig.6)
IMPORTANT - PLEASE READ CAREFULLY
We recommend that this performance part be installed by a qualified ATV technician. If you have any doubts as to your ability to install this performance part, please consult with your local ATV dealer. Read all instructions first before starting installation. Make sure the vehicle and exhaust system are completely cool before starting the installation. Also, make sure the vehicle is secure during installation. Be sure to save all stock components for possible use later. The Juice Box is legal ONLY for closed course race vehicles. The Juice Box is not applicable, nor inteded for use on EMISSIONS CONTROLLED street, highway or off-road vehicles. The Juice Box is not applicable, nor inteded for use on aircraft.

Fig 3b

Warranty
Two Brothers Racing warrants that this product carries a warranty for 2 years from date of purchase against original defects in materials and workmanship. Should this product fail to perform for either of the above reasons, Two Brothers Racing will repair or replace it with an equivalent product at no charge, except for postage, to the original retail purchaser. To obtain the benefits of this warranty, the retail purchaser must return the product and proof of purchase to the place of original purchase.

8. Using the supplied Velcro secure the Juice Box to the rear fender under the tool kit holder. Secure the Juice Box harness to the frame with the supplied zip ties. Take care to leave slack in the harness so engine vibrations do not strain the harness.

Continued on page 2

Operation Manual
1. It is recommended that the pre-programmed settings of the Juice Boxbe used. However, the Juice Box can be adjusted to suit different engine modifications, states of tune and environmental conditions. o begin this process, T press the mode button. o enter each successive mode, just T press the mode button again. Note that every mode will be identifiable by the color(s) of the flashing LED(s) on the LED display. There are six modes that are distinguished by an LED color or color combination. The 6 modes are as follows, respectively: Green, Yellow, Red, Green-Blue, Yellow-Blue and Red-Blue. 2. You are now ready to manually program each mode. Consult the base settings supplied with the unit. To program the Juice Box, the bike must be running in order to supply power to the Juice Box. Simply press the mode button to activate the first mode. If at anytime you stay in an adjustment mode for longer than 5 seconds without pressing any buttons, the Juice Box will exit the adjustment mode and will return to the operational mode. To save settings in a particular mode press the MODE button which goes to the next adjustable mode or wait for the Juice Box to exit back to the operational mode. The settings in each mode are adjusted by pressing the (+) and (-) buttons located on the right and left side of the mode button, respectively. For easy reference, the LEDs are numbered 1 through 8. However, the LEDs can be adjusted to the following positions: 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 8. For example, in a particular mode, if LED ,.5, 4 is flashing then the LED display is set to 4 in that mode. If the (+) button is pressed once then LEDs 4 and 5 will flash simultaneously and the LED display is set to 4.5. If the (+) button is pressed once again, only LED 5 will flash and the LED display is set to 5. he LED display can also be set T to 0.5 by pressing the (-) button and scrolling the colored LED to position 1 and then pressing the (-) button once more until the LED in position 1 is flashing twice as fast as normal. I. The first mode (Green Mode) represents an additional amount of fuel added under cruise conditions. A flashing green LED should appear on the LED display. To add more fuel, scroll the flashing green LED to the right using the (+) button. o add less fuel, scroll the flashing T green LED to the left using the (-) button. If you set the flashing green LED to the 0.5 position on the LED display, no fuel will be added to the stock fuel curve. II. The second mode (Yellow Mode) represents an additional amount of fuel added during acceleration. A flashing yellow LED should appear on the LED display. o T add more fuel, scroll the flashing yellow LED to the right using the (+) button. o add less fuel, scroll the flashing T yellow LED to the left using the (-) button. If you set the flashing yellow LED to the 0.5 position on the LED display, no fuel will be added to the stock fuel curve. III. The third mode (Red Mode) represents an additional amount of fuel added during full throttle conditions. A flashing red LED should appear on the LED display. o add T more fuel, scroll the flashing red LED to the right using the (+) button. o add less fuel, scroll the flashing red LED to T the left using the (-) button. If you set the flashing red LED to the 0.5 position on the LED display, no fuel will be added to the stock fuel curve. Note: If the flashing green, yellow and red LEDs in modes 1 through 3 (Green, Yellow and Red) are set to the 0.5 position on the LED display then the Juice Box will not add any fuel to the bikes stock fuel curve. This setting will essentially turn off the Juice Box even though it is still attached to the bikes fuel injection system. The bike will run as though the Juice Box is not installed. The Juice Box LEDs will still operate normally even though no fuel is being added. IV. The fourth mode (Green-Blue Mode) is an adjustment to determine the point on the RPM range when the cruise/Green Mode fuel turns ON. A flashing green LED appears on the LED display while at the same time a flashing blue LED appears on the 8th LED. he cruise/Green T Mode fuel can be set to turn on at idle or just above idle at a point selected by the user by adjusting the green LED in this mode. he Green-Blue mode is RPM based only. Each T LED position represents a specific RPM on your bike. In this case, LED 0.5 will turn ON the cruise/Green Mode fuel at 1,500 RPM and LED 8 will turn ON the cruise/Green Mode fuel at 2,100 RPM. Each LED setting in between 0.5 and 8 will turn ON the cruise/Green Mode fuel in between the above-mentioned RPM points. ou can calculate what RPM Y corresponds to what LED by interpolation. If at idle, the Green LED is solid, then the Green Mode is active and the Green-Blue LED is set to a RPM that is lower than the idle RPM of the ATV; Green Mode fuel is being added at idle. If at idle, the Green LED is slowly flashing, then the Green Mode is NOT active and the Green-Blue LED is set to a RPM that is higher than the idle RPM of the ATV; Green Mode fuel is NOT being added at idle. V. The fifth mode (Yellow-Blue Mode) is an adjustment to determine the time when the acceleration/Yellow Mode fuel amount turns on. A flashing yellow LED appears on the LED display while at the same time a flashing blue LED appears on the 8th LED. o increase the sensitivity and T therefore cause the Yellow Mode fuel to turn on sooner, scroll the flashing yellow LED to the left using the (-) button. To decrease the sensitivity and therefore cause the Yellow Mode fuel to turn on later, scroll the flashing yellow LED to the right using the (+) button. VI. The sixth mode (Red-Blue Mode) is an adjustment to determine the time when the full throttle/Red Mode fuel amount turns on. A flashing red LED appears on the LED display while at the same time a flashing blue LED appears on the 8th LED. o increase the sensitivity and therefore T cause the Red Mode fuel to turn on sooner, scroll the flashing red LED to the left using the (-) button. o decrease T the sensitivity and therefore cause the Red Mode fuel to turn on later, scroll the flashing red LED to the right using the (+) button.

2008 Kawasaki KFX450R0 Installation & Operation Manual Part # 008-166
Installation Instructions continued.
9. Start the ATV. The green LED should scroll left to right and back for about 3-5 seconds and then go to 1-2 steady or slowly flashing green LEDs. If the number 1 green LED and number 8 red LEDs continue flashing after startup or idling, an injector wiring error is indicated. Re-check the wires from the JUICE BOX and make sure they are connected to the proper wire of your ATVs stock harness. MAKE SURE you have the correct wires selected in the stock harness. DO NOT PROCEED UNLESS ABOVE CONDITIONS ARE MET. 10. Reinstall the tool kit holder. 11. Reinstall the screws and bolts for the fuel tank. 12. NOTE: Re check your wire routing and JUICE BOX location and make certain that in no way the wires can come into contact with any moving parts or high heat source and that the JUICE BOX is mounted in a way as to not cause a handling problem with the machine.

Cleaning

If the unit requires cleaning, use a cloth that is only lightly dampened with water or mild detergent.
Operation Manual - JUICE BOX Settings Pre-set Settings: KFX450R with stock airbox, TBR Slip-on exhaust with spark arrestor and P1 Power Tip installed. (G=4, Y=4, R=1, GB=8, YB=4, RB=4)
Mode 1 - Green Mode 2 - Yellow Mode 3 - Red

Mode 4 - Green/Blue

Mode 5 - Yellow/Blue

Mode 6 - Red/Blue

Additional Tested Setting: KFX450R with stock airbox, TBR Slip-on exhaust with NO spark arrestor and NO P1 Power Tip installed. (G=4, Y=4, R=2, GB=8, YB=4, RB=4)

For Race Use Only

The Juice Box is legal ONLY for closed course race vehicles. The Juice Box is not applicable, nor inteded for use on EMISSIONS CONTROLLED street, highway or off-road vehicles. The Juice Box is not applicable, nor inteded for use on aircraft.
For additional settings please visit our website at www.twobros.com.