Pro-Tec Power Valve Controller Settings and Wiring Diagram

INSTALLATION INSTRUCTIONS

PART # 14-5100

Pro-Tec Power Valve Controller - 1200R / LTD / XLT

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NOTE: READ INSTRUCTIONS COMPLETELY BEFORE STARTING

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Important: This item has no warranty. It has been thoroughly tested for proper function by Pro-Tec before packaging.

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Prior to any work, please remove seat to allow adequate ventilation of fumes. Disconnect battery.

1.      Remove power valve servo motor.

2.      Cut center of wire loom (between servo motor and connector).

3.      Strip wire loom wires 3/8” and insert into connector barrels and crimp barrels onto wires. Note: Do not crimp through outer cover.

4.      Insert power valve controller wires into opposite ends of the connector barrels. Black to black, red to red and gray to gray. Crimp barrels onto wires. Note: Wires with black shrink tubing should be installed in wire loom point toward servo motor and wires with red shrink tubing point toward the power source. Important: If wires are installed in reverse power valve damage and/or failure will occur.

5.      Heat connector barrels until tubing recovers and adhesive begins to flow.

6.      Remove heat from connector barrel and allow to cool completely before continuing.

7.      Double check all connector barrels for solid connection and proper direction of power valve controller wires.

8.      Reinstall servo motor.

9.      Reconnect battery.

Important Note

The power valve controller can be reset by disconnecting the battery, waiting 30 seconds, then reconnecting the battery.

Erratic Power Valve Operation

 Yamaha has reported that there is the possibility of having the power valve operate erratically, sometimes cycling on its own.

System Description:

The power valve system is controlled by a chip in the servo motor. The servo motor receives a signal from the CDI unit much like a tachometer signal. The processor in the servo motor reads this signal, then operates the power valve based on the MAP stored in its controlling chip. Note: This signal is adjusted by the Pro-Tec Power Valve Controller before being received by the servo motor. The servo motor has constant power and operates based on engine RPM. After the engine stops, a timer starts in the servo motor processor. After a few seconds, the processor will cycle the power valve for its cleaning cycle.

Cause:

The block connector for the servo motor may have corrosion present. With corrosion in the connector, voltage can short from the battery side to the signal side simulating an ignition signal. This will restart the “Engine Off” timer, and the servo motor will again start a cleaning cycle. Corrosion may also cause loss of the signal from the CDI unit during normal operation, causing the servo motor to operate erratically or not at all.

Remedy:

Clean the servo motor connections. Use dielectric grease to protect the connection when reassembling.