2005-2007 Polaris Sportsman 800 - Power Commander · i912-411 2005-2007 Polaris Sportsman 800 PCIII USB - 3 7 Route the white connectors from the PCIII down the right hand side of

i912-411 www.powercommander.com 2005-2007 Polaris Sportsman 800 PCIII USB - 1

2005-2007 Polaris Sportsman 800Installation Instructions

Dynojet Research 2191 Mendenhall Drive North Las Vegas, NV 89081 (800) 992-4993 www.powercommander.com

Parts List1 Power Commander1 USB Cable1 CD-ROM1 Installation Guide1 Power Adapter2 Power Commander Decals2 Dynojet Decals2 Velcro® Strip1 Alcohol Swab2 Zip ties

You can also download the PowerCommander software and latest mapsfrom our web site at:

www.powercommander.com

The ignition MUST be turnedOFF before installation!

PLEASE READ ALL DIRECTIONS BEFORE STARTING INSTALLATION

Button Adjustment Display

Faceplate Buttons

Expansion Port USB Port

1 Remove the grey side panesl fromeach side of the ATV.

2 Prop the front rack open.

3 Remove both access covers shown inFig. A.

5 Locate the stock Throttle PositionConnector on the right hand side ofthe throttle bodies. This is a white 3pin connector (Fig. C).

6 Unplug this connector.

i912-411 www.powercommander.com 2005-2007 Polaris Sportsman 800 PCIII USB - 2

4 Install the PCIII to the side of theECU (Fig. B).

Use the supplied velcro to mount thePCIII. Make sure to use the suppliedalcohol swab to clean both surfaces.

It is important to keep the PCIIItowards the bottom side of the ECUto allow clearance for the cover to bereinstalled. Mount the PCIII with thewiring harness routing towards thebottom.

Fig.

AFi

g. B

Fig.

C

TPS connector

Remove these covers

9 Locate the stock #2 injector harnesson the right hand side of the ATV.This connector is located in the rightwheel well of the ATV. This may belocated by following the wiring har-ness back from the injector until youfind the connector shown in Fig. E.

10 Unplug this connector.

11 Plug the YELLOW colored wiresfrom the PCIII in-line of the stockwiring harness (Fig. F).

Fig.

EFi

g. F

i912-411 www.powercommander.com 2005-2007 Polaris Sportsman 800 PCIII USB - 3

7 Route the white connectors from thePCIII down the right hand side of theATV and plug them in-line of thestock TPS connector (Fig. D).

8 Use one of the supplied zip ties tohold the PCIII harness to the frame.

Fig.

DStock connectors

Unplug this connector

Stock connectorsPCIII connectors

PCIII connectors

12 On the left hand side of the ATVremove the two bolts that hold thecoil bracket to the frame (Fig. G).

To access the bolt on the left you willneed to pull the spark plug wires fromthe coils.

Removing the coil bracket will allowyou access to the #1 injector harness.Fi

g. G

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Remove these bolts

12 Locate the stock #1 injector harnesson the left hand side of the ATV. Thismay be located by following thewiring harness back from the injectoruntil you find the connector shown inFig. H.

13 Unplug this connector.

Fig.

H

Unplug this connector

14 Plug the ORANGE colored wiresfrom the PCIII in-line of the stockwiring harness (Fig. J).

15 Reinstall the coil bracket.

Fig.

J

Stock connectors

PCIII connectors

16 Attach the ground wire to frame boltshown in Fig. K. This bolt in locatedunder the access panel in the frontstorage compartment.

It is recommended to scuff the paintof the frame where the wire contactsthe frame. Make sure to install thebolt through the plastic bracket first,then the PCIII ground wire.

17 Reinstall the body panels.

Fig.

K

i912-411 www.powercommander.com 2005-2007 Polaris Sportsman 800 PCIII USB - 5

Ground wire from PCIII

Radiator cap