How a ‘Dry’ System Works
Installation
Nitrous
Assisted
Dry
System #109-214
Use your motorcycle's specific Service
Manual as a guide for any procedure not
detailed in these instructions.
Product Overview
This product is legal in California only for
racing vehicles which may never be used
upon a highway. Not legal for sale or use on
pollution controlled vehicles.
also requires a ThunderMax ECM with AutoTune system (sold separately). Please read
through the instructions entirely before
performing this installation.
This kit is designed to be installed on stock
or modified Harley-Davidson® motorcycles.
This kit is not designed as a plug-and-play
system. Installation of this kit on any
modified or larger displacement engine will
require larger injectors and custom mapping.
This product and its required service must
be performed by an experienced high
performance tuner familiar with ThunderMax.
Oversize injectors should be sized for the
proper fuel flow at peak torque while
spraying the engine with Nitrous. You should
not proceed with installation and use of this
kit if you have limited skills using-alteringdeveloping custom maps using a
ThunderMax system.
If you are a professional tuner who
methodically reviews his work with a dyno to
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 in it that recognizes the
nitrous system and increases the fuel ‘pulse
width’ and retards engine timing when activated.
Once additional fuel is introduced, it burns with
the extra oxygen provided by the nitrous,
providing additional power.
1. Remove seat, air cleaner cover, element and
backplate from the motorcycle. Retain the
original cover screw, breather bolts and ‘S’
hoses for future use.
assure you have stable Air/Fuel ratio while
spraying the engine, there should be no
reason why you cannot achieve success with
this product. Depending on your set up and
understanding of nitrous systems, damage
to your engine may be a real possibility.
Neither Zippers Performance Products nor
Thunder Heart Performance Corporation is
responsible for ANY consequential damage
related to the use of this product. There is
no warranty written or implied in any way
when using this product.
Nitrous oxide designed for vehicle use
should never be inhaled as it contains sulfur
dioxide which can cause death. Contact with
liquid nitrous may cause burns/frostbite.
Never vent nitrous oxide in a confined space.
Wear safety glasses and rubber gloves when
handling.
This product is sold as a 2-part kit, the main
component consisting of the air cleaner
backplate with solenoid assembly, air filter and
harness. The bottle/bottle mounting brackets are
sold separately and are model specific. This kit
2. Locate the supplied NADS harness and
arming switch. The female spade wire terminals
are marked with color codes; male spades are
numbered on the
switch. Connect to
switch in the following
manner:
Switch #1 – Yellow
Switch #2 – Green
Switch #4 – Red
Center spade – Black
3. Unplug the throttle body harness and install
the arming switch over the rear cylinder head
throttle body support bracket using the original
breather bolt. Install supplied breather spacer to
the front head using the other original breather
bolt. Re-install throttle body harness with NADS
harness routed under T-Body harness plug.
4. Install supplied breather spacer chrome caps
onto the breather ‘S’ hoses and install the hoses
to the breather bolts.
7. Insert supplied gasket between backing plate
and throttle body. Apply blue threadlocker to
threads of (3) supplied air filter stanchions and
install. Tighten stanchions to 120-140 in/lbs.
8. Plug two-wire harness connector into NADS
solenoid attached to backing plate. Route
remaining harness up to frame backbone, under
fuel tank to ECM area under seat as shown.
5. Slide the chrome breather caps along the
breather hoses and push them into place on the
breather spacers/arming switch housing.
6. Position the NADS backing plate over the
throttle body; insert the breather hoses through
the two openings in the backing plate as shown.
9. Electrical Harness
Installation: Remove
left side frame cover
and remove the ECM
fuse. Disconnect the
negative battery
cable. Carefully
disconnect the wiring
harness connector
from the ThunderMax.
10. Carefully push the black housing cover locks
of the ECM connector in to release the housing
cover. Note there are (4) rows of terminal ports
in the harness housing, (2) rows of 16 ports and
(2) rows of 20 ports, each row has a starting
number to identify the port number on the wire
entry side (1st row [1-16] not used). You will be
inserting (2) wires from the NADS harness into
two unused ports that have sealing pins in them
which must be removed before wires are added.
From the other side of the connector, remove
the seal pin from port #26. Remove the
unlocking clip or tool from the terminal side.
11. Snip wire tie holding harness to connector
housing. Remove the green terminal lock pin
from the housing using a small screwdriver (lock
has one short, one long leg; note orientation).
12. Note on the terminal side of the connector,
that the terminal ports are grouped in pairs two
with a small hole located between the pairs
(think opera glasses). You must “unlock” the
wire terminal/seal pin by inserting HD® tool
#45928 (or a small paper clip) into the center
hole between the paired set of terminals.
Locate port numbers 25/26 and insert the
appropriate tool in the opening between the
ports as shown.
Install the white wire with black tracer into
port #26. Bottom the terminal into the chamber
then gently tug on the wire to verify that it has
locked into place. Repeat this process for the
yellow wire with black tracer into port #47.
13. Install new wire tie to hold harness to
connector housing. Re-install connector housing
cover and green secondary locking pin (correctly
oriented) until it bottoms on connector housing.
Re-install ECM connector to ThunderMax ECM.
Replace ECM into ECM caddy.
14. Route the power harness under the left
frame rail to the gray 4-pin diagnostic port
located just below the fuse box area and plug it
in. Re-install the battery negative cable, then
the ECM fuse. With the handlebar switch in the
‘RUN’ position, cycle the ignition switch on for 20
seconds without starting the engine to initialize
the ThunderMax ECM. Secure all harnesses
with supplied wire ties away from sharp edges,
components that move or create high heat.
12. Install the nitrous line to the solenoid fitting.
Bottle / Bracket / Line Kit Assembly
Software Setup
Route line down towards front tappet block,
forward of the front cylinder to the left frame
down tube.
13. Apply blue threadlocker to threads of (3)
supplied air filter element screws and install the
air filter element.
14. Locate the supplied A/C cover washer.
From inside the cover, place the supplied
washer over the cover bolt. Apply blue
threadlocker on the threads of the bolt and
install the cover assembly onto the air filter
element.
After filling bottle, install the nitrous bottle using
supplied model-specific brackets. The bottle
mounts with the outlet at the bottom. Install the
brackets to the left frame down tube; 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 for attachment to tappet cover screw).
Tighten all clamp screws securely.
You should always check to see if you are
running the latest available version of
ThunderMax software and your module’s
firmware is up to date. Software and firmware
updates are available with a high-speed Internet
connection through your TMax software. Please
verify you have the latest version before you
proceed.
Open the TMAX software. Link to the module
and select [CONFIGURE], scroll down to
[MODULE Settings] [NITROUS] and the
following dialog page appears:
DEFINITIONS:
Summary of Operation
Suggestions and Recommendations
Conservative Settings
1. Nitrous Enable/Disable - Enables (turns on)
or disables (turns off) all nitrous
functions, regardless of other settings or switch
positions.
2. [Engine RPM] - Sets minimum rpm for
nitrous activation (maximum rpm remains
located in [BASIC SETTINGS] under [REV
LIMIT]).
3. [Vehicle Speed] - Minimum vehicle speed
for nitrous activation regardless of other settings.
4. [Fuel Enrichment] – Percentage of additional
fuel (global override) that is applied to the
installed base map fuel delivery during nitrous
activation. AFR’s for nitrous activation in the low
to mid 11's are safe. More power may be
available with a leaner mixture.
5. [Ignition Timing] - A flat value of spark
retard (global override) on nitrous activation.
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.
The NADS system has only has 2 states,
"Active” or "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 TMax software. From the toolbar [Configure]
[MODULE Settings] [Nitrous] (requires module
link).
2. The arming switch, located on the rear
cylinder breather port, must be cycled from the
"disarmed" (switch light off) to the "armed"
position (switch light on) after the engine is
started. If the switch was left in the “on” position
when ignition was cycled off, arming switch must
be cycled off / on before system will activate.
This prevents accidentally 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.
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
Tuning Strategies and Suggestions for Modified Engines
Your first objective is to make sure you have large enough injectors selected for your application. Your
injectors must be able to supply the proper amount of fuel required with nitrous so engine damage does
not occur when nitrous is activated. The factory injectors have only enough capacity to operate safely on
stock 96 or 103” applications with nitrous; larger injectors will be required for modified 96 or 103” engines,
and any engine larger than 103”. Select an oversize injector and first develop a map for proper engine
operation with the new injectors without nitrous activation.
1) Select and install the proper sized injector for the engine. You need enough capacity to cover the
engine at peak torque (max cylinder fill) plus enough capacity for an additional 15-25% fuel
override when spraying. Once you have determined the size of the oversize injector required for
your application, install the injectors then develop the map for proper operation on gasoline only.
2) Make sure the fuel system is equipped with a new fuel filter, fuel line and fuel pressure is proper
(58-62psi) before you start the mapping operation.
3) Update your software, make sure you are using the TunerPlus (advanced) version of the software
(dark blue screen with right click functions).
The following are the tuning steps required to develop a custom map for a ThunderMax-equipped nitrous
system engine (these steps are for creation and stabilization of a map without nitrous activation, in
preparation for use with nitrous activation):
1) Select a map with closest match to the injector flow rate and key engine parts like cam timing and
compression (pumping pressures) of the engine.
2) Review the map’s air/fuel target pages to make sure they are compatible with the desired target
you want for your engine. Revise the targets as required for your application. Displayed air/fuel
targets are for normal engine operation on gasoline. Nitrous override percentage will richen these
targets (20% is usually a good amount of enrichment from a 13:1 AFR target at WFO under
normal engine operation without nitrous).
3) We have found ideal target air/fuel ratio while
spraying nitrous is between 11:1 to 11.75:1, which
is achieved by the Fuel Enrichment value entered
in the Nitrous Setup window. This fuel override is
activated when the system is armed and the
motorcycle has met the additional presets of
[Engine RPM] and [Vehicle Speed] - once
roughly 70% throttle is reached (this setting is not
adjustable). Note- Fuel and spark overrides are
not active unless system is armed and presets
have been reached, therefore the same map for
general engine operation is used with and without
spraying nitrous.
4) Once injectors and map have been selected, if the
engine is unstable with the first start up (rich or
lean) you can globally adjust the map fuel flow either way to obtain stability. In the TunerPlus tool
bar labeled [Tools], use [Injector Size Compensation] to adjust fuel flow (we suggest entering a
value of no more than +/- 10% at a time, check results).
5) Change the setting in [Configure] [Closed Loop Module Settings] [Max Session (Map)] to 10%
to allow larger fuel adjustments per session, then click [Write (Map) Settings To (Module)].
6) Start the engine, adjust the warm up fuel pages to obtain a stable warm up and idle for both front
and rear cylinders. Air/fuel should track in the range of the air/fuel targets.
7) Ride the motorcycle for about for about 30 to 40 miles. During this ride, try to ride through different
rpm ranges at different throttle positions, example hold at 3/8, ½, ¾, and full throttle. During this
ride, stop and cycle switched power about every 10 miles to re-set session adjustment limits. You
should start to notice the engine running better after the third ignition cycle. This same procedure
can also be performed on a dyno with a 10 to 15 percent load applied.
8) Link to the ThunderMax and from the toolbar, chose [TMax-ModuleControlCenter] [AutoTune
Analyzer] and review the AutoTune Checkup notes. If suggested, perform the AutoMap function
[Run AutoMap]. This feature creates a new, modified base map with the adjusted fuel flow
values smoothed and now established as the baseline. If a large change has been made in the
injector size it may be necessary to repeat the above process again.
9) Once you and the ThunderMax AutoTune Analyzer are satisfied with the non-nitrous activated
map with the larger injectors, move to dyno to verify nitrous settings and operation.
10) Many tuners will complete their base map development then activate the Nitrous setting on their
dyno without filling the bottle so they can verify enrichment and timing adjustments while running
the engine on gasoline. This provides a level of comfort before you actually spray the engine with
Nitrous. Once spraying, if you desire a richer mixture than what you observe on the dyno increase
the Fuel Override percentage in the [Nitrous Setup] window.
This product was developed for professional tuners. Neither Zippers Performance Products or Thunder
Heart Performance Corporation provides ThunderMax nitrous map calibrations for custom engine
applications.
If you do not understand these instructions or the strategies explained within you should not
attempt to install or use this product.
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
Performance Products and/or Thunder Heart Performance Corporation are not
responsible for your engine, and/or the safety of others or yourself…..YOU ARE. There
should be no reason why a seasoned tuner 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!
Support@Thunder-Max.com 109-214 v20130225
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