ThunderMax PN-309-366 User Manual

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309-466 Installation / Setup Guide V2013.09.16

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1

Part # 309-366 / 309-466 for V-Rod®
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 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.

Step 2 Install the ThunderMax and AutoTune modules.

(See dielectric grease tip for ECU on bottom of page 7)
Due to the mounting location and space constraints on
the V-Rod® for the ECM, your ThunderMax system is
supplied with a separate AutoTune module. The
ThunderMax ECM mounts in the same location as the
factory ECM; the AutoTune module mounts separately.

2002-2005 MODELS

Step 2a

Remove the
seat, air box
cover and
front frame
side covers
(2) to expose
the airbox
and battery
area.
Remove the
airbox lid with
snorkel.

Installation / Setup

Please Note: This product is Legal in

only for racing vehicles which may never be

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

Guide

Locate fuse box just
forward of the seat and
remove fuse labeled

POW

“ECM
fuse, right side).

Unplug and remove the
factory ECM from the
motorcycle (located just
behind the steering
stem).

Due to the tight restrictions of the location of the ECM on
2002-2005

Option 1 - The

communication

cable can be
installed into the
communication port
of the ThunderMax
ECM

attached

ECM and stored on

the motorcycle

(how you

route/store

cable is up to you, you can run it through the frame and
along the airbox housing and store it under the seat or
roll it up and store it under one of the side covers), or
Option 2 –(PREFERRED not required) Install
ThunderMax Pigtail Communication Port Harness
( i nc l u d ed) and wire it to the ECM harness plug on
the motorcycle for an alternate port location.

Once option 1 or 2 is performed, install the ThunderMax

ECM to the motorcycle in the stock location. Plug the

main harness into the ECM and reinstall the ECM fuse.

ER” (center

model bikes:

and

remain

to

the

the

California

used

th

e

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309-466 Installation / Setup Guide V2013.09.16

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2

Either

of

these

options

will

allow

Step 2b Remove

2006-UP MODELS

the front and rear
seat, air box cover
and front frame
side covers (2) to
expose the airbox
and battery area.
Remove the airbox
lid with snorkel.

Step 2c Trial fit the

ThunderMax to the
plastic ECM caddy.
Note that some parts
of the caddy will need
to be modified for
proper fit. This is
easily accomplished
with a saw blade.

Cut the caddy in three
places as shown and
remove the ‘T’ shaped
section. Trial fit the
ThunderMax ECM into
the modified caddy; re­trim as necessary. Re­install the caddy with
the ThunderMax ECM
in place.

Locate and remove
the ECM fuse.
Unplug the ECM and
remove the ECM with
the plastic ECM
caddy (unsnap the
caddy from the
fender). Separate the
ECM from the caddy.

Remove the
“loop” from the
left side of the
caddy with a
hacksaw blade or
similar cutting
tool.

Plug the ECM main

harness into

the
ThunderMax and
reinstall

the ECM
fuse. At this point,
you have two options
for linking to

the
ThunderMax with the
supplied
communication

Option 1

cable:

- The
communication cable can be installed into the
communication

port of the ThunderMax ECM and remain
attached to the ECM and kept stored on the motorcycle
under the seat, or
Option 2 – Install t h e ThunderMax Pigtail
Communication Port Harness (included) and wire it to the

ECM harness plug on the motorcycle for an alternate port
location.

quick communication
with the ThunderMax
without removing the
passenger seat to
plug in the cable.
Reinstall the
passenger seat.

ALL

MODELS

Step 2c Install the supplied wide band oxygen sensors

into the exhaust pipes. If your exhaust system is not
equipped with oxygen sensor bungs, they must be
added to the exhaust pipes. The supplied wide band
sensors are longer than the factory sensors. Installation
of the wide band sensors into factory headpipes
equipped with bungs should present no clearance
problems, however, some aftermarket pipes may require
exhaust pipe modification or sensor bung relocation for
interference-free installation. The sen
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.
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 2008-up models).
available from Zipper’s (#272-200, straight; #272-202,
angled). After installation, route the sensor harnesses
through to the left side of the bike as shown.

sors must mount

W

eld-in bungs

W

eld-in bungs are

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309-466 Installation / Setup Guide V2013.09.16

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3

Locate the gray 4-pin data link
port connector near the frame
neck behind the louvered side
panels (left side on ’02-’05, right
side on ’06-up models) and
remove the rubber plug from it.

Install the AutoTune
module flat side up, wires
toward rear. Slip loose wire
ties over front airbox cover
mounting tabs, pull wire ties
tight so that the AutoTune
module is mounted to the
bottom of the bracket as
shown.

Plug the oxygen sensor
harness into the AutoTune
harness plug marked
“FRONT”. Avoid routing
harnesses where engine
movement or moving parts
can contact and damage
the harnesses or connector
plugs.

Loosely loop a wire tie
through each slot in the
supplied AutoTune
module.

Route the oxygen sensor
harness from the front pipe
along the left frame
downtube, across to the
right side of the frame in
front of the cylinder head
cover, away from the
engine and along the frame
when possible.

Plug the 4-pin AutoTune
connector into the gray data
port connector. It is
through the data port that
data from the AutoTune
module is transferred to the
ThunderMax.

Route the rear oxygen
sensor harness between
the engine and fuel tank
under the seat . 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/rear use.

poorly! Tie the harnesses

Route the harness along
the upper left frame rail
and

plug

the oxygen
sensor harness into the
AutoTune harness
marked

“REAR”.

It is
very important to install
these correctly

or the
engine will perform
to the frame or existing

plug

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.

Some riders prefer to remove the airbox lid altogether for

increased airflow to the intake. If you chose to leave it

on, the “snout” must be removed due to the AutoTune

W

module mounting.

cutting tool, cut the airbox snout off the airbox lid.

Reinstall the airbox and frame louvered covers.

ith a hacksaw blade or similar