Thunder Heart EA4250D Owner's Manual

Owner’s Manual

Electronic Harness Controller
P/N EA4250D

Thunder Heart Performance Corporation MANUAL P/N EI4250

120 Industrial Drive Revision 5/26/11
White House, TN 37188
www.thunder-heart.com

TABLE OF CONTENTS

CHAPTER 1 INTRODUCTION ...............................................1

1.1 General Information....................................................................1

1.2 Special Tools Required ..............................................................2

1.3 Connector Assembly ..................................................................4

1.4 EHC Component Overview ........................................................5

CHAPTER 2 SYSTEM INSTALLATION.................................6

2.1 Finding a Suitable Location for the Electronic Harness Control

Module.................................................................................................6

2.2 Trial Fitment of the Harness to the Bike.....................................7

2.3 H-D 1996-2003 Hand Control Connections ...............................8

2.4 Rear Lighting Options.................................................................9

2.5 Harness Assembly .....................................................................9

CHAPTER 3 INDICATORS AND INSTRUMENTATION ......10

CHAPTER 4 OPERATION....................................................11

4.1 Diagnostics...............................................................................11

4.2 Turn Signals .............................................................................11

APPENDIX A FREQUENTLY ASKED QUESTIONS ........... 11

APPENDIX B OPTIONAL AND REPLACEMENT PARTS... 12

APPENDIX C TROUBLESHOOTING...................................12

APPENDIX D WIRING TABLES AND DIAGRAMS .............13

CONTACTING THUNDER HEART PERFORMANCE CORP.

Mailing Address................................120 Industrial Drive

White House, TN 37188

Shipping Address .............................120 Industrial Drive

White House, TN 37188

Phone ...............................................615-672-8811

Fax....................................................615-672-1353

Tech Support [e-mail]

Website.............................................www.thunder-heart.com

Thunder Heart Performance Corp. 615-672-8811 www.thunder-heart.com

CHAPTER 1 INTRODUCTION

1.1 General Information

The Electronic Harness Controller consolidates all of the electronic functions
of a motorcycle (with the exception of instrumentation and engine
management) into one, easy-to-hide system. The Electronic Harness
Controller avoids the wiring “bird’s nest” of other systems so you spend less
time wiring your bike…and more time riding!

Perfect for split t ank bikes, the Electr onic Harness Controller system includes
a self-diagnostic electronic harness controller, un-terminated “fantail”
harness, shrink tubing, and all necessary connectors, a comprehensive
instruction and troubleshooting manual for a durable, professional
installation.

The information inc luded in this m anual is inten ded to pr ovide a guideli ne for
installing the Electronic Harness Controller system on your motorcycle.
However, each m otorcycle is different. Due to the “ universal” nature of this
system, a certain level of technical skill is required to assure a complete,
trouble-free installation.

Please read through this entire manual before attempting any part of the
installation. If you are uncomfortable with the level of skill required to
complete the installation of this system, either contact a Thunder Heart
Performance technical specialist, or hire a professional to complete the install
for you.

Note: The EA4250C and EA425 0D differ in the function of the turn signals w hen

the brakes are applied. The EA4250C flashes the turn signals three times
prior to keeping them illuminated for 30 seconds, or until the brakes are
released (whichever comes first). It can only be installed on bikes with a
center taillight. The EA4250D does not flash the turn signals when the brakes
are applied. It can be installed on bikes with and without a center taillight.

EI4250

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1.2 Special Tools Required

Most of the installation of the Micro Harness Controller can be completed
with basic hand tools. However, a few special tools make the job much
easier:

x A heat gun (such as the unit s ho wn in F igure 1) is re quired to s hrink

the heat shrink tubing o nto the harness. The heat gu n makes quick
work of shrink ing the tubing, as it provi des a broad, even so urce of
heat. No other means of shrinking the tubing is recommended.

Figure 1 – Heat Gun

x A good-quality wire-crimping tool is also required. The “W” style

(shown in Figure 2) is available at www.digikey.com
number WM9999-ND).

x The AMP style (shown in Figure 3), while considerably more

expensive, will produce better results. The AMP style is
recommended if you plan on wiring many bikes using the AMP
connectors included with the Electronic Harness Controller system.

(Digikey part

Figure 2—“W” crimping tool

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Thunder Heart Performance Corp. 615-672-8811 www.thunder-heart.com

Figure 3—“AMP” crimping tool

x A multi-meter is useful for diagnosis. A common “test light” is OK,

but a test light will not tell you if you have a short to ground, or a
resistance problem. In other words, a pinched wire may provide
enough current for the test light, but not enough to power the horn,
ignition, etc. A multi-meter allows you to check current, and you can
check the suspect circuit for any grounding issues.

Figure 4—Multi-Meter; useful for circuit diagnosis

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