ThunderMax Conductivity - How To Improve and Maintain User Manual

Improving Conductivity of Your Electrical

Version 01-24-2013

The Product Support Team has identified poor conductivity as the most common source of problems that might
falsely lead the user to believe there could be a problem with their ThunderMax® EFI system.

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Interruption of 12v power to the EFI module causes some unusual problems with the engine management
system, gauges or other electrical functions on the motorcycle.

Occasionally we hear reports of situations where performance has changed or diminished, or momentary
gauge loss has occurred. These issues are abnormal and should be corrected.

If you ever incur gauge loss, simply cycling the main power may restore the gauge functionality
With the guidance of this tech document, it is likely you will find the correct process needed to address the root

cause of the conductivity problem. This should be performed at your earliest convenience.

1. Read DTC’s Harley Diagnostic Codes and How To Access Them

There may be stored Diagnostic Trouble Codes (DTC) in the module which could provide you with
insight to specifically what is wrong with the motorcycles 12v power source.

Record any DTC’s prior to clearing.
If no DTC’s are present, move on to checking for Corrosion or Oxidation on electrical components

and connections.

2. Check For Corrosion and Oxidation

Corrosion/Oxidation is the #1 enemy of your motorcycle’s electrical system and power source

connections.
Corrosion/Oxidation can cause a faulty or inconsistent ground which can lead to number of problems,

one of which being voltage spikes or surges that can cause VERY harmful effects to your motorcycle.
Corrosion is routinely found in the field and will also cause problems related to insufficient or

interrupted voltage that can affect the performance of your motorcycle.
It can be found on battery cables, electrical connectors, fuse connections, relays or completely hidden

within the ECM connector and other connectors.

1) Fuse Box
All 12v power for the entire motorcycle goes through here and it’s a common source of problems. The

fuse box is not sealed unit therefore even garages kept motorcycles are highly venerable to problems
due to the elements of exposure like moisture, humidity, washing and rain water etc..

Note- corrosion / scale on spades

Inspect the fuse panel sockets and fuse spades for scale and corrosion. Clean with alcohol and apply
dielectric grease.

2) TMax-ECM Connector
With the ECM Fuse removed it’s safe to unplug the ECM 36-pin connector. Swab the connector with

alcohol then apply dielectric grease to the inside lip of the ThunderMax ECM (Photo A) to allow the
connector rubber weather seal to slide into the housing without rolling or binding.
Also apply a light film to the female pin receptacles housed within the clear terminal guide on the 36 pin
ECM connector (Photo B) making sure to lightly cover the entire the surface of the terminal pins.

Initialize the system after reinstallation of the 36-pin connector and ECM fuse (with the handlebar
switch in the “Run” position, turn the ignition switch ON 30 seconds, OFF 30 seconds, 3 times before
moving the throttle or starting the engine).

(Photo A) (Photo B)