PowerTRONIC Installation Manual- Hero Xpulse 200 (2019-2020) 

 
 
 
Document Version  1  Release Date  14 Nov 2019 
 
 
 
Application information  Vehicle Specific 

Vehicle  Hero 

Model  Xpulse 200 

Year of manufacture  2019-2020 

PowerTRONIC application  All PowerTRONIC ECUs, from firmware version F.3.x onward 
 
 
Note: 
 
● Read through all instructions before installation and use. 
● Ensure that the bike is switched off and the key is out of the ignition before proceeding with the 
installation. 
● Some parts of the bikes might be hot/sharp and may cause burns/cuts. Proceed with extreme 
caution or wait until the bike has cooled down. Always wear safety gloves.  
● When the installation is complete, make sure to secure the wiring loom away from the movable parts 
or components which tends to heat up during the normal operation of the vehicle at any chance.  
● PowerTRONIC is intended for motorsport use on a closed course, please check with your local laws 
before using this product. Race Dynamics / PowerTRONIC is not liable for consequences arising out 
of using the product. 

 
Call/Whatsapp:  +919916229292 / +918040929292  
E-Mail:  support@powertronicECU.com  
Official Website:  www.powertronicECU.com 
Social:  www.facebook.com/PowertronicECU/  
www.instagram.com/powertronic_ecu/  
   

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Table of Contents 
1. Parts list 
2. Tools required 
3. Installation procedure 
​ emoving panels, fairing etc 
3.1​ R
3.2 Routing the harness   
3.3 Fuel Injector Connector 
3.4 Ignition coil connector 
3.5 Crank position sensor connector 
3.6 Throttle position sensor tapping 
  3.7 Ground terminal 
3.8 Securing the routed harness 
3.9 Testing with Stock Coupler 
3.10 Plugging in the PowerTRONIC 
3.11 Attaching the panels, fairing etc 
  
1. Parts list 
1  PowerTRONIC    Piggyback ECU 
2  Stock Coupler  Stand by unit 
● Can be connected in place of the PowerTRONIC to run the bike in stock 
mode if need be. 
● Used for the verification of the connectors involved. 

3  Harness  Bike specific harness contains the following connectors 

● Fuel injector connector 
● Spark connector 
● Throttle position sensor tapping wire (TPS) 
● Crankshaft position sensor connector (CKP) 
● Map selection connector 
● Quick shifter connector 
● Ground terminal 
4  USB cable  Can be used to connect the PowerTRONIC to a laptop for throttle calibration or 
changing maps 
5  Nylon Tags  To secure wiring harness 
6  User guide and Warranty card  Instructions 
  
2. Tools required 
Serial No  Item with description 
1  M12 Hexagonal socket 
2  Phillips-Head screwdriver 
3  M12 T bar Hexagonal Socket wrench 
4  Wire stripper 
5  Nose plier 

2
 
3. Installation procedure 
3.1 Removing panels, fairing 
Begin at the left side of the bike. 
 
Park the bike using the centre stand on a level surface (Or a paddock stand).  

 
​ Image 1 
 
 
 
 
 
 
 

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3.1.1​ Locate the rider seat lock shown in I​ mage 2​ a
​ nd unlock the rider seat. Refer​ Image 3​.  

Image 2 

Image 3 

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3.1.2​ ​Image 4​ shows how the how the rider seat detached.   

Image 4 
 
3.1.3​ ​Locate and unscrew the side screw using a Phillips-head screwdriver. Refer ​Image 5​. 

Image 5 

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3.1.4​ L
​ ocate and unscrew the side screw using a Phillips Head screwdriver​. R
​ efer ​Image 6​. 

Image 6 

3.1.5​ ​ L
​ ocate and unscrew the side screw using a Phillips Head screwdriver​.​ Refer the ​Image 7 

Image 7 

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3.1.6​ After removing the screw and the bolt from side panel, gently detach the panel. Repeat the process on the other side 
also. Refer the I​ mage 8  

Image 8 

3.1.7​ Locate and unscrew the tank rear bolt using M12 Hexagonal socket. Refer I​ mage 9​. 

Image 9 

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3.1.8​ Detach the fuel line carefully. Refer i​ mage 10 

Image 10 

3.1.9​ Detach the fuel pump connector carefully. Refer ​Image 11. 

Image 11 

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3.1.10​ Detach the vacuum hoses carefully. Refer I​ mage 12 

Image 12 

3.1.11​ After disconnecting all the connections from the tank, lift the tank gently and carefully place it safe..  

     

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 3
​ .2 Routing the harness 

3.2.1​ Start from the rear end and route each connector to the front. Refer I​ mage 13​. 

Image 13 

3.2.2​ Starting from the glove compartment, route each connector terminal between the welded plate and the mud guard. 
Refer I​ mage 14​ and I​ mage 15​. 

  

Image 14 

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Image 15 

3.2.3​ Refer the completed view. Refer ​Image 16​. 

  

Image 16 

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3.2.4​ Refer the completed view. Refer ​Image 17. 

  

Image 17 

   

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 3.3 Fuel Injector Connector 
3.3.1​ Locate the injector connector. Refer I​ mages 18 

Image 18   

3.3.2 ​Identify the fuel injector connector in the PowerTRONIC wiring harness. The connectors are labeled 'INJ' 

3.3.3​ Disconnect the injector connector on your bike. Refer the zoomed view (​Image 19​) 

Image 19 

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3.3.4​ Connect the female PowerTRONIC injector connector to the stock male injector connector. Refer I​ mage 20   

Image 20 

3.3.5​ Connect the stock female injector connector to the PowerTRONIC male injector connector. Refer I​ mage 21  

.  

Image 21 

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 3.4 Ignition Coil Connector 
3.4.1​ Locate the Ignition coil. Refer ​Images 22​ and I​ mage 23  

Image 22 

Image 23 

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3.4.2​ Identify the Spark/Ignition coil connector in the PowerTRONIC wiring harness. The connectors are labelled 'SPK'. 

3.4.3​ Disconnect the stock ignition coil 12 V connector pins. Refer I​ mage 24 

Image 24 

3.4.4​ Connect the PowerTRONIC Ignition coil 12 V female pins to the stock ignition coil mating pins on the coil. Refer 
Image 25. 

Image 25 

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3.4.5​ Connect the PowerTRONIC Ignition coil 12 V male pins to the stock ignition coil female pins on the coil. Refer ​Image 
26 

Image 26 

3.4.6​ Disconnect the stock ignition coil signal connector pins. Refer I​ mage 27 

Image 27 

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3.4.7​ Connect the PowerTRONIC Ignition coil signal male pins to the stock ignition coil mating female pins. Refer ​Image 
28  

Image 28 

3.4.8​ Connect the PowerTRONIC Ignition coil signal female pins to the stock ignition coil mating male pins. Refer ​Image 
29  

Image 29 

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 3.5 Crankshaft position sensor connector 
3.5.1​ Locate the CKP connector of your bike. Refer I​ mage 30​ and I​ mage 31 

Image 31 

3.5.2​ Identify the Throttle Position sensor connector in the PowerTRONIC wiring harness, labeled as 'CKP' 

3.5.3​ Disconnect the stock CKP connectors. Refer ​Image 32​. 

Image 32 

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3.5.4​ Connect Stock male CKP a connector and PowerTRONIC female connector. Refer I​ mage 33​. 

Image 33 

3.5.5 ​ Connect Stock female CKP connector and PowerTRONIC male connector. Refer I​ mage 34​. 

Image 34 

   

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 3.6 Throttle position sensor connector 
3.6.1​ Locate the TPS connector of your bike. It is generally located on the throttle body, parallel to the throttle cable return 
springs. Refer I​ mage 35.  

Image 35 

3.6.2​ Identify the Throttle Position sensor connector in the PowerTRONIC wiring harness, labeled as 'TPS' 

3.6.3​ Tap theBlack-Green stripe wire using the tapping clip provided. Refer ​Image 36​ and ​Image 37. 

Image 36 

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Image 37 

3.6.4​ We advise you to perform a TPS calibration after the installation of PowerTronic ECU.  
Refer the detailed TPS calibration document. 

   

22
 3.7 Ground Terminal Connector 
3.7.1​ Identify the Ground terminal connector labelled as GND and connect it to the negative terminal of the battery.  
Refer I​ mage 38 

 
Image 38 

   

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 3.8 Securing the harness using ties 
3.8.1​ ​Secure the harness away from general heating areas by attaching it to the chassis or frame using the zip 
ties provided wherever necessary. Refer I​ mage 39 

Image 39 

Important note:​ The PowerTRONIC harness contains Quick shifter connector. If you have bought the Quickshifter please 
attach the connector to it. [Please refer Quick shifter installation manual] 

If you have not bought the Quickshifter, you can leave it disconnected but make sure the harness is secured using zip ties 
provided. 

   

 
   

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 3.9 Testing with the stock coupler  
3.9.1​ Attach the fuel tank. 
3.9.2​ You can verify the connections by attaching the stock coupler. Refer detailed Stock coupler test 
document. Refer ​Image 40 

 
Image 40 
3.9.3 DO NOT proceed with PowerTRONIC ECU without verifying the connections with stock coupler. 

 
   

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 3.10 Plugging in the PowerTRONIC 
Connect the PowerTRONIc to the harness by connecting the 24 pin connector. Secure it in the glove box. Refer 
Image 41    

    
Image 41   
 
3.11 Attaching the panels fairing etc 
Attach the panels, fairing as removed from the bike. 

 
 

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