Electronic Fuel Injection

Basic Guide
 EFI
Electronic Fuel Injection

A computer controlled fuel- delivery system.

Uses fuel injectors controlled by the computer …no carburetor

The computer uses sensors to gather information from the

engine, then calculates the required fuel pulse needed .

The amount of fuel injected into the engine is determined

by how long the injector is open. ( Pulse width )
 Introduction to EFI
Harley-Davidson motorcycles first introduced EFI systems
back in the 1990’s on their touring motorcycles.

These systems were produced by Magneti-Marelli and use

the Alpha-N (throttle position based) technology for
controlling fuel and timing.
 Delphi EFI system
First introduced in the softails in 2001
Touring and V-rod motorcycles in 2002

Dyna motorcycles in 2004

Standard in all models in 2007
 Major difference
One of the major differences between fuel injection systems is
how it senses the amount of load that is placed on the engine.
The load can be sensed by :

1. Throttle position sensor

2. MAP map sensor

EFI systems that sense engine load by the use of the throttle
(throttle position sensor) are referred to as an Alpha-N system.

EFI systems that sense engine load by the use of a MAP sensor
are referred to as a Speed-Density system …currently used
 ECM

Electronic Control Module

The computer or brains of the ECM system.

The ECM calculates the proper air/fuel ratio and spark

needed for the engine. The demands of the engine change
constantly and so the ECM must make instant changes to
the pulse width of the injector and by advancing or retarding
the spark .
ECM Computer
Module
ECM Data Port
 Model years

For model year 2005 bikes, the ECM hardware was updated
to a higher performance processor with more memory and
capabilities and is called the “VooDoo” ECM.

Two basic types of this ECM have been produced to date:

One works with the normal “Big Twin” models, and the other
works only with the Sportster models.

The Sportster ECM has some capability removed as a cost

reduction measure, and cannot be used in any of the
“Big Twin” bikes.
 Model years
For model year 2008, a new ECM was released on some of
the touring bikes.

This was a major evolution of the VooDoo, and was called the
“FreeBird” ECM.

The Freebird is only used on the 2008 – 2009 Touring bikes.

Over the years, various Delphi replacement ECMs have been

produced and used on Harley Davidson models.
A high volume and pressure of fuel is required to run
an EFI system. EFI fuel pumps are capable of producing
60-90 pounds of pressure in the fuel line.
 Injector

A/F ratio:
The ratio of air to fuel that is injected into the engine
Example : 14 to one = 14 parts air to one part fuel
Longer pulse width = More fuel Shorter pulse width = Less fuel
Richer mixture Leaner mixture
12 : 1 15 : 1
 Air/ Fuel mixtures
Too Rich

Rich mixture
More fuel less air Rich
Lean mixture
More air less fuel
Lean

Too Lean
 Air / Fuel ratio AFR
The AFR is constantly changing as the engine starts, warms
up , idles, cruises, or runs at wide-open throttle.
Even during de-acceleration the AFR is being modified.
Air/Fuel Ratio
Landscape

RPM
 The Delphi EMS system
The Delphi system is able to use the manifold pressure from the
air intake, allowing it to more accurately determine the load on
the engine based on the actual pressure in the manifold rather
than the position of the throttle.
 Service Bulletin
M-1185

Most 2006 models came with narrow 8 degree spray pattern

injectors ( P/N 27625-06 ) that cause poor start, idle , and
cruise. The replacement injectors (P/N 27709-06A ) have a
25 degree spray pattern.

Verify that the injectors have been replaced.

 Government Regulations
The government works to protect the environment and in so
doing makes motorcycle manufacturers follow a strict set of
guidelines they must follow when setting up a tune for your
bike from the factory.
 Factory Settings

Harley Davidson programs the tune into the ECM at the factory
and must conform to government standards and regulations.

Government regulations for A/F ratio settings is 14:7

* Leaner fuel mixtures will burn hotter.

* Richer fuel mixtures will run cooler.

 Basic Tune
The Delphi EFI system is used on current Twin Cam engines
produced by Harley Davidson using the Speed Density system..

A TUNE is a process of calibrating the ECM to factory specs.

and working toward improving overall performance.
 Catalytic converters
A component made of specialized materials that help reduce
exhaust emissions established by the government.

They are placed in the exhaust pipe , either in the upper or lower
header pipe. As far as the catalytic converters in the exhaust goes,
a certain amount of heat is dictated by the catalytic reaction.
 Effects of a lean mixture
The tune set by the manufacturer with the air/fuel ratio very lean
and the use of catalytic converters will make the bike run hot.
Converter Damage
 AFR Fuel Mixtures
Signs an engine is running too lean

Bike hesitates when throttle is increase

Bike runs jerky or surges at steady throttle openings
Engine spits back or coughs through intake system
Spark plug color is white

Signs an engine is running too rich

Engine chokes when throttle is increased

Engine fouls spark plugs…. Dark deposits in the exhaust
Black smoke from exhaust
 Computer sensors
Electronic sensors are located around the engine that
send voltage signals back to the ECM .

The ECM uses the signal values from the sensors to

make calculations for fuel and spark.
 List of Sensors
MAP sensor – measures manifold pressure

TPS sensor – measures throttle position

CKP sensor – measures the crankshaft position and RPM

IAT sensor – measures intake air temperature

ECT sensor – measures engine coolant temperature

VSS sensor – measures vehicle speed

O2 sensor – measures oxygen in the exhaust

BAS – Bank Angle Sensor – detects if bike is tipped more than 45 degrees
Receives voltage signals
 Engine
Temperature Sensor
It doesn't take long after purchasing your new HD to figure
out that this is a very hot running engine. One of the most
common complaints about the new bikes is the heat that
comes off the engine and exhaust system.

Temperatures can range anywhere from

300 – 600 degrees.
16 min. Idle
 Air Temperature Sensor
The temperature of the air going into the engine is important
to the ECM for making fine adjustments to the fuel mixture.

Cold air has more oxygen present , causing the ECM to richen
the fuel mixture.
 Throttle Position Sensor
The throttle position sensor provides the ECM with an indication
of how much the throttle has been opened. Higher voltage
signals sent to the ECM means more throttle.

The TPS sensor uses an electronic component that provides

a 0-5 volt signal to the ECM.
 Crank Sensor
Measures speed and location of the crankshaft
 Map Sensor
Measures air pressure entering the throttle body

kPa (kilopasca ) is a unit of measure

that describes air pressure.

The Harley MAP reading at idle is typically

30 to 40 kPa, while under full load the MAP
pressure is close to 100 kPa.
 Knock Sensor
Measures engine detonation . The ECM will retard the timing &
richen the fuel mixture to reduce the knock.
Note: Not all engines have a knock sensor.

Detonation - when the spark

occurs too early in the engine
creating a pinging noise .
 Bank Angle Sensor

This sensor determines the lean angle of the motorcycle.

If the banking on the bike exceeds designated levels, the

engine will turn off. Usually, beyond 45 degrees.
Location and application depends on the model of the bike.

This sensor is a safety feature on EFI systems.

 Idle Air Control
Idle Air Control controls and maintains a consistent engine
idle RPM under a wide variety of conditions by making
minor adjustments to the airflow into the engine.

The IAC is a stepper motor, similar to a valve that can allow

varying amounts of air into the engine to keep the idle stable.

Idle speed is also managed by a memory table in the ECM that

responds to engine temperature.

When the engine is keyed-off, the

Idle Air Control is reset to a
“parked” position
 Oxygen Sensor
Measures the amount of oxygen in the exhaust
which is a reflection of the Air/Fuel ratio. ( AFR )
Sends a voltage signal to the ECM

Signal: 0 to 1 volt

Narrowband sensor

Measures a/f ratios in the

range of 14.3 – 15 :2
O2 Sensor Locations
 O2 Sensor

If the o2 sensor sends a signal to the computer that the exhaust

mixture is lean, the computer adds fuel by lengthening injector
pulse . If the o2 sensors send a voltage signal to the ECM that
the engine is running rich, then the computer takes fuel away.

This is known as : Fuel Trim

Since the computer is monitoring the

AFR at the exhaust using the o2 sensors
this is known as running in Closed -loop
Added to some models in 2006
 Narrowband O2 Sensor

A narrowband O2 sensor only works for adjusting low load/cruise

area and does not work well in performance applications because it
can only monitor a small area within the 14.7 AFR.

This range is considered too lean a fuel mixture for performance.

Therefore, if you are wanting to monitor the AFR outside the

range of a narrowband sensor, then you must install a wideband
sensor instead.
 Narrowband vs.
Wideband O2 Sensors
Narrowband sensors are used as a stock sensor from the
manufacturer and has a small range of operation ..
14.3 – 15: 2 AFR Size: 12 mm insert

The Wideband sensor is used for performance applications

when you need to read the AFR at much richer value.
10 – 18 :1 AFR Size: 18 mm insert

Narrowband 12 mm Wideband 18 mm
 Closed vs. Open- Loop

In closed-loop, the O2 sensors are used to monitor the AFR

prompting the ECM to make changes in the AFR to maintain
a 14:7 ratio.

At all other times, the system is in "Open-loop" and the

O2 sensors are not being used and the ECM will be using the
“look up “ tables to make fuel and spark calculations.

Look-up tables are areas within the ECM that store data from sensors
and are used to calculate the AFR when the engine is in open –loop.
EXHAUST
EXHAUST O2 Sensor readings
Closed-loop operation

ECM

O2
Sensor
14.7
 O2 Output Voltage
Rich side 1 volt
14.3
14.7 450 mv.

15.2
Lean side
0 volts

The ECM constantly adjusts the AFR to stay within this window

The ECM adjustments to maintain a 14.7: 1 AFR are known as FUEL TRIMS

Narrowband Oxygen Sensors send signals from 0 to 1 volt back to ECM

 Fuel Trim
For the engine to operate within the factory specs , the
air/fuel ratio needs to stay within a small window of 14.7:1.
It has to remain in this zone under all the various conditions.

The engine computer is trying to maintain this proper air/fuel

ratio by fine-tuning the amount of fuel going into the engine.

This tuning of the fuel and making adjustments

on the fly is known as Fuel Trim.

This fuel trim value is then stored in the ECM and is

later used as part of the overall fuel equation.
 Fuel Trim

Fuel trim: The ability of the ECM to make AFR corrections during
engine operation. These are learned values and any corrections
are stored in the ECM memory and become a part of the TUNE for
the bike.

Note: Fuel trims can be erased using a tuner program.

When the battery is dis-connected , it also erases the
fuel trim values stored in the ECM memory.
 Volumetric Efficiency
The amount of air that enters the engine compared to what
the the engine could theoretically could manage is the
volumetric efficiency . It is the air moving in and out of the engine.

Air management can be changed by adding different exhaust

systems, adding a performance cam, or changing the air cleaner to
provide more unrestricted air flow.

AIR
 VE Table
The ECM looks at the volumetric efficiency data by reading a VE Map
that is stored in the ECM memory. Tuners can change this data , which
in effect will change the AFR.

Pressure

RPM
 VE Table
Increasing these values ..tells the ECM that more air is entering the engine,
and through its calculations for determining AFR , will richen the mixture.
Q: Why are the VEs different for the front and
rear cylinders?

A: The VEs will never be identical because of

differing intake length, exhaust pipe length,
reversion, timing, cooling and other factors.
 Engine Timing

The ignition spark plug firing must occur at the proper time for
the engine to run its best.

Spark timing can be advanced or retarded .

BTDC Before top dead center.

Timing of the spark is controlled by the ECM for start, idle, cruise
and power ranges.

Setting the correct ignition timing is crucial in the performance of an engine.

Sparks occurring too soon or too late in the engine cycle are often
responsible for excessive vibrations and even engine damage.
 Ignition Timing

The computer has a timing map (lookup table) with spark

advance values for all combinations of engine speed and load.
These tables are used by the ECM to calculate the engine timing.

Top Dead Center

Bottom Dead Center

Spark “Look-up “ Table
Pressure
 Dyno Tuning

The process of tuning a bike using a machine that allows for

the motorcycle to operate while simulating an on the road
riding experience.

Tuning sets the bike back to factory specs. or allows the

user to adjust the ECM programming for even better
performance .

There are different methods used for tuning a bike and

generally include making adjustments to the programming
of the ECM.
 How the ECM works

ECM Output
Signal

The ECM receives voltage The ECM makes calculations

signals from the different
sensors located on the bike
based on the inputs and from
the tables programmed into its
memory to provide an output
signal for fuel and spark timing.
 Understanding
“look-up” Tables
Most tuning involves making changes to tables (also called
“look-up” tables) that the ECM uses to control various
functions during engine operation over various loads & Rpm.

The ECM takes inputs measured by the bike’s sensors and looks
up the values in the tables that are needed to make AFR and
spark timing calculations.
 Look-up Tables

The ECM uses its calibration setup or (tune) to determine

if it should maintain closed- loop fuel control, or go into
open-loop using the fuel maps stored in memory.

Closed- loop Base Fuel maps are ignored

Open –loop Base Fuel maps are used

 “Look-up” Tables

Input sensor data is stored as Memory in the ECM.

These tables are used in the calculations for AFR and spark
timing to be delivered to the engine. Each table can be
written into the ECM using a programming tuner and a laptop.

Harley Davidson
Screaming Eagle performance tuner
attaches to the data port
 Fuel-maps
The ECM manages the AFR to the engine. Stored in the memory is
a fuel map the ECM uses in its mathematical equation to develop
the right fuel mixture.

Tuners can make changes to the fuel maps that alters the AFR .

Fuel maps can be downloaded

from the manufacturers websites
and flashed into the ECM.
 Targeted AFR

The target AFR is found on the fuel map that is part of the
ECM equation when determining the pulse width of the injected
fuel. The target AFR is what the rider is expecting to acquire
during riding. It is programmed into the ECM computer.

The target AFR can be changed using tuner connected to the

ECM.

The actual AFR is what is actually created and can be measured

in the exhaust. It is the goal for the engine for the actual A/F
ratio to be the same as what is TARGETED.
 Target vs. Actual AFR

Fuel map targeted AFR

Actual AFR output at the exhaust

Setting a cell to the value of 14.6

acts as a switch telling eh ECM to
enter into closed –loop mode in
that region on the map.
 Target vs. Actual AFR

The goal in tuning is to make these two values as close

together as possible.

If they are far apart, then the tuner needs to make adjustments
to VE table to correct the problem. The a/f ratio at the
exhaust should match the targeted a/f ratio.

Changes to the VE and fuel maps can be done with a TUNER.

Tuner : A device attached to the ECM computer data port that allows the user
to make changes to the maps and tables stored in the ECM using a laptop
 ECM Programming
Example: If the ECM has a fuel map target value of 12.6 but
the measured exhaust AFR is 13.5. Then , the ECM needs to be
re-programmed and the VE table needs to be adjusted . The fuel
calculations used by the ECM are only as accurate as the data
being used.
VE Table Fuel Map
Fuel Map Landscape
 Fuel-Map
Pressure
RPM
 AFR Switch
Setting the fuel map to read: 14. 6 acts like a switch and tells the
computer to run in the closed –loop mode.
 Lambda

AFR have an equivalent value called Lambda (λ).

Lambda is representative of the stoichiometric ratio where

a λ=1 will always be stoichiometric, regardless of the fuel in use.

Standard or lambda values may be used when tuning a bike.

Stoichiometric : Optimized AFR of 14.7

 Lambda

Lambda is scale that relates the air to fuel ratio of ANY fuel.
1.0 is stoic for every fuel. (the chemically perfect ratio of air
to fuel for a complete burn).

However, stoic is different for every fuel. Some fuels may

need 14.7 lbs of air some may need 6 lbs of air for a complete
burn. Lambda 1.0 is always the perfect ratio for the fuel in use
Lambda conversion chart
Lambda Values
Fuel Map
Fuel Map
Fuel Map
Fuel-Map
 Basic ECM
Look-up Tables
• Cranking table
• Engine crank to run
• Warm up enrichment table
• Idle air control table
• Idle RPM table Stored in the ECM
• Fuel map AFR table flash memory

• Volumetric Efficiency table

• Accelerator enrichment table
• Power enrichment table
• Deceleration en-leanment table
 Crank Table
During crank mode, timing is always fixed at 0 degrees Top Dead
Center (TDC) and the AFR is controlled by the Cranking Fuel table

Pulse width (milliseconds) vs. Temperature

68 104 140 176 212 248 284 320

Degrees F
 Engine Crank to Run
As soon as the engine fires, it begins a transition to the “Run” mode. During
this transition, additional fuel and air is needed to prevent the engine from
stalling or hesitating. This transition is controlled by the IAC Crank to run table.

Idle air steps vs. Temperature

68 104 140 176 212 248 284 320

Degrees F
 Warm-up Table

During engine warm up, the engine will run in open loop mode and
use a 12.5:1 Rich AFR.

AFR vs. Temperature

68 104 140 176 212 248 284 320

Degrees F
 Idle Rpm Table

As the engine warms up, the idle speed is controlled by the Idle RPM table.

Idle RPM vs. Temperature

68 104 140 176 212 248 284 320

Degrees F
 Idle Air Control
Warm-up Steps
Is used to maintain stable idle speed during warm-up.
If the bikes warm-up idle speed is unstable,
try adjusting this table

IAC steps vs. temperature

68 104 140 176 212 248 284 320

Degrees F
 Accelerator Enrichment
Table
Multiplier table that injects fuel on acceleration to prevent hesitation when
the throttle is opened quickly . To increase the AE fuel delivered, increase
the multiplier value.

68 104 140 176 212 248 284 320

Degrees F
 Power Enrichment
Table
Operates when the throttle is Wide –Open …for a period of time.
The AFR gradually richens over time to prevent engine overheating.

Seconds in PE mode
 De-Leanment
Table
The table affects exhaust popping when the throttle is closed.
Control is by the multiplier table. Most often the popping occurs because the
mixture is too lean. Setting the multiplier value lower will richen the AFR.

68 104 140 176 212 248 284 320

Degrees F
 Clear Flood Mode

A mode that overrides the Cranking Fuel table.

If the throttle is held at 70% or more open during cranking, no fuel will be
delivered to the engine to help flush out any excess fuel that has
accumulated in the cylinders.
 EITMS
The EITMS system (Engine Idle Temperature Management System) was
developed to reduce heat buildup in the engine during prolonged idling.

Mode 1 AFR fuel enrichment

Mode 2 Skip fire / rear cylinder shuts off to keep it cool

Mode 1 Activated under the following conditions

1. Engine temperature exceeds 290 F
2. RPM is under 1200

Mode 2 For Big Twins only

1. Engine temperature exceeds 300
2. Bike speed is less than 10 mph
 EITMS
Parade Mode
 EITMS
Turning on /off
The ETIMS (Engine Temperature Idle Management System) can be turned on
or off by the rider on all touring models 08 and later, the 07 models have the
ETIMS but the dealer has to hook in a external computer to turn it on/off.

The ETIMS will then turn off the rear cylinder to help slow down the over
heating process. As soon as you give the bike some throttle the rear cylinder
will turn back on and the engine will run on both cylinders.

Consult your manual for learning how your particular model works.
Convert Degrees C to F

20 68
40 104
60 140
80 176
100 212
120 248
140 284
160 320
 ECM Memory

ECM Computer
Table # 1 Table # 2 Table # 3
Output

Table # 4 Table # 5 Table # 6

Feedback
Fuel Map VE Table from
O2 Sensor
Fuel trim values Spark timing

AFR
 Fuel Equation
The ECM takes all of the voltage inputs from the sensors
and uses that data along with the fuel map and other tables
programmed into its memory to come up with the proper
AFR needed for the engine to run in : Open - Loop

Fuel map+ VE table+ Look-up tables =

ECM
Calculations

AFR
 Summary

The accuracy of the of the equation programmed into the ECM

to deliver the proper air/fuel ratio and timing is determined by
how accurate the data is that it gets form its sensors.

Reliable information for the ECM to make decisions is critical for

proper engine operation. The goal is to get the proper air/fuel
ratio and timing for the engine to run efficiently at different
operating ranges. Start, Idle, Cruise, Power, De-accelerate.

As the engine runs…. It will constantly be running in and

out of open and closed loop operation.
 Why Tune ?

Tuning provides the opportunity for your bike to run its very
best under all riding conditions. Tuning calibrates the ECM and
balances out the look up tables so they are accurate.

Just a small difference in AFR and spark timing can dramatically

change the reaction in the combustion chamber , effecting how
the bike performs.
 Tuning

Q: I installed a Hi-flow air cleaner. Do I need to update the tune?

A: Closed-loop bikes will compensate for minor changes if you

give the system time to learn. ( 100 miles of riding )

It can be made to run better with tuning, but it is not necessary

to re-tune or update the fuel maps when adding a high –flow
air cleaner or a new exhaust system.

If you make tuning adjustments , it will be to the VE table ,

letting the engine know it is getting more air.
 Tuning

For reasonable performance and drivability the manufactured

spec of 14.7:1 A/F is extremely lean and this is the reason for
bikes to run very hot with poor drivability.

This condition gets even worse when you change your exhaust
or air cleaner.

Optimum AFR for cruise area is 13.4 - 13.6:1

Wide open throttle : 12.8 - 13.2:1

 Reasons for Tuning

1. Provide improved torque and horsepower

2. Improve throttle response
3. Improve fuel mileage
4. Adjust for little or no decel pop
5. Provide cooler running at idle speeds
 Major Tuning Variables

RPM – The engine RPM

MAP – The Manifold Absolute Pressure, in kPa

TPS – The throttle position in percent

Temperature – The engine temperature

 Tuning
When you make a change to add or subtract ignition timing, you
will normally see a corresponding change in power output.

One thing you will want to make sure you do is TURN OFF CLOSED
LOOP O2 when you are starting out tuning the bike.

This is because as you are trying to get a good base fuel map, you
will want to see the actual AFR value’s your map is producing.
 Modifications
When a bike is modified with an improved airflow filter and a
performance exhaust system , the fuel map needs to be modified
to compensate for the increased air getting into the engine.

Slip-on mufflers, conventional 2-2 and 2-1 exhaust systems all

allow more air into the engine by reducing the exhaust.
 Add on Fuel Modules
Are used to override the bike’s ECM and factory settings by
providing more fuel control to the engine. In effect,
en-riching the fuel mixture.

Commonly known as:

Post- fuel devices , Signal modifiers or Piggy –backs

Aftermarket performance upgrade that adds more fuel

* Power Commander by Dynojet

* Fuel Pak by Vance & Hines
 Add on Module

ECM Add on
module
Fuel output
signal

The add on fuel module is connected to the output of the ECM and
makes a change in the signal , adding more fuel to the engine.
 Power
Commander V

The Power Commander is a small, square-shaped device that

plugs inline into the motorcycle engine's electronic control unit.

The Power Commander comes with several factory-installed

"maps," which is a PC term for a program that tunes the engine to
run at a level that matches the bike's specifications.

In fact, all the owner has to do is remove the Power Commander

from the bike to restore its original engine settings.
Power Commander V
By Dynojet: With wideband O2 sensor and
Autotune
 Vance & Hines
Fuel/Pak
The Vance and Hines Fuelpak system is designed specially for
monitoring and managing the AFR on Harley-Davidsons.
 Module ECM
Replacement
The ThunderMax is the most common ECM replacement.

It can improve overall rideability and performance, with a

smoother & cooler running engine using a richer air/fuel ratio.

ThunderMax utilizes 18mm Bosch wide-band oxygen sensors and

requires compatible oxygen sensors bungs located in your exhaust
systems’ header pipes.

ThunderMax offers hundreds of different basemaps which have

been pre-dyno tuned and can be selected / loaded through the
TMax software.
 Thundermax
ECM Module
Programmed maps can be
downloaded from the internet

Replaces stock ECM Connects to a

laptop computer

Wide band
Data Port
Oxygen sensors
Thunder-max.com
 Tuners
A windows-based ECM reprogramming tool specifically for use
with 2001 and later Delphi-equipped Harley-Davidson
motorcycles that utilize the diagnostic interface. ( data port )

Tuners attach to the bike through the data port interface

on the bike and allow the user to view the ECM maps and
memory tables.

Changes to the TUNE can be made using the tuner.

Tuners are (married to the bike ) .. Meaning that each bike

has to have its own tuner device and they can’t be shared .
 Harley Davidson
Screaming Eagle Race Tuner

Connects to the bike vs. data port

connection then to a laptop computer
 TTS MasterTune
Tuning Device
A Windows-based ECM reprogramming tool specifically for use with 2001 and
later Delphi-equipped Harley-Davidson motorcycles that utilize the diagnostic
interface using a 4 or 6 pin port. The tuner is (married to the bike ).
 Power Vision Tuner
The Power Vision can tune any fuel injected Harley-Davidson
motorcycle with the Delphi ECM , including 2014 models.

The Power Vision Product Suite includes a full color touch screen
flash device, built in Autotune feature , vehicle interface cable,
and WinPV (Windows PC based tuning software).

6 pin data port

 Touch Screen Display

6 pin data port

Power Vision is the most powerful and quickest flash tuning

device for Harley-Davidson motorcycles in the market today.

It is a performance tuner and data monitor that offers the latest

flash tuning technology, data logging and other great features.

The power vision can be mounted to the bike for on the road
viewing of the gauges and other functions.
 Power Vision Tuner

The Power Vision incorporates a very sophisticated, yet

simple touch screen display that DOES NOT require the use of a
laptop computer to flash your bike .

Simply select the tune, follow the on-screen prompts to

download the tune, and if you’d like, edit your tune without ever
touching a computer. You can flash and make changes to your
TUNE without ever getting off your bike.
Power Vision Tuner
 Vance & Hines
Fuel/Pak 3 Wireless

Connecting wirelessly by Bluetooth to any iPhone or

Android Smartphone, Fuelpak FP3 uses Flash technology to
recalibrate engine parameters and mapping for exhaust
systems and other performance upgrade.
Downloaded from the expansive library of calibrations.

Also standard for the Fuelpak FP3 is an Autotune feature,

making use of all factory sensors to add another layer of
precision tuning for specific requirements .
 Vance & Hines
Fuelpak 3
With the Fuelpak FP3 module plugged-in, Live Sensor Data can
be viewed through the smartphone to display speed, RPM,
cylinder head temperature, voltage, gear selection and other
vital information.
Vance & Hines
Fuelpak 3
 Flashing a Tune
Flash tuning is a process of making ECM computer adjustments
to your bike. The process loads a new program into the ECM.

Several resources are available for tunes to be used that have

been tested and approved for use on your bike. Dyno tuning
is a professional way of getting a complete tune designed
specifically for your bike. Flash tuning using existing tunes
that match your bikes’ setup is the easiest way to go.

• From the tuner device itself … stored tunes

• From manufacturers of tuning devices off the internet
• From supply companies that sell tuner devices off the internet
 Auto Tune
Auto-tune is a programming feature that allows the user to
automatically calibrate (TUNE ) the bike while riding.
Narrowband and wideband oxygen sensors can be used to
monitor AFR. It’s basic application provides for some simple
tuning without using a dynamometer.

Sometimes referred to as reverse-engineering, the auto-tune

program makes changes to the VE table.

VE table is one of the main memory tables

used by the ECM in making calculations for
determining the required AFR .
 Auto Tune
During the AutoTune process, the program will make changes to the VE table,
making any corrections to the TUNE that are necessary to match the
target AFR with the actual AFR… An example of Reverse-Engineering .
 Auto Tune

Here is an example of the Autotune device developed by

Dynojet that utilizes wideband oxygen sensors.

Harley –Davidson uses a program

called: Smart -Tune
 AutoTune Modules
Power Vision can automatically fix the deviation between
the target AFR and actual AFR by adjusting the VE tables.
 Auto Tune
Reverse Engineering
The AutoTune program will use the data from the O2 sensor and target
fuel map to determine the new values needed for the VE table.

VE table corrections Target fuel map

New
Values

O2 Sensor
Readings
 VE Table
Basic Calibration
Set the entire AFR table to a constant value ( 13.5) and adjust the VE table
so that you get a measured AFR value of 13.5 out the tailpipe. Once this
calibration is complete, the Fuel Map can be changed as desired and the
ECM will calculate the correct targeted AFR using these calculations.
Re- Set all values to 13. 5
Adjust VE Table
Fuel Map
 Relationship

There is a complex relationship between what the sensors

report to the ECM and what the resultant fuel and timing are.
This relationship is controlled by hundreds of look-up tables
and settings built into the ECM calibration . “TUNE”
 Tuning Q and A

Q: When do you need to clear trim values ?

A: When a TUNE is flashed into a bike, trim tables need to

be cleared from the ECM so they do not influence the new
calibration.

The goal is to get the TUNE very close to the optimum values
(target vs. actual a/f ratio ) so very little trim is needed.

Tuning programs usually clear the trim tables every time a

calibration is flashed into the bike.
 Tuning Q and A

Q: How do I decide which TUNE is best for my bike?

Can I swap TUNES from other bikes ?

A: As a starting point, select the TUNE that best matches the

components on your bike. Many tune calibrations can be
downloaded from the dealer or manufacturer on the internet.

Most of the Twincam TUNE calibrations can be swapped around

without too much trouble.
 Tuning Q and A

Q: I flashed a TUNE calibration but still have exhaust “popping”

during de-acceleration .

A: Exhaust popping is caused by too rich or too lean a mixture.

If the popping happens immediately after the throttle is closed,
adjust the “Decel Enleanment” table to increase or decrease
the AFR ratio. Generally the AFR ratio needs to be richer.

If the problem lasts for a longer period of time, try changing the
AFR table 4 to 10 percent richer in the region on the fuel map
where the popping occurs.
 Tuning Q and A

Q: When knock retard occurs, how long is it active?

A: When knock is first detected, the timing is immediately

retarded up to 5 degrees .

The ECM decays the retard back to zero over a 10 to 20 second

period (assuming there is no additional knock detected).
 Tuning Q and A

Q: Does the fuel I’m running make any difference to my tune?

A: Yes, changes in the fuel quality will change the tune.

For best results, always tune with fresh fuel .

Most bikes will run on E 10… 10 % alcohol 90 % gas

Best to run: Unleaded 92 % or better octane

Octane : A value that describes the burn rate of the fuel.

Higher octane fuels burn with a slower flame front in the cylinder.
Helps to eliminate pinging.
 Oxygen Sensor
Eliminator Plugs

The oxygen sensor eliminator plugs are used to mimic the output
signal that will replace the original O2 sensor’s signal to the
ECM when rich a/f ratios are being used outside the sensor’s range.

They are used in off road and racing vehicles to prevent the check
engine light from coming on.
 O2 Wideband
Sensor Bung
This is an 18 mm bung that is welded into the exhaust pipe ,
allowing a wideband sensor to be installed. A normal
narrowband sensor is installed into an opening of 12mm.
 O2 Sensor Bungs

12 mm

O2 Sensor Bungs need to be welded in place

18 mm

12 to 18 mm O2 sensor adapter
Can be used to insert a wideband
sensor into a 12 mm slot designed for
a narrowband.
Wideband AFR gauge

Reads 10 – 18 :1 AFR
 Sniffers
Sniffers are devices placed into the exhaust system during a
tuning session. Exhaust gas analyzers are able to measure the
actual AFR at the tailpipe.
 Sniffer
Homemade sniffer
Sniffer

Innovate product
 O2 Sensor Plugs
Used to plug an 18 mm hole in the exhaust pipe.
 Special O2 Sensor
Socket Wrench

Used to remove and

install an O2 sensor
 IED Devices
Inline Enrichment Devices

Devices only work in closed –loop mode.

O2 sensor Inline Enrichment Device (IED) for 2007 and later

Harley-Davidson motorcycles with OEM narrow band O2
sensors richens the fuel mixture from 14.7 to 13.8
 IED Devices

By slightly richening the mixture, the engine and exhaust

temperatures are lowered. The IED's will work on Twin Cam,
Sportster and V-Rod engines.

Simple plug-n-play upgrades are inexpensive and can be

installed in under 15 minutes. They are the quickest and
easiest way to reduce engine heat compared to other
tuning choices.
 IED Devices

What they will do is alter the signal from the O2 sensors that
fools the ECU into thinking it is running leaner than it really is,
so it provides more fuel , enriching the AFR.

Purchased through Nightrider.com

O2 IED at 14.2:1 AFR

X14IED at 14.0:1 AFR
XIED at 13.8:1 AFR
 IED Devices
This is a reasonable option if you plan on keeping the bike
stock, or a muffler change only, but if anything else is done
(air cleaner , etc.)

It is suggested that you buy a real tuner that will provide

optimal performance throughout the RPM range.
 Dyno Tuning

Dyno tuning provides a professional

tune designed for each individual bike.

This tuning process may take

several hours to complete.

Horsepower, torque and engine

parameters are closely monitored using
a tuning program and a computer.
Tuning Shop
Tuning Shop
 Evolution Engines
Single Cam

The Evolution engine (popularly known as Evo) is an air cooled 45-

degree, V- twin manufactured from 1984 .

It was made in the 1,340 cc (82 cu in) displacement for Harley

Davidson Big V-twins bikes, replacing the Shovelhead engine
until 2000 when the last EVO was manufactured.

In 2001, it was replaced by the Harley-Davidson Twin Cam 88.

 Evolution Engine
EVO

Single Cam Drive

82 Cu. In.
1340 cc
EVO Engines
 Twin Cam Engine

Two sets of camshafts

 Twin Cam engines

Twin Cam 88 1999 88 cu. In. 1449 cc.

Twin Cam 96 2007 96 cu. In. 1584 cc.

Twin Cam 96A,B Balanced engines used on softail

bikes to eliminate vibration

Twin Cam 103 2012 103 cu. In. 1690 cc.

Twin Cam 110 110 cu. In. 1803 cc.

Twin Cam Engines
 Diagnostic Codes

Diagnostic codes provide insight to specific problems when

troubleshooting an engine.

Refer to your manual on how to retrieve diagnostic codes

from your bike using the odometer display.

Or you can use diagnostic code readers that plug into the data
port on the bike. The code readers are able to list the trouble
codes and also have the ability to clear the codes.
 Diagnostic Codes

TTS MasterTune and SERT devices used to tune your bike

can also be used as code readers.

These tuning devices are married to the bike when tuning and
flashing updated maps. However, they can be used freely
from one bike to another when reading diagnostic codes.
_Resources and Credits
Harley-Davidson
3700 W. Juneau Avenue
Milwaukee, WI 53208
Phone: 1-800-258-2464
Website: harley-davidson.com
Kuryakyn parts and accessories
454 County Road
Somerset, WI 54025 USA
Phone: 1- 866-277-9598
Website: kuryakyn.com
Nightrider performance parts
PO Box 2157
855 Dunbar Ave Unit C
Oldsmar, FL. 34677-7157
Phone: 1-313-444-9433
Website: nightrider.com
J&P Cycle parts and accessories
13225 Circle Drive
Anamosa, IA 52205
Phone: 1-800-318-4823
Website: www.jpcycles.com
Vance and Hines
13861 Rosecrans Ave.
Santa Fe Springs, CA 90670
Phone: 1-562- 921-7461
Website: www.vanceandhines.com
Dynojet Research, Inc.
2191 Mendenhall Drive
North Las Vegas, Nevada 89081
Phone: 800-992-4993
Website: www.dynojet.com