ThunderMax PN-309-380 User Manual

Video Instructions Available on You Tube

Part # 309-380 2012-15 Softail® / Dyna®

309-382 2014-15 XL Sportster®

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
TMax Tuner .pdf Manual, included on the CD (Help

Menu) with this package. Record serial number NOW

on your warranty card, and below for your records!

Installation / Setup Guide

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

FX/FLST-C: Spread the plastic latches holding the factory

ECM in place and lift the ECM from the mounting
bracket. Depress the latch on the main connectors and

remove the ECM from the wiring harness.

California

used

Serial # TMCM

Step 1 (All Models) Insert the

included Tmax Tuner CD into
your computer. Tmax Tuner
will automatically open the

W

InstallShield
the computer finds the CD­Rom. Follow the instructions
and install the software on
your computer.

Step 2 - Module Installation - Softail® Models

FX/FLST-A: Remove the seat

to access the factory
Electronic Control Module
(ECM). Slide the fuse box to
the left to release it from the
plastic bracket. Open the
fuse box and remove the main
fuse.

FX/FLST-B: Remove the

battery cables (negative first)
and remove the battery from
the motorcycle. Remove any

previously installed
ancillary tuning device
including oxygen sensor
eliminators that may be
plugged into the factory

oxygen sensor harness.

izard when

(Skip to page 3 for Dyna® models,

page 4 for XL® models)

FX/FLST-D: Unplug the tail light harness connector plug.

Remove the (2) bolts holding the steel fuse box
mounting bracket.

FX/FLST-E: Clip the

right rear wire tie
holding the harness
trough to the frame
as shown.

FX/FLST-F: Lift the

steel fuse box mounting bracket to ex
plastic battery tray / wiring caddy. Firmly push the caddy
forward to create space needed to feed the “Front”
ThunderMax oxygen sensor harness (shown in yellow)

pose rear of the

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309-380 / 309-382 Installation / Setup

Guide V2014.9.23

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connector through the
opening between the frame
and the caddy, exiting behind
the right wing of the oil tank.

FX/FLST-G:

dielectric grease is included
with your ThunderMax.

installing the ECM, apply the
provided dielectric grease to the inside lip of the
ThunderMax ECM to ensure the rubber weather seal
does not bind upon installation, and across the pin
casing on both 18 pin ECM connectors. Spread the
grease across all of the female terminal openings,
making sure the grease penetrates openings. This
grease will help to maintain vital conductivity between the
ThunderMax and the 18 pin connectors.

A packet of

W

hen

added to
models (3-4” from the cylinder head at the top of the

W

pipe).
style from many industry sources as well as plugs for the
stock 12mm sensors (video installation link on page 8).

On '07-'11, if you wish to cap off the bike side of the
harness connector, protective caps are provided. See Tips
and General Information section on page 8 for further
detail.

headers in a similar location as ’07-’11

the

eld-in bungs are available in straight or angled

FX/FLST-K: Once your wide-band sensors are installed,

route rear sensor harness under oil tank, feeding
connector plug up though opening in the right front
bottom of the battery cavity in the oil tank.

FX/FLST-H: Apply dielectric

grease to the ThunderMax

oxygen harness connector

female terminals to hepl

maintain vital conductivity,

and to the outer housing to

prevent binding upon

installation to the ECM.

FX/FLST-I: Install the ThunderMax ECM onto the ECM

caddy; insert the oxygen harness connector into the

ECM with the imprinted “ThunderMax” logo facing up.
Tighten the (2) Phillips connector screws. Lift ECM and
install the two 18-pin connectors, ensuring they are fully
seated and latched. Replace ECM into the caddy.

FX/FLST-J: Unplug and remove factory oxygen sensors

from the exhaust pipes (rear sensor plug located under

oil tank). If using an exhaust system equipped with

18mm sensor bungs (‘07-‘11 style), install the supplied

sensors into the exhaust pipes and tighten. If retaining

factory exhaust headpipes, 18mm bungs will need to be

FX/FLST-L: Position

rear oxygen sensor
harness connector on
top of oil tank, just
forward of the battery
under battery ground
cable as shown.

FX/FLST-M: Route front oxygen sensor harness behind

and under transmission with connector plug just under
the engine/transmission mounting boss; connect to front
oxygen sensor.

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309-380 / 309-382 Installation / Setup

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FX/FLST-N: Securely tie all harnesses to the frame

and/or other harnesses. Avoid routing harnesses where
engine movement, sharp edges, exhaust systems or hot
engine components can contact and cut into the
harnesses or connector plugs. Be aware that swingarm
movement at full suspension compression reduces the
clearance opening at the rear of the oil tank where the
front oxygen sensor harness is routed (tie harness
inboard of swingarm).

FX/FLST-O: Install

steel fuse box

mounting bracket.

Plug in the tail light

harness plug, re-

install the battery

(positive cable first).

Re-install the main

fuse. Replace the

fuse box cap and

attach the fuse box to the pl

Step 2 - M

odule Installation - Dyna® Models

FXD-A: Remove seat.

Disconnect fuel line from fuel

tank by carefully pushing up the

quick disconnect ring on the

tank fitting while gently pulling

the fuel line down. Loosen front

fuel tank mounting bolt; remove

rear mounting bolt, prop up tank

rear 4-5” with a wood block.

FXD-B: Remove left side cover

to expose electrical caddy.

Remove fuse box cover and

remove Maxi-fuse.

FXD-D: Remove the three

caddy mounting bolts (do not
remove caddy from bike) to
allow caddy to drop down
slightly towards primary cover.
Pull caddy slightly towards you
to allow room for oxygen
sensor harness routing.

astic fuse box bracket.

FXD-C: Remove factory
ECM from caddy by
pushing up ECM from
bottom and sliding it out
towards you. Depress
locking tab on
connectors and remove
the ECM from the wire
harnesses.

FXD-E: Starting
at the rear

cylinder
head, route the
oxygen sensor
harness behind
the coil and ECM
caddy up through
the frame opening
as shown, then

back down
through the frame
opening, through
the back of the
ECM opening of
the ECM caddy.
Pull the harness
through far
enough to allow it
to be attached to
the ThunderMax
ECM. Apply di­electric grease
(see page 2, G&H)
and attach the
harness to the
ECM using screws
provided; plug
black and gray
harness plugs into
ThunderMax ECM.
With ECM still
“out” of its home

position as shown,
reinstall (3) caddy
mounting screws.
Verify that oxygen
sensor harness
moves freely (not
pinched by caddy
reattachment).
Enough slack
must be left in
harness to allow
ECM to be pulled
out far enough for

temporary attachment of the ECM
communication cable for map programming and
adjustments.

FXD-F: Unplug and remove factory oxygen sensors from

the exhaust pipes. Remove any previously installed

ancillary tuning device including oxygen sensor
eliminators that may be plugged into the factory
oxygen sensor harness. If using an exhaust system

equipped with 18mm sensor bungs (‘06-‘11 style), install
the supplied sensors into the exhaust pipes and tighten.
If retaining factory exhaust headpipes, 18mm bungs will

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309-380 / 309-382 Installation / Setup

Guide V2014.9.23

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