2008 Yamaha Tmax 500

Installation Instructions 1 Parts List Button Adjustment Display Power Commander USB Cable Wire Tap CD-ROM Installation Guide Power Adapter Power Commander Decals Dynojet Decals Wire tap Faceplate Buttons Velcro Strip Alcohol Swab

Expansion Port

USB Port
The ignition MUST be turned OFF before installation!
You can also download the Power Commander software and latest maps from our web site at: 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
i437-411 www.powercommander.com 2008 Yamaha Tmax 500 - PCIII USB - 1

1 Fig. A 2

Remove the bodywork panels shown in Figure A. Remove the front fairing panel to access the battery.

Remove

Fig. B
Remove the panel shown in Figure B.

4 Fig. C 5

Install the PCIII next to the battery (Fig. C). Attach the ground wire of the PCIII to the negative side of the battery.

i437-411

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2008 Yamaha Tmax 500 - PCIII USB - 2

6 Fig. D

Guides
Route the PCIII harness down the right side following the stock wiring harness.Use the 2 stock plastic ties to secure the PCIII harness (Fig. D)

PCIII harness

Fig. E
Locate the black rubber cover on the right hand side of the scooter that contains the injector connectors (Fig. E)

Fig. F

Unplug the 2 pin GREEN connector and the 2 pin BLACK connector (Fig. F).

Unplug

2008 Yamaha Tmax 500 - PCIII USB - 3

9 Fig. G

Plug the PCIII connectors in line with the stock injector connectors (Fig. G). The PCIII ORANGE wires go to the GREEN connector for cylinder #1. The PCIII YELLOW wires go to the BLACK connector for cylinder #2.

10 Fig. H

Route the GREY wire of the PCIII harness to the throttle body. Locate the Throttle Position Sensor on the right side of the throttle body, below the air filter cover (Fig. H).
Unplug the TPS harness to gain access to the wiring harness.

Fig. J

Crimp the supplied wire tap to the YELLOW wire of the stock TPS harness (Fig. J). Attach the GREY wire of the PCIII to the wire tap (Fig. J). It is recommended to use dielectric grease on these connections.
Plug the TPS back onto the throttle body. Reinstall all bodywork.
2008 Yamaha Tmax 500 - PCIII USB - 4

2004-2007 Yamaha TMax 500
Installation Instructions Parts List
Ignition module Installation Guide Velcro Strip Alcohol Swab
You can also download the Power Commander software and latest maps from our web site at: www.powercommander.com
The ignition MUST be turned OFF before installation! This module is intended to be used in conjunction with Power Commander 404-411
Before this module can be used the Power Commander may need to be updated.
(see included instructions)
PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION
Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 6-59 www.powercommander.com 2004-2007 Yamaha TMax 500 - Ignition module - 1

1 Fig. A 2

Lift up the seat Remove both side panels on each side of the scooter (Fig. A)

Remove

3 Fig. B 4
Install the Ignition Module near the Power Commander using the supplied velcro. Remove the fuel tank cover

IM harness

Fig. C
Route the IM harness through the hole on the fuel tank cover following the Power Commander harness (Fig. C).

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2004-2007 Yamaha TMax 500 - Ignition module - 2

Fig. D

Route the crank pick-up connector harness to the left side of the scooter between the fuel tank and the storage compartment (Fig. D)

Unplug

Fig. E
Locate the 2 pin white crank pick-up connector (Fig. E). Unplug this connector. This connector is located on the left side of the scooter.

Fig. F

Connect the Ignition Module crank pick-up connectors in line with stock connectors (Fig. F)
2004-2007 Yamaha TMax 500 - Ignition module - 3

9 Fig. G

Route the Ignition Module coil connector harness to the front of the scooter following the Power Commander harness. Locate the coil on right side of the scooter (Fig. G)

Fig. H 14

Connect the Ignition Module Orange wires inline of the stock Orange wire and coil (Fig. H). Connect the Ignition Module RED wires inline of the stock Red/Black harness and coil (Fig. H). Attach the ground wire of the Ignition Module to the negative side of the battery. Plug the white 10 pin connector from the ignition module into the expansion port of the PCIII. Reinstall the bodywork.
2004-2007 Yamaha TMax 500 - Ignition module - 4