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Performance Electronic Fuel Injection

by Luuezz on 2010-04-28 20:36:40


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 Made Simple



 

Performance Electronic Fuel Injection Made Simple


Installing The New Thunder Max With Auto Tune On H-D Motorcycles With Throttle By Wire
Text and Photos by Rogue


Zippers Banner

bike
 
                                        The master's motorcycle.

This install was handled on a 2009 Harley FLHTC Electra Glide Classic with 3837 miles on the clock. This bike is owned by master technician and Sturgis Hall Of Fame member, Rogue. I've known him almost 40 years, so I can testify that he knows what he's talking about. I'll let Rogue take it away:

Bandit

 
tool
 
 

                                   An official 02 sensor socket tool.

 

Read The Instructions
Before You Attempt The Install
and Follow Them Closely
 

crow
 
 

                       Only Master mechanics have tools like this one.

 

crowworking

It is an easy procedure and can be done with basic hand tools. An O2 Sensor socket or crow foot will make the job even easier. You will also need access to a computer preferably a lap top.

cd

Start by inserting the supplied CD into your computer. Follow the instructions and install the software.

fuze

fuze2

Remove the seat and both side covers. The fuse panel is located on the left hand side and the cover is removed by pushing up on it. Remove the Engine Control Module (ECM) fuse. The fuse is easily identified by the image on the cover.

o2

Remove the stock narrow band sensor from the exhaust pipe. On the 2008-2009 models they are located at the top of the exhaust pipe near where it joins the engine. If they have been in for awhile you can add a few drops of throttle body choke and carb cleaner to loosen them up.

o2new

02hole

02inplace

Install the supplied wide band sensors into the pipes and route the front wires across the brace in front of the engine and along the lower frame rail on the right side of the motorcycle.

rear02sensorcable

 

                  Here's the rear 02 sensor cable connector in place.

 

                            rear02sensorcable2

rear02sensorcable3

 

Basically unplug the stock sensor and plug in the Zipper's 02 sensor connector.

 

rear02sensorcable5

rear02sensorcable4

Route the rear lead between the transmission top cover and the starter then towards the ABS caddy.

removing old one

 

                                   Removing the factory ECM.

Remove the factory ECM by spreading the plastic latches that secure it and lift up and to the right to release it. To release the wiring from the ECM press the release button and move the locking bar to the full rearward position. Care must be taken to make sure the bar is in the full rearward position and then remove the connector from the ECM.

Eficonnector

 

                                    Note the gray locking slider.

 

Eficonnector2

With the factory ECM removed, continue routing the wires from the Thunder Max through the opening on the right side of the frame below the down tube and towards the ECM holder.

Eficonnector3

If the motorcycle has a factory alarm as mine did simply detach the alarm antenna from the clip and slide it out of the way Do Not Disconnect.

ECM

Insert the Auto Tune harness into the Thunder Max with the logo facing up and secure with the two screws.

Make sure that the gasket is seated all the way in the connector, make sure the locking bar is all the way open and then install to the Thunder Max

Important: You must be sure every thing slides into place smoothly and that it is all the way in before engaging the locking bar.

Replace the Thunder Max into the exact same factory position.

Connect the oxygen sensor harnesses to the Auto Tune Harness. Make sure that all the wires are clear and away from hot and moving parts. Secure the harnesses with wire ties.

Re-install the ECM fuse. It is a good idea to lubricate it and all the other fuses with dielectric grease

That is how easy it is to install the new ECM.

Now back to the computer. Follow the instructions that come with the kit they are step by step and easy to follow.

You will end up down loading a base map. Which map you use will be determined by what if anything you have done to your engine. The program will give you options just pick the one that is closest to what you have.

Once you have selected all the information that applies to you, you hook up the computer to the module with the supplied cable and send the information to your new ThunderMax ECM.

finishedbike

IMPORTANT STEP BEFORE STARTING MOTORCYCLE

This is required for a new module install or when interruption of 12 volt power takes place. Turn the ignition switch on and the handlebar switch to run for at least 20 seconds. Then cycle the ignition switch off and on and start the engine.

Let the motorcycle idle on its own for at least 15 seconds. Turn off the ignition and then restart the motorcycle. Normal idle speed should be attained depending on engine temperature. The warm up cycle will have slightly higher idle speed than a warm engine and will go lower as the engine warms up.

I went for a ride and going up the ramp on to the interstate I grabbed a hand full and the motorcycle accelerated quickly. Just to see what the rev-limiter was set at I hit slightly over 6000 RPM. As I shifted gears I was quickly over the speed limit and still had two more gears to go.

I do not remember ever changing a part that was so easy to install and made such a difference in performance as the Thunder Max did.

 
Here's the New ThunderMax with AutoTune Specs:

ThunderMax with AutoTune is the industry’s first and only stand-alone Performance EFI Engine Management System. Developed specifically to meet the tuning needs of Throttle-By-Wire H-D motorcycle owners, this highly advanced tuning system allows the user to support a wide range of performance upgrades with ease.

The all new ThunderMax AutoTune TBW module includes all of the great performance enhancements that made the brand famous ��" with benefits you’ll notice immediately, including quicker throttle response, increased power and cooler operating temperatures.

Improve the performance and fuel mileage of your H-D motorcycle without compromising over-all power output! Make adjustments to your EFI system without a master’s degree in electronics and computers!

The ThunderMax EFI System is purpose-built to deliver uncompromising performance, and you don’t have to be a rocket scientist to install it, program it or make adjustments. The ThunderMax with AutoTune is a Wide-Band, Closed-Loop system which means it continually and automatically adjusts your air-fuel ratios every time you ride, regardless of changes in ambient conditions. All you have to do is ride and enjoy!

The ThunderMax System can never be out grown... Change pipes, add cams, whatever! Just download a new map. ThunderMax software, firmware and map updates are accessible 24/7 with an internet connection.

The ThunderMax with AutoTune is made in the USA and backed by a 3-year warranty.

System Features:
Dyno Developed Base Maps
Adjustable Rev Limit and Idle Speed
Enhanced Throttle Blade Control
On-Board Diagnostics
Easy-to-Use TMax Tuner Software

Click here for Zippers Info

For more information or to purchase one contact Zippers Performance Products. 6655-A Amberton Drive, Elkridge, MD 21705 410-579-2828 and on the internet www.Thunder-Max.com

--ROGUE