ThunderMax ARB EO K-001 User Manual

# 309-375 for Cable Big Twin Models

Thank you for purchasing a ThunderMax 50 ECM!

Please read through the following instructions before
beginning the installation procedure. Following these
instructions will ensure that the ECM is installed and
setup properly for optimal results. If you have any
problems or questions, please refer to the SmartLink
Tuning .pdf Manual, included on the CD (Help Menu)
with this package.

Step 1 Affix the
Executive Order Label.
Enclosed in this
package are (3) labels
with the approved Air
Research Board
Executive Order
identification number.
This label must be
affixed to the module in
the machined pocket
found on the face of the
ThunderMax 50 ECM
(see photo). You must

attach the correct
label for your bike’s model year:

2008 – E.O. # K-001
2009 – E.O. # K-001-1
2010 – E.O. # K-001-2

Step 2 Insert the SmartLink

CD into your computer.
SmartLink will automatically
open the InstallShield
Wizard when the computer
finds the CD-Rom. Follow
the instructions and install
the software on your
computer. If you do not
have a serial port on your computer for the
communication cable, you will need to use a USB to
Serial converter (an inexpensive converter is available
from Zipper’s, # 372-000). Install the included driver disc
at this time; follow the instructions given by the
manufacturer of the converter for installation.

Installation / Setup Guide

This product is Legal in California for use on:

2008 Softail® Models w/96”Engine ARB EO # K-001
2009 Softail® Models w/96”Engine ARB EO # K-001-1
2010 Softail® Models w/96”Engine ARB EO # K-001-2
2008 Dyna® Models* w/96”Engine ARB EO # K-001
2009 Dyna® Models* w/96”Engine ARB EO # K-001-1
2010 Dyna® Models* w/96”Engine ARB EO # K-001-2
* Except Dyna® Fat Bob® FXDF models

Step 3

Special Note: Module location on some model

motorcycles (notably all Dyna® and Softail® Rocker®
models) makes it difficult to insert the communication
cable once the module is installed. An 8” ‘pigtail’
harness is available (# 309-324) that can be
permanently connected to the bike’s ECM harness plug,
allowing a remote port for the communication cable if
desired.

All Models - Locate the fuse box that contains the ECM
fuse, remove fuse labeled “ECM POWER”.

Install the ThunderMax with AutoTune modules.

Softail® Models

ST-A: Remove the seat, locate and remove the ECM

fuse. Remove the stock ECM from the motorcycle and
the wiring harness plug from the ECM. Lift the battery
up from the oil tank and remove the battery cables
(negative first). Remove the battery.

www.Thunder-Max.com 309-375 Installation / Setup Guide V2009.10.30 [e-mail]

1

ST-B: Remove the bolts holding the fuse block bracket
to the frame and lift the bracket away from the frame to
allow access to the gap between the frame and oil tank
on the right side of the motorcycle.

ST-C: Connect the ThunderMax ECM to the harness
and position it loosely in the ECM tray. Feed both
oxygen sensor harnesses (front cylinder first) through
the gap between the frame and oil tank on the right side
of the motorcycle.

ST-F: Re-install the fuse block
bracket bolts and attach the
ThunderMax 50 ECM to the ECM
tray. Re-install the battery (positive
cable first) and install the ECM fuse.

Plug the AutoTune module into
the 4-pin gray data port plug on
the motorcycle.

FXD (Dyna®) Models

FXD-A: Remove the left side cover to reveal the

electrical caddy. Remove the main fuse (1). Use a
small screwdriver to release the catches holding the fuse
block, relay block and TSSM module to the electrical
caddy (2). Unplug the main harness from the ECM and
remove the data plug from its holder (3). Remove the 2
hex head and 1 socket head mounting bolts to free the
caddy for removal (4). Unplug the plug wires and
harness from the coil and remove the caddy.

ST-D: At this time you may want to snake the rear
oxygen sensor towards the rear exhaust pipe by starting
it from the right side of the bike, under the oil tank, and
around the seat post to the rear exhaust position (do not
connect it to the harness until after it has been installed
and tightened into the exhaust pipe, so the harness can
turn freely). Ensure that the rear O

harness plug is

2

positioned closer to the swingarm pivot bolt so it will not
be crushed between the upper swingarm and the oil tank
at full stroke (suspension bottomed).

ST-E: Position the harness plug for the front pipe under
the transmission, along the frame rail. Install the oxygen
sensors into the exhaust pipes, connect the harness
plugs to the oxygen sensors and secure the harnesses
to the frame (above the lowest point) with wire ties.

FXD-B: Remove the
stock ECM from the
electrical caddy. The
caddy must be slightly
modified for additional
main harness
connector clearance.
Use a Dremel or Roto-Zip tool to provide additional
clearance for the harness plug catch; also remove
approximately 3/8” from the partition support as shown.

FXD-C: Because of the impossibility of connecting the
communication cable without disassembly once
assembled on FXD models, the cable should be
permanently installed to the ThunderMax, or the optional
‘pigtail’ harness mentioned in step 2 used. If using the
communication cable, feed it and the AutoTune power
harness through the ECM plug port of the caddy and
mount the ECM to the caddy as shown. The oxygen

www.Thunder-Max.com 309-375 Installation / Setup Guide V2009.10.30 [e-mail]

2

sensor harnesses should exit towards the opposite side
of the caddy.

FXD-D: Before reinstalling the caddy, feed the front
cylinder oxygen sensor harness through to the right side
of the bike, over the top and to the rear of the starter
motor. Reinstall the caddy with fuse and relay blocks in
place. Reconnect the TSSM, coil and ECM harnesses
and main fuse. If equipped with AutoTune, plug the

closed loop module into the 4-pin gray data link on
the bike. It is through the data port that data from the

AutoTune module is transferred to the ThunderMax. A
‘Y’ harness is available (# 309-343) to keep an open
data port if desired. After programming and setup, the
communication cable can be coiled up and kept under
the caddy cover if not using the ‘pigtail’ harness.

Dyna®: ECM installed with

communication cable attached.

Oxygen Sensor Installation (AutoTune)

Install supplied wide band oxygen sensors in the front
and rear exhaust pipes. Unplug and remove the stock
narrow band oxygen sensors and replace with the
supplied wide band units. The wide band sensors are
longer than the factory sensors. Installation of the wide
band sensors into factory headpipes presents no
clearance problems, however, some aftermarket pipes
may require exhaust pipe modification or sensor bung
relocation for interference-free installation. The sensors
must mount freely without contacting surrounding
components. If this is not possible, do not attempt to

bend or modify the sensor in any way as it is a
sensitive electronic component and will be damaged
if you do. Modify the pipe if required for clearance.

Weld-in bungs are available for exhausts systems not
equipped with bungs or if current bungs present
clearance issues. Bungs should be located no more
than 3-4” from the head/pipe connection (for ideal

location, refer to the factory location on 2007-up
models). Weld-in bungs are available from Zipper’s
(#272-200, straight; #272-202, angled). After
installation, route the sensor harness away from the
engine and along the frame when possible, above the
lowest frame point to avoid the possibility of dragging
ground during operation. Avoid routing harnesses where
engine movement or moving parts can contact and
damage the harnesses or connector plugs.
Connect the sensors to the closed loop module. The
AutoTune harness for the rear cylinder sensor is shorter
and can be easily identified by black tracers on all of its
wires; both plugs are clearly marked for front and rear
use. It is very important to install these correctly or the
engine will perform poorly! Tie the harnesses to the
frame or existing component harnesses, taking care to
avoid contact with any vibrating component that may
chaff the sheathing or wires. Some disassembly of bike
components may be required for best harness routing.

FXD Tips: The rear harness mounts easily, just coil

the excess wires and locate them above the
transmission. To install the front harness, remove the
rear gas tank mounting bolts and loosen the front
mounting bolt. Lift the gas tank from the rear, pivoting it
on the front bolt. Prop the tank up with a block of wood,
exposing the frame backbone. The front harness should
travel from the AutoTune module, along the left side of
the frame backbone with the oxygen sensor connector
plug positioned just above the top engine mount. After
installing and tightening the sensor, route the sensor
lead up along the left front downtube to the frame
backbone and complete the connection to the AutoTune
harness. View the connector position with the gas tank
in place and tie the wires to the frame; once you have
verified gas tank/motor mount clearance, re-tighten tank.

Step 4 Load a Base Map to your SmartLink software.

Selecting a base map for your ThunderMax is easy
thanks to the filtering system in the SmartLink software.
Open SmartLink; from the toolbar choose [EFI Maps]
[EFI Map Listings / Definitions]. You should first
update the Map Definitions file to ensure you have the
latest available maps. [Close] the [Base Map

Definitions] window, then click the [Check Internet For

www.Thunder-Max.com 309-375 Installation / Setup Guide V2009.10.30 [e-mail]

3