INSTALLATION INSTRUCTIONS

R

UNLEASH.

THE SMARTEST PERFORMANCE TUNING TECHNOLOGY

HYOSUNG GT650R 2009 - 2013

F2040

FUEL CONTROL

1>READ

WARNINGS > INSTALLING

• We strongly suggest that an experienced technician install this product.

• Read through all instructions before beginning installation.

• This document is intended for use by qualified technicians.

• This is not a replacement for the factory Engine Control Unit (ECU).

• Refer to a factory service manual for more specific stock component identification/location information and removal/assembly procedures.

WARNINGS > USING

• Use only in race or other closed-course applications and never on public roads.

• Z-Fi products are not certified by the California Air Resource Board (CARB) for use on CA public lands.

GETTING HELP

• Factory support is available in the US at 909-597-8300.

• For fastest support outside of the US, find your local importer at bazzaz.net.

2>IDENTIFY

INCLUDED PARTS

1. Z-Fi TC control unit

2. Fuel harness

3. USB cable

4. O2 eliminator

5. Scotchlok (2)

6. Zip ties

7. Velcro

FUEL HARNESS

TPS

REAR

INJ

MAP SELECT

POWER

GROUND LUG

FRONT

INJ

Z-AFM

CONNECTOR

CKPS

MAIN

3>REMOVE

1. Seat

2. Fuel tank

3. Both left side fairings

4. Right side fairing, beneath seat

5. Airbox

4>SECURE

1. Mount the control unit in the tail section of the bike.

CONTROL

UNIT

5>CONNECT

5.1

1. Connect the main connector of the Bazzaz fuel harness to the control unit.

2. Begin routing the fuel harness down the left side of the bike.

INJECTORS

TPS

GROUND

CKPS

O2 SENSOR

CONNECTOR

CONTROL

UNIT

POWER

5>CONNECT (CONT.)

5.2

1. Locate the factory Crank

Position Sensor (CKPS) connector which can be found on the left side of the bike, near the factory regulator/ rectifier connector.

2. Separate the green wire of the factory CKPS connector.

3. Crimp a supplied Scotchlok onto the separated green wire.

4. Insert the Bazzaz CKPS connector into the Scotchlok.

BAZZAZ

CONNECTOR

FACTORY

CONNECTOR

SCOTCHLOK CRIMPED

ONTO THE GREEN WIRE

6>GROUND

1. Continue routing the Bazzaz harness down the left side of the bike, towards the throttle bodies.

2. Locate the Bazzaz ground lug on the fuel harness.

3. Install the Bazzaz ground lug with any of the factory 8mm case cover bolts.

7>CONNECT

7.1

1. Locate the factory (black)

Throttle Position Sensor (TPS) and connector which can be found on the rear throttle body, on the left side.

2. Disconnect the factory TPS connector from the sensor.

3. Connect the Bazzaz TPS connectors in-line, between the factory connector and sensor.

TPS

FACTORY

CONNECTOR

BAZZAZ

CONNECTORS

7.2

1. Continue routing the remaining portion of the harness (that contains the Bazzaz injector connectors) between the front and rear throttle bodies.

2. Locate the front factory injector.

3. Disconnect the factory injector connector from the injector.

4. Connect the Bazzaz front injector connectors in-line; between the front factory connector and injector (Bazzaz lead will be labeled FRONT).

5. Now disconnect the factory rear injector connector from its injector.

6. Connect the Bazzaz rear injector connectors in-line; between the rear factory connector and injector.

FACTORY REAR

CONNECTOR

FACTORY FRONT

CONNECTOR

REAR

INJECTOR

FRONT

INJECTOR

BAZZAZ REAR

CONNECTORS

BAZZAZ FRONT

CONNECTORS

7>CONNECT (CONT.)

7.3

1. Locate the factory tail light connector found in the tail section of the bike, near the

Bazzaz control unit.

2. Separate the yellow wire of the factory tail light connector.

3. Crimp a supplied Scotchlok onto the separated yellow wire.

4. Insert the Bazzaz +12V switched power connector into the Scotchlok.

SCOTCHLOK CRIMPED

ONTO THE YELLOW WIRE

FACTORY

CONNECTOR

BAZZAZ

CONNECTOR

8>O2 SENSOR

1. Locate the factory O2 sensor and follow the lead up to the

O2 sensor connector.

2. Disconnect the sensor connector from the factory harness, as it will no longer be used.

3. The wires should be neatly secured away from any moving components, or the sensor may be removed and the remaining port/bung in the exhaust can then be plugged.

4. Install the Bazzaz O2 eliminator in place of the factory sensor connector.

5. Attach the O2 eliminator ground lug with the factory battery ground lug.

FACTORY

CONNECTOR

BAZZAZ GROUND

BAZZAZ O2

ELIMINATOR

9>SECURE

Use the supplied cable ties to secure the harness neatly along the routing path free of any moving or hot components

(which could cause damage or failure of the system) .

10>CHECK

1. In order to check that the system is installed correctly, download the Bazzaz

Z-Fi Mapper software at bazzaz.net.

2. Plug the USB cable into the control unit and computer.

3. Locate and open the Z-Fi Mapper software.

4. Check that the pre-programmed map matches the model of your bike on the fuel map page within the software. You can switch from map 1 to map 2 by unplugging the map select jumper on the Bazzaz fuel harness. Map 1 will be pre-programmed; depending on your model, there may be a pre-programmed map in the map 2 slot. If map 2 is blank, stock ECU settings are used. Make sure that the jumper is left plugged in or unplugged, depending on which map you choose.

5. Start the vehicle and begin to check that the following inputs read correctly on

•

• the fuel map page.

RPM - Make sure that the RPM is reading near what the vehicle is idling at.

TPS - When throttle is applied, the TPS should read accordingly. Fly-by-wire models must be running to check TPS. Normal cable operated throttles can be checked with just the key on, not running.

Also use software to:

•

•

•

•

•

View and/or make adjustments to fuel maps

Activate Z-AFM self mapper (sold separately)

Save and load new fuel maps

Re-calibrate throttle position sensor after throttle modifications

View diagnostics for troubleshooting

If any problem is found, please carefully follow through the installation steps again.

If problem still persists, please contact Bazzaz tech support

• Factory support is available in the US at 909-597-8300.

• For fastest support outside of the US, find your local importer at bazzaz.net

11>REINSTALL

After it is determined that everything is correct, reinstall the components removed in step 3.

12>USE

MAPS

The Bazzaz controller is capable of storing two maps.

Switch maps by connecting or disconnecting the map select jumper supplied with the kit.

Or use the optional handlebar-mounted switch to switch maps on the fly (sold separately).

MAP 1 MAP 2

13>NEXT LEVEL

SELF MAPPER

Purchased separately.

Build race-level fuel maps for your specific modifications, fuel type, engine, and atmospheric conditions simply while riding.

02 sensor mounts into exhaust and control box easily plugs in to any Bazzaz Z-Fi product.

299.95

R

THE SMARTEST PERFORMANCE TUNING TECHNOLOGY

F2040