Thunder Max Max 309-355, Max 309-360 Installation Manual

Part # 309-360 for Big Twin Models

Thank you for purchasing a ThunderMax 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 Inse 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.

Step 2

equipped) modules. 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. Compatible with ThunderMax ECM serial
number 114000 or higher (starting August 2008).

fuse, remove fuse labeled “ECM POWER”.

rt

Install the Th

- Locate the fuse box that contains the EAll Models

underMax and AutoTune (if

CM

Installation / Setup Guide

Please Note: This product is Legal in California

only for racing vehicles which may never be used

upon a highway.

product for his or her use. Installation and use on a pollution-

controlled vehicle constitutes tampering under the U.S. EPA

guidelines and can lead to substantial fines. Review your

application and check your local laws before installing.

The user shall determine suitability of the

Touring Models

FL-A. Unplug the ECM wiring harness from the factor

CM.

E

L-B: Remove the factory ECM from the motorcycle

F

e ECM is held to the electrical caddy by socket he

th

p screws. The screws have a locking agent on th

a em

c

nd can be difficult to remove. Work the screws back

a
and forth slowly

FL-C: Install the ECM wiring harness to the
ThunderMax ECM. Do not install the ECM onto the

motorcycle at this point. If the ECM is mounted onto the
electrical caddy at this step, it is difficult to get the fuse
box in place.

FL-D: Route the AutoTune harnesses (if equipped)
through the frame opening before positioning the ECM
for installation. Re-install the ECM fuse and secure th
fuse box back into position on the electrical caddy.

FL-E: Mount the ThunderMax ECM onto the electrical
caddy using the two factory socket head cap screws.

Plug the Auto

port (shown).

to break them loose.

e

Tune harness into the 4-pin gray data

y

,

ad

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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.

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.

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

west point) to the frame (above the lo

with wire ties.

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

Plug the AutoTune module into

e 4-pin gray data port plug on th

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 catche
block, relay block and TSSM module to the electrica
caddy (2). Unplug the main harness fr
remove the data plug from its holder (3
hex head and 1 socket head mountin
caddy for removal (4). Unplug th
harness from the coil and remove the c

s holding the fuse

om the ECM and

). Remove the 2

g bolts to free the

e plug wires and

addy.

l

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

www.Thunder-Max.com 309-360 Installation / Setup Guide V2009.04.23 [e-mail]

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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 m
communication cable, and
feed it and the AutoTune
ECM plug port of the cadd
caddy as shown. The ox
exit towards the opposite side of the cad

entioned in step 2 used. If using the

if equipped with AutoTune,

power harness through the

y and mount the ECM to the

ygen sensor harnesses should

dy.

FXD-D: If equipped with AutoTune, 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

ith AutoTune, plug the closed loop module into the

w

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)

If equipped with AutoTune, install supplied wide band
oxygen sensors in the front and rear exhaust pipes.

FXD and all 2007-up models are equipped with

2006
narrow band sensors, which must be removed and
replaced with the supplie d units. The wide
band sensors are long factory sensors.
Installation of the wide ors into factory
headpipes presents no lems, however,

d wide ban

er than the

band sens

clearance prob
some aftermarket pipes may require exhaust pipe
mo bung relocation for interference-

dification or sensor

free sors must mount freely without

installation. The sen

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. The front harness should travel from the
AutoTune module, over and to the rear of the starter
motor, behind the exhaust support bracket and between
the crossover pipe and the transmission.

Remove the footpeg/brake pedal bracket mounting bolts
and move the assembly towards the exhaust pipe.
Route the front exhaust sensor harness under the cam
cover exhaust support bracket and behind the brake
pedal; connect it to AutoTune harness.

The sensor plug and harness will drop down to the frame
rail with a little brake pedal wiggling where it can be zip­tied to the frame rail, out of sight and out of harm’s way.

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