EFI Basics

EFI Basics
Electronic Fuel Injection
KbrWebworks Educational Resources
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
Richer mixture
12 : 1
Shorter pulse width = Less fuel
Leaner mixture
15 : 1
Air/ Fuel mixtures
Too Rich
Rich mixture
More fuel less air
Lean mixture
More air less fuel
Rich
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
14.7
O2
Sensor
O2 Output Voltage
14.3
Rich side
1 volt
14.7
15.2
450 mv.
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
The ECM receives voltage
signals from the different
sensors located on the bike
Output
Signal
The ECM makes calculations
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
Fuel map AFR table
Volumetric Efficiency table
Accelerator enrichment table
Power enrichment table
Deceleration en-leanment table
Stored in the ECM
flash memory
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
Degrees F
284 320
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
Degrees F
248
284
320
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
40
60
80
100
120
140
160
68
104
140
176
212
248
284
320
ECM Memory
ECM Computer
Table # 1
Table # 2
Table # 3
Table # 4
Table # 5
Table # 6
Fuel Map
Fuel trim values
VE Table
Output
Feedback
from
O2 Sensor
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
Wide open throttle :
13.4 - 13.6:1
12.8 - 13.2:1
Reasons for Tuning
1. Provide improved torque and horsepower
2.
3.
4.
5.
Improve throttle response
Improve fuel mileage
Adjust for little or no decel pop
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.
www.vanceandhines.com
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
Wide band
Oxygen sensors
Connects to a
laptop computer
Data Port
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 ).
www.mastertune.com
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
Fuel Map
Adjust VE Table
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 45degree, 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.
KbrWebworks Educational Resources
Harleytune.com
_Resources and Credits
Harley-Davidson
3700 W. Juneau Avenue
Milwaukee, WI 53208
Phone: 1-800-258-2464
Website: harley-davidson.com
J&P Cycle parts and accessories
13225 Circle Drive
Anamosa, IA 52205
Phone: 1-800-318-4823
Website: www.jpcycles.com
Kuryakyn parts and accessories
454 County Road
Somerset, WI 54025 USA
Phone: 1- 866-277-9598
Website: kuryakyn.com
Vance and Hines
13861 Rosecrans Ave.
Santa Fe Springs, CA 90670
Phone: 1-562- 921-7461
Website: www.vanceandhines.com
Nightrider performance parts
PO Box 2157
855 Dunbar Ave Unit C
Oldsmar, FL. 34677-7157
Phone: 1-313-444-9433
Website: nightrider.com
Dynojet Research, Inc.
2191 Mendenhall Drive
North Las Vegas, Nevada 89081
Phone: 800-992-4993
Website: www.dynojet.com

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