Zipper's Performance 109-213 User Manual

y

Assisted

Use your motorcycle's specific Service
Manual as a guide for any procedure not

Dry

detailed in these instructions.

S

Product Overview
This product is legal in California only for

racing vehicles which may never be used
upon a highway.

Please read through the instructions entirely

before performing this installation. If you do feel

not capable to perform this work, we
strongly recommend you find a professional
installer. If you are not entirely confident in
what you are doing, then stop now. This kit is

designed to be installed on modified engines
using oversize ThunderMax® throttle bodies.
Based on your engine’s output it will likely
require oversize injectors and base map
calibration changes for the selected injectors.
This system is not designed as a “bolt on and
ride Nitrous kit” as will require some degree of
professional tuning. This product is sold as a 2­part kit, the main component consisting of the air
cleaner backplate with solenoid assembly, air
filter and harness. The bottle and bottle
mounting brackets are sold separately (model
specific). It requires a ThunderMax® ECM and
is best used with the ThunderMax® Auto-Tune
module.

How a ‘Dry’ System Works

A ‘dry’ system introduces the required extra fuel
nitrous demands through the EFI fuel injectors,
rather than using a secondary fuel delivery
system. The ThunderMax® ECM has
programming built it that recognises the nitrous
system and increases the fuel ‘pulse width’
when activated. Once additional fuel is
introduced, it burns with extra oxygen provided
by the nitrous, providing additional power.

Installation

1. Remove the air cleaner cover, element and
backplate from the motorcycle. Retain the
original cover screw for future use.

2. Electrical Harness Installation: Remove the
ECM fuse. Disconnect the negative battery
cable. Locate the
ThunderMax®
ECM and
disconnect the
wiring harness
connector from it.

Nitrous

3. Route the NADS electrical harness along the
backbone of the motorcycle and position the end
of the harness near the ECM.

Note: Depending upon your model, you may

need to remove the seat and/or raise

the gas tank to route the harness.
Carefully pry the strain relief (gray housing) of
the ECM connector apart.

4. Depress the tabs on the connector retainer
(clear plastic) and remove it from the connector.

5. Locate positions 9 and 32 on the "wire side"
of the connector. On the nitrous harness, insert
the terminal of the white w/black tracer wire into
position 9 and the terminal of the yellow w/black
tracer wire into position 32. Be sure to insert
them until they "click" into position and are at the
same depth as the other terminals.

stem #109-213

6. Re-install the connector retainer. Position
the wires of the nitrous harness so that they exit
the strain relief along the same path as the OEM
wires. Close the halves of the strain relief
around all the wires.

9. Use wire ties to secure the harness to the
motorcycle.

7. Insert the connector back into the ECM.

8. Locate the data link connector. Connect the
four-position Deutsch connector on the nitrous
harness into the data link connector. (If you are
also using ThunderMax® AutoTune, you must
purchase a Data Plug ‘Y’ Harness, # 309-343, to
run both systems.)

10. Assuming that you have already mounted
the ThunderMax® throttle body/manifold to your
engine per instructions, install the NADS
backplate and air cleaner assembly with the
following supplied components:

(2) Breather bolts with
(4) Washers 2 ea 3/8, 1/2" ID
(2) Breather vent banjo fittings
(2) Socket head bracket
screws

(2) Air cleaner support brackets
(1) 5/16" ID shim washer assortment
(1) Air filter element
(1) Air cleaner backplate w/stanchions
(1) Air cleaner cover washer
(2) 5/16-18 x 1-1/4" buttonhead bolts
(2) 5/16 hardened washers
(2) 5/16-18 locknuts
(3) ¼-20 x ½” Torx-head A/C-to-stud screws
(3) Nylon washers
(3) ¼-20 x ¾” Torx-head cap screws

11. Apply blue Loctite® and
install banjo fitting with sealing
washers covering both sides
onto each banjo bolt. Install
banjo fitting assemblies into
breather ports on heads and
tighten, with banjo hose fittings
facing down. Attach suitable
3/8" vent hose to banjo fittings
and rout vent hoses to
atmosphere or accessory
breather filter(s).

12. Install backplate support brackets over
raised bosses in banjo bolts, secure with 5/16­24 socket head screws (do not fully tighten).

15. Install air filter onto backplate, line up holes
to stanchions. Apply blue Loctite and attach
with (3) 1/4-20 Torx head screws and nylon
washers and tighten (do not distort plastic
washers).

13. Apply blue Loctite to (3) 1/4-20 x 3/4 Torx­head socket screws and install backplate to
throttle body; tighten securely.

14. Attach backplate to support brackets
using 5/16-18 bolts, nuts and washers provided.
Use shims provided to fill any gap between
bracket and backplate so that there is no stress
or binding between the bracket and backplate
while tightening (brackets may be bent slightly to
ensure even alignment with backplate). Tighten
the 5/16-24 sockethead screws securing the
brackets to the banjo bolts.

16. Install the original air cleaner cover screw
through the air cleaner cover. From inside the
cover, install the supplied thick 5/16” washer
over the air cleaner cover screw threads. Apply
a drop of LOCTITE THREADLOCKER 243
(blue) to the threads of the air cleaner cover
screw. Position the air cleaner cover over the
filter with the washer positioned between the air
filter and the cover. Install the screw and tighten
to 36-60 in-lbs.

Bottle/Bracket/Line Kit (Sold separately)

Install the nitrous bottle using supplied model­specific brackets. The bottle mounts with the
outlet at the bottom. Install the brackets to the
left frame downtube; leave the clamp screws
slightly loose. Place the bottle in the bracket
cradle and install the clamps loosely. Attach the
nitrous line and orient the bottle so that the hose
is routed without interfering with the shift linkage
or any other component (clamp provided if
needed). Tighten all clamp screws securely.

FXD (Dyna®) and Touring Models: The lower

bracket frame clamp is notched to locate around
the frame cross brace.

Touring Bottle Installation

FXD Bottle Installation

FXST Bottle Installation

Software Setup

You should always check to see if you are
running the latest available version of SmartLink
software and your module’s firmware is up to
date. Software and firmware updates are
available with a high-speed Internet connection
through your SmartLink software. Please verify
you have the latest version before you proceed.

You must have a ThunderMax® ECM # 309-340
(modular type) to use the NADS system.
Earlier, first generation ThunderMax® may also
be used if purchased after March 1 2006, and
are identified by a laser-engraved “E” on the
right hand side of the module lower casing,
below the main harness plug opening.

Open the SmartLink software. Link to the
module and select [CONFIGURE], scroll down
to [MODULE SETTINGS] ► [NITROUS] and the
following dialog page appears:

DEFINITIONS:

1. Nitrous Enable/Disable - Enables (turns on)

or disables (turns off) all nitrous
functions, regardless of other settings or switch
positions.

2. Strategy - (Not used at this time) Strategy

window is reserved for future expansion of the
system. There is no function available currently.

3. Engine RPM - Sets minimum rpm for nitrous

activation (maximum rpm remains located in
[BASIC SETTINGS] under [REV LIMIT]).

4. Vehicle speed - Minimum vehicle speed for

nitrous activation regardless of other settings.

5. Fuel Enrichment – Percentage of additional

fuel that will be applied to the installed base map
during nitrous activation. Target AFR’s in the
low to mid 11's are safe. More power may be
available with a leaner mixture.

6. Delivery Delay – Fuel and timing. Sets a

time delay due to solenoid opening and purging
of air in the system. Fuel enrichment and timing
adjustment are delayed by this number in
milliseconds after all other conditions are met.

7. Ignition Timing - A flat value of spark retard

on nitrous activation.

Summary of Operation

The NADS system has only has 2 states,
"Active” and "Not Active". In order to go into the
active state all of the following conditions must
be met:

1. System must be "enabled" from nitrous menu

in SmartLink software.

Note - This is done by clicking on “configure” on

the tool bar and then “module settings”.

2. The arming switch, located on the air cleaner

backing plate, must be moved from the
"disarmed" to the "armed" position after the

engine is started. This prevents accidentally

leaving the arming switch on between rides from
causing an inadvertent charge of Nitrous or
activation on the following ride.

Note - On some models, the check engine and

battery lamp will be lit together when the system
is armed to provide another visual reminder that
the system is in an active mode. This is normal
and intended.

3. Rpm must be above the target nitrous menu

rpm setting and below the prescribed rev limit.

4. Vehicle speed must be above the nitrous

menu vehicle speed setting.

Conservative Settings Suggestions and Recommendations

The bottle is equipped with a valve that can be
opened or closed. We suggest closing the valve
when not in use. Extra bottles are available for
purchase to quickly replenish exhausted nitrous.

Change and vent bottles only in a well ventilated
area. When changing the bottle, close the bottle
valve before disconnecting the line. Slowly
loosen the line until a hissing sound is heard; let
the line pressure escape slowly. Do not inhale
nitrous as continued exposure can cause death.
Do not allow liquid nitrous to touch your skin as
it will burn like dry ice. Carefully check for leaks
any time a connection has been broken. Do not
use Teflon® tape on the tapered line fittings.

With a 12oz bottle, you can expect 3-4 full
throttle pulls per bottle. Degree of engine
modification and engine size will affect this
estimation.

When the available nitrous is used up and the
system remains enabled, The additional fuel
dictated by the active system will cause the
engine to run in a rich condition absent the
presence of available nitrous. Turn off the
arming switch to avoid overfueling the engine
when the nitrous runs out.

Lower fuel enrichment settings will increase

performance but will lean out the air/fuel ratio

Target air/fuel ratio while system is activated is
between 11.25 and 11.75

Adding nitrous oxide to your engine and properly managing it can significantly increase
its output. Used improperly, it can also shorten its lifespan. The purchaser of this
system assumes all responsibility in regards to its usage and compatibility. Zipper’s
and/or Thunder Heart are not responsible for your engine, and/or the safety of others or
yourself…..YOU ARE. There should be no reason why you cannot achieve success with
this product. This conservative kit should not damage your engine, but it is certainly
possible. Depending on your riding habits and quality of installation, damage to your
engine may be a real possibility. Neither Zipper’s or Thunder Heart Performance is
responsible for any consequential damage related to the use of this product. Nitrous
oxide designed for vehicle use should never be inhaled as it contains sulfur dioxide
which can cause death. Contact with liquid may cause burns/frostbite. Never vent
nitrous oxide in a confined space. Wear safety glasses and rubber gloves when
handling.

Thanks for your purchase of our product!

www.Thunder-Max.com [e-mail] 109-213 v04072011