2008 Suzuki BKing

I n s ta l l a t i o n I n s t r u c t i o n s Parts List
Power Commander USB Cable CD-ROM
Button Adjustment Display
Installation Guide Power Adapter Power Commander Decals Dynojet Decals Velcro
Alcohol Swab O2 eliminator Wire tap
Faceplate Buttons USB Port

Expansion Port

The ignition MUST be turned OFF before installation!
You can also download the Power from our web site at:
Commander software and latest maps www.powercommander.com
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 www.powercommander.com
i336-411 www.powercommander.com 2008 Suzuki BKing - PCIII USB - 1
Remove the main seat and the passenger seat.
Hold the front of the fuel tank up using the prop rod located in the trunk area.

Fig. A

PCIII harness
Lay the PCIII in the tail section and hand side of the bike towards the throttle bodies.
route the PCIII harness down the left
At the ECU route the PCIII harness in Figure A.
underneath the left hand frame spar as
Remove the bolt that holds the tool kit box to the frame (Fig.B).

Fig. B

routed behind this bracket.
This allows the PCIII harness to be

Remove bolt

Fig. C
Unplug the stock wiring harness from each injector (Fig. C).

Unplug these connectors

i336-411

www.powercommander.com

2008 Suzuki BKing - PCIII USB - 2
Plug the PCIII wiring harness in-line tors (Fig. D).
of the stock wiring harness and injec-

Fig. D

Cylinder 1 - ORANGE Cylinder 2 - YELLOW Cylinder 3 - GREEN Cylinder 4 - BLUE
Locate the Throttle Position Sensor connector (Fig. E).

Fig. E

This connector is located on the right hand side of the throttle bodies.
Follow the wiring harness of this conTPS connector
nector back to where it joins the main wiring harness.
Crimp the supplied wire tap to the ness.
PINK/BLACK wire of the TPS har-

Fig. F

Wire tap
Connect the GREY wire from the PCIII to the wire tap (Fig. F).
It is recommended to use dielectric grease on these connections.

Grey wire from PCIII

2008 Suzuki BKing - PCIII USB - 3

Fig. G

Attach the ground wire from the PCIII to the negative side of the battery (Fig. G).

Ground wire

Install the PCIII in the tail section using the supplied velcro. swab before attaching.
to clean both surfaces with the alcohol

Make sure

Locate the stock O2 sensor connection.

Fig. H

Plug the Dynojet O2 eliminator into the stock wiring harness. anything. O2 sensor will not be connected to The stock
Bolt fuel tank back into place.
2008 Suzuki BKing - PCIII USB - 4

Installation Instructions
1. Make sure the bike is completely cool before starting the installation. Make sure the bike is secure on a centerstand or ideally a service lift. 2. Remove seat and tail cover.

B-King

2008 Suzuki

V.A.L.E.

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

5. Attach TBR muffler to slip-tube using the 8 V.A.L.E. 6x14mm S.H.C.S. and lock washers provided. Leave loose for now.
V.A.L.E. Slip-on Exhaust System with Dual M-2 Canisters Part # 005-1950406DM / 005-1950407DM / 005-1950408DM

3. Remove rear cowling.

6. Attach the TBR muffler assembly to the headpipe using the barrel clamp provided. Slide the rubber lined muffler clamps over the muffler and muffler assembly to motorcycle. Make sure the barrel clamp is at the slip tube joint with the head pipe. Use the OEM muffler mounting bolts to attach muffler clamps to frame.

Parts List

Qty. Description Part Number
Varies Varies 005-19504V 005-2C-113 005-195-3 005-7-2-3 005-19504B 005-195-21 005-195042K 005-PW218 005-BS1614 005-27-63MSH 005-ZT458B 005-ZTM4 005-FB616 005-FN6 005-SH614 005-9-18610 005-WL6 005-WFMuffler Canister (Left Side) 1 Muffler Canister (Right Side) 1 Slip tube 2 Muffler Canister Clamps 1 HARDWARE KIT 4 X-Ring (half) 1 Fender Eliminator 2 Turn Signal Brackets 1 B-King Lights Kit Parallel Wires 8 Butt Splice 16-14 AWG (Blue) 1 Barrel Clamp 4 Zip Ties 4 Zip Tie Tabs 2 6x16mm Flange Bolt 2 6mm Flange Nut 8 6x14mm Socket Head Cap Screw 1 5mm Long Handle Ball End Hex Wrench 8 6mm Split Lock Washer 2 10mm Flat Washer
4. Remove OEM muffler assembly and fender section. 7. Align the mufflers and tighten the 8 V.A.L.E. 6x14mm S.H.C.S. and barrel clamp. Make sure the muffler clamps are tight and check the clearance between all plastic parts.
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 motorcycle and exhaust system are completely cool before starting the installation. Also, make sure the bike is secure on a centerstand or ideally a service lift during installation. Be sure to save all stock components for possible use later.
8. Attach the fender eliminator to the rear frame with OEM bolts. Double check the clearance between the mufflers and plastic parts once more and adjust as needed.

Continued on pg. 2

13. Add parallel wire to both L & R turn signals and attach to new turn signal brackets. A 10mm washer is provided to use as a spacer for the turn signals in front of the OEM nut. Zip tie wires away from exhaust tube.
9. Tighten the barrel clamp.
14. Plug wires into main wire harness and attach to motorcycle.
10. Attach tail led light and plate lite bolts to fender eliminator.
15. Attach tail and plate light bolts as shown in Wiring Diagram. You will need to cut the OEM plugs and attach with the supplied connectors.
WIRING DIAGRAM Wiring Harness
11. Remove wire harness and turn signals from OEM fender section.
(Lt. Blue & Black/White)

Left Turn Signal

Right Turn Signal
(Black/White & Black)

Plate Light

16. Check all lights to be sure they function correctly including your brake lights. 17. Re-install the rear cowling and seat.

Black/White

Brake Lights
12. Remove rubber grommets from frame and attach TBR turn signal brackets using the OEM 8mm button head S.H.C.S. and the 6x16mm flange bolt and nut provided.
18. Double check all your work.

Brown Red Black

LED Brake Light

Warranty

Two Brothers Racing products are intended for closed course competition purposes only, and therefore are sold as is without warranty. Two Brothers Racing specifically disclaims any warranties of merchantability or fitness for a particular purpose and disclaims all responsibility for consequential and incidental damages or any other losses arising from the use of these products or parts.

Light Bolts

White/Black Green
* The splice connectors can be heated to make them waterproof. They will shrink around the wires.
19. Before you run the bike, clean off all fingerprints and dirt, as any oily residue will etch the metal and become somewhat permanent when the system gets hot. Also, remove any plastic film from the name badge(s) and or canister clamp(s). Run the bike and enjoy. It is normal for some white smoke to appear the first time you start the bike. This is packing/manufacturing oil from inside the pipe burning off. Check for gaps or leaks. If you find a leak, a little high temperature silicon sealant should fix it. After 50 to 100 miles, recheck all fasteners for tightness.

Care & Cleaning

Care & Cleaning Keep system free of dirt and moisture. Store in a cool, dry place. Make sure vehicle is completely cool before maintenance. Stainless Header System: Polished stainless steel pipes will turn a light golden hue after a few heat cycles, this is a normal characteristic of high quality stainless steel. Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth.
Titanium Header System: Polished titanium pipes will experience color shift ranging from deep blue/purple through amber after a few heat cycles. This is a normal characteristic of high quality titanium. Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Polished Aluminum Canisters: Use an aluminum or mag wheel polish to restore the bright finish to factory spec. Brushed Aluminum Canisters: Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Carbon Fiber Canisters: Clean using a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Always make sure the fiberglass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deteriorate the carbon fiber sleeve. TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do it yourself. Titanium Mufflers: For cleaning use a mild water based spray cleaner. Always apply cleaner or polish with a soft, clean cloth. Always make sure the fiberglass packing inside is in good condition and not burned out, as exhaust heat inside an empty canister will deteriorate the carbon fiber sleeve. TBR sells repack kits (Road - #005-10038, Offroad - #005-10038MX) that include everything you need to easily do it yourself. Repack all road canisters at the first signs of packing material deterioration. Part #005-10038 Repack all offroad canisters after every 10 hours of use. Part #005-10038MX NEVER dyno test your bike with carbon fiber or titanium canisters installed - the intense heat and lack of cooling air can quickly burn through the canister material. Two Brothers Racing does not provide a warranty for burned canisters.

005-1950406DM

005-1950407DM

005-1950408DM

Qty. Description 1 Muffler Canister (Left Side) 1 Muffler Canister (Right Side) 1 Slip tube 2 Muffler Canister Clamps 1 HARDWARE KIT 4 X-Ring (half) 1 Fender Eliminator 2 Turn Signal Brackets 1 B-King Lights Kit Parallel Wires 8 Butt Splice 16-14 AWG (Blue) 1 Barrel Clamp 4 Zip Ties 4 Zip Tie Tabs 2 6x16mm Flange Bolt 2 6mm Flange Nut 8 6x14mm Socket Head Cap Screw 1 5mm Long Handle Ball End Hex Wrench 8 6mm Split Lock Washer 2 10mm Flat Washer