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! 6. Rotate the fuel tank back and prop up or completely remove from the bike for access to the fuel injector. Two breather hoses may need to be disconnected from the fuel tank in order to lift the fuel tank. To remove the fuel tank, the fuel line and fuel pump connector must be disconnected. Locate the fuel injector connector. Disconnect the two wire black OEM fuel injector connector. Connect the JUICE BOX connector to the fuel injector and the OEM fuel injector connector.
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Juice Box - Fuel Controller
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 bolts (3) securing both right and left rear covers. Remove both the right and left rear covers.
2008-09 Kawasaki KLX250 [Non US Model Only] Installation & Operation Manual Part # 008-171
7. Route the JUICE BOX ground lead (black wire) to the engine ground located behind the rtadiator and connect to the ground bolt.
3. Rermove bolts (2) securing the seat to the frame. Remove the seat.

Parts Incuded

Qty. 1 Description Juice Box Fuel Control Kit Zip Ties Adhesive Velcro Square Part Number 008-171

(#9310179)

8. Route the JUICE BOX harness to position the JUICE BOX to the left of the ignition key.
4. Remove bolts (3) securing both right and left front covers the remove both front covers.
IMPORTANT - PLEASE READ CAREFULLY
We recommend that this performance part be installed by a qualified motorcycle technician. If you have any doubts as to your ability to install this performance part, please consult with your local motorcycle 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. 9. Make sure all wires are secured. 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. 10. Start the bike. The green LED should now be scrolling for about 3-5 seconds and then go to 1 or more steady green LEDs or a single slow flashing green LED. If the number 1 green and number 8 red LED continue flashing after startup, an injector wiring error is indicated. Re-check the wires from the JUICE BOX and make sure they are connected to the proper wires of your bikes stock harness. MAKE SURE you have the correct connectors selected in the stock harness. DO NOT PROCEED UNLESS ABOVE CONDITIONS ARE MET.
5. Remove bolts (3) that secure the fuel tank to the frame.

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.

Continued on page 2

Operation Manual
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Installation Instructions continued.
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. To begin this process, press the mode button. To enter each successive mode, just 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. 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. The LED display can also be set 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. To add less fuel, scroll the flashing 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. To add more fuel, scroll the flashing yellow LED to the right using the (+) button. To add less fuel, scroll the flashing 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. To add more fuel, scroll the flashing red LED to the right using the (+) button. To add less fuel, scroll the flashing red LED to 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. The Green-Blue mode is RPM based only. Each LED position represents a specific RPM on your bike. In this case, LED 0.5 will turn ON the cruise/Green Mode fuel at 1,150 RPM and LED 8 will turn ON the cruise/Green Mode fuel at 2,000 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. You can calculate what RPM corresponds to what LED by interpolation. If during cruise, 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 current RPM of the motorcycle; Green Mode fuel is being added. If during cruise, 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 current RPM of the motorcycle; Green Mode fuel is NOT being added. 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. To increase the sensitivity and 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. To increase the sensitivity and therefore cause the Red Mode fuel to turn on sooner, scroll the flashing red LED to the left using the (-) button. To decrease the sensitivity and therefore cause the Red Mode fuel to turn on later, scroll the flashing red LED to the right using the (+) button.

Cleaning

If the unit requires cleaning, use a cloth that is only lightly dampened with water or mild detergent.
Operation Manual - JUICE BOX Settings
Kawasaki KLX250 Pre-set Settings: KLX250 baseline settings with stock air filter and TBR complate exhaust system. (G=2, Y=3, R=4, GB=3, YB=3, RB=4.5)
Mode 1 - Green Mode 2 - Yellow Mode 3 - Red

Mode 4 - Green/Blue

Mode 5 - Yellow/Blue

Mode 6 - Red/Blue

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.

2008 Kawasaki KLX250S Q & A with Product Manager Karl Edmondson
Q: Why did the engineers stick with a steel perimeter frame, instead of a KX motocross type aluminum twin-spar design? A: There are actually two reasons for using a steel box-section frame on the KLX250S. First; a steel frame and its smaller cross-section spars gives a more comfortable ride on pavement, thanks to its natural vibration damping abilities. In other words; this frame is smoother and more-comfortable than a stiff twin-spar aluminum motocross setup. Second, the use of steel box-section spars is more-efficient for mass production and therefore less expensive than a cast/extruded aluminum design. This helps keep the total price low, for buyers in this segment. Q: Isnt 250cc small for a streetbike? A: Yes, 250cc is smaller than the average street motorcycle. Please remember this is dual-sport that can also be ridden off-road, where small size is often a plus. However, the KLX250S has plenty of performance for use in the real world, with enough power to keep-up on the highways, backroads and around town. Kawasaki already has the larger KLR650 dual purpose model for riders seeking extra power or payload, so the 250S is targeted directly at those who want a more nimble and easy to handle machine. Its compact size and light weight, compared to some other dual purpose bikes, makes the KLX250S well-suited for transporting in a truck or RV and then riding-off to explore new areas, or to ride into town for camp supplies.
Q: Why the redesign, didnt Kawasaki already have a competent 250cc dual purpose machine? A: Yes, the previous KLX250S was a good choice for those seeking a lightweight dual purpose machine. However, since it was not certified for use in California, it was unavailable to a significant number of potential dual sport buyers. So, when the decision was made to update the KLX250S, Kawasaki took the opportunity to not only improve its function and appearance, but also ensure it would be eligible for sale in all 50 states. With all of these mechanical and cosmetic changes, this new model represents a significant upgrade from the previous 250S.
Q: Tires play a big role in the overall competence of a dual-sport bike. What can you tell us about the tires on the new 250S? A: To answer that question, we really need to include the wheels. Most DOT legal dual-sport tires deliver a less-precise feel on pavement, because their open-tread design allows more squirm in the tread blocks. Some of that squirm is unavoidable, but the effect can be minimized by making the wheels more rigid. Kawasakis engineers accomplished this on the 09 KLX250S by increasing the spoke diameter by 1/2mm. Not only does this reduce unwanted wheel flex, it also makes them more durable on rough surfaces. Ok, back to the tires in a further effort to reduce squirm on pavement, the engineers decided to switch to Dunlop 605s with smaller tread blocks. These new tires work with the stiffer wheels to offer a significant on-road handling improvement, without sacrificing the KLX250S excellent off-road ability.
Q: Stiffer wheels, better tires, and 50-state street legal? Sounds great, but what else does the new model bring to the table? A: Without covering the entire features & benefits listing on Kawasaki.com, Ill mention some of my personal favorites: The new all-digital instruments offer a ton of added functionality and are easy-to-read, even in direct sunlight. The new swingarm is stiffer, which helps improve handling in unison with those new wheels and tires, and I especially like the re-tuned suspension on the 09. Finally, the firmer urethane in the seat makes the bike much more comfortable on longer rides.