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.

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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

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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

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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

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Updates] button (requires internet connection; follow
prompts). After updating, select [Select BaseMap].

Available base maps will be shown (if the [Clear Filters]
button at the lower left of the screen is highlighted, click
it to clear filtered maps so all maps will be shown).

Filter the maps to locate a base map that best matches
your application by placing your curser first over any
‘Engine Type’ that matches your engine and right-click it.
All maps that do not match your selection will be filtered
from the screen.

Fourth, right click the ‘Muffler’ column if further definition
of the exhaust system is required (depends on exhaust
application). Keep right-clicking the application columns
until you have located the best map match (in the case
of identical maps, choose the latest date; if no more
options are available, you’re done). Highlight the map
you’ve chosen (left-click; blue bar indicates selected
map) and click [Close] button. This brings you to the
‘Base Map Name Encoding’ page, from which you can
review the map parameters. Click the [Load BaseMap]
button to load the map into the software.

Second, place your curser over the ‘Throttle’ column
and right click your match.

Third, if more options exist, right-click the ‘Exhaust’ type
that closest matches your application.

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From this page you can load the base map into the
software by clicking the [Load Base Map] button.
[Close] this page to view the open map page. From the
‘Tuning Maps’ Tree, click the + sign next to [Module
Configuration], then double-click ‘Basic Settings’.
The basic settings page opens. Check to see if the

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Step 7 Verify Module Settings. Before performing this
step, clear any active Diagnostic Code readings. While
linked, from the Tuning Tree select [Module

Configuration] [Diagnostic Codes].

[Speedo Cal] calibration setting matches your year and

model; if not, click the button, enter the correct value as
shown, then click [Close].

Speedometer Calibration Settings

Dyna®

Softail©

2008-09 FXD 42450

2010 FXD 44750

2008-09 42450

2010 44750

Step 5 Now you are ready to ‘Link’

and ‘Write’ the map to the ECM.
Attach the communication cable
from your computer to the
ThunderMax module, making
certain that the cable is routed away
from any part of the motorcycle that
generates heat.

Step 6 To link to the module, turn the key switch to the

“Ignition” position, making certain the “RUN / OFF”
rocker switch (Kill Switch) on the handlebar controls is in
the “RUN” position. Select the “Link” Button in the
SmartLink software. The button turns green to indicate a
successful link. Answer [No] to the “Do you wish to
READ the module map now” question at this time.

From the toolbar, click [File] [Write Module Maps and
Settings], answer OK to the message that informs you
that you are about to overwrite the current map in the
module; the transfer bar appears during the map load.

When the Diagnostic Codes window appears, select
[Clear Diagnostic Codes]. After completing this step,
select Basic Settings from the Module Configuration
menu and verify that the speedometer calibration is
correct and if the bike is a 2007 or later model the 6

th

gear indicator settings are correctly set (Final drive ratio
[87] for Touring & Softail®, [84] for Dyna® models) Gear
6 Min TPS [40]). After verifying these settings, click

[Write Basic Settings].

IMPORTANT STEP BEFORE STARTING

Next, ‘Initialize’ the ThunderMax ECM. Initializing
synchronizes ‘home’ positions for the TPS and IAC, and
is a required step any time battery power has been
interrupted or established to the ThunderMax 50 ECM.

With the handlebar switch in the ‘ON’ position, cycle
the key switch on and off 3 times, leaving the
ignition on for 30 seconds, then off for 30 seconds,
each cycle. DO NOT start the engine or move the

throttle during this process. After 3 on/off cycles, make
certain that the motorcycle is in neutral and start the bike
2 times, letting it settle at idle for 10 seconds; the idle
should be smooth and steady. Some engines may
require several on/off engine starts to initialize properly.

This initialization process must be performed any
time battery power is interrupted to the module (after
battery servicing/winterization, etc). After initialization,

shut off the engine, but stay linked for step 8.

Step 8 Before restarting the engine, from toolbar click

[Monitoring] [Show Gauges]. The “Engine Speed”,

“Engine Head Temp”, “IAC Position”, “AFR Front”, AFR
Rear” and “AFR Target” gauges are automatically
formatted and are shown on the screen. Additional
gauges can be created if desired (see SmartLink Tuning
Manual under Help menu), but the above gauges are
most helpful during initial set up. You may select any
gauges that you deem important; if too many are chosen
your screen may appear cluttered.

Step 9 Select the “Monitor” button to active the gauges.

It is located beside the “Link” button and will turn green

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when the monitor gauge functions are live. The gauges
will be displayed if they were not already on the screen.

Step 10 Now select the IAC Stops vs. Engine

Temperature page from “IAC Curves” menu within the
tuning tree. Strike the

To perform the AutoMap function, first ride the
motorcycle for 100+ miles, stopping several times to
cycle the ignition switch off and on. Vary the RPM and
load as much as possible for the ECM to “see” as much
RPM variances and throttle positions as possible for it to
auto-adjust the fuel points. Once this is done, link and
“read” the module [File] [Read Module Maps and

Settings], then select [Map Editing] [AutoMap (Write
“Learned Fuel Adjustments (CLP OFFSET)].

spacebar to show the actual values of the tuning block
(use left/right arrow keys to move the block marker).
Make certain that the motorcycle is in neutral and the
engine is cold, and then start the engine. Once the
engine idle is stable after 15- 20 seconds, select the
“IAC-Auto” button (Idle Air Control Auto Adjustment).
Allow the “IAC-Auto” function to run at idle until the
engine head temperature reaches 275 degrees. After
reaching temperature of 275 degrees, the “IAC-Auto”
function automatically shuts off. You can terminate this
function at any time, and re-run it at a later time if you
wish.

Step 11 Unlink the SmartLink software from the ECM,

turn off the ignition switch and remove the
communication cable from the ThunderMax 50 ECM.

The flowing window will appear; choose [Read Module,
Perform AutoMap, Write Module].

Use the ‘Save As’ command to create a folder and save
the map to your hard drive. The motorcycle is now
ready to be ridden. Several riding sessions that allow
the engine to reach normal operating temperature
should be completed. During this process, the IAC
virtual stops will automatically be adjusted to the IAC
target values set within the map’s basic settings. This
feature automatically adjusts how the engine comes
back to the specified idle speed. If the IAC stops are set
too low, the engine will dip below the specified idle
speed during certain transient conditions. If the IAC
stops are above the IAC position, the engine will idle
above the idle rpm specified in the idle speed vs. engine
temperature page.

Step 12 After riding the motorcycle, re-link and “write”

the AutoTuned map points to the base map within the
module. The AutoMap (Map Editing) function resets the
Base Map points to the learned offset point values. This
"reset" allows the AutoTune systems to use its maximum
range to make future adjustments. Some examples of
conditions the AutoMap functions will correct for are:

The adjusted fuel points will be automatically smoothed
and the base map re-written with the new, optimized fuel
points. Save the modified map to your hard drive before
unlinking, and go ride!

• Different Exhaust Pipes

• Injector Flow Rates, Spray Angles

• Throttle Body Tolerances

• Fuel Pressure Variances

• Large Changes in Ambient Conditions

• Normal Engine Wear.

• Fuel Quality (ethanol, octane ratings etc.)

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TIPS AND GENERAL INFORMATION

• Several support features are located under the
[Help] menu; some require an internet
connection.

• A comprehensive Tuning Manual in PDF
format is included on the CD for viewing and
printing from your desktop.

• When the SmartLink program is opened, it
will automatically retrieve and open the last map
that was open.

• Any time you link to your motorcycle: Read
the map that is installed in the ThunderMax
ECM by selecting [File] then [Read Module
Maps and Settings] on the SmartLink toolbar.
This will synchronize the map file loaded into the
ThunderMax ECM with the SmartLink software.

• 2007-up Big Twin models: There are two
settings in the [Module Configuration] [Basic
Settings] page that should to be set to the
following to enable the 6

th

gear indicator light to
function:
Final drive ratio [87] Gear 6 Min TPS [40].

• Target air/fuel ratios can be viewed on the
Air/Fuel-TPS @ RPM pages. When these
pages are open, you can view the target AFR by
clicking on a dot and tapping the space bar to
view the target at a specific throttle position for
that RPM. Use arrow keys to raise/lower targets.

• In-Tank Fuel Filters should be inspected as a
part of routine maintenance. The filter is small
and one bad load of fuel can clog it. The factory
recommended service interval is 25K miles.

• Oxygen Sensor Care: Items that can damage
or shorten the life of your sensors:

Leaded fuel – Race fuel
Oil deposits from oil consumption problems
Excessive (extreme) heat

Improper installation (damage)
There is no warranty on sensors damaged by
improper installation or wire chaffing (bare
wires). Replacement P/N is 309-355. See
warranty information sheet for more details.

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