Zipper Mowers Thunder Max 309 365 User Manual

Installation / Setup Guide  
Please Note: This product is Legal in California  
only for racing vehicles which may never be used  
upon a highway. The user shall determine suitability of the  
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.  
Part # 309-365 for Sportster® Models  
Step 2b Unplug and remove the factory ECM from the  
motorcycle (located on top of the rear fender under the  
seat). Plug in and install the ThunderMax ECM in the  
same location over the locating pins shown.  
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  
Step 2c Install the AutoTune module. Mount the  
AutoTune module to the frame backbone using supplied  
wire ties (right side view below). Position housing so  
wires exit to the left as shown below.  
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.  
Due to the mounting location and space constraints on  
the Sportster® 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 under the seat; the AutoTune module must  
be mounted separately.  
Step 2a Remove  
the seat. Open the  
left  
side  
frame  
cover (opposite the  
oil tank) to expose  
the fuse panel.  
Locate and remove  
fuse labeled “ECM  
POWER” (top left  
fuse; sticker with  
fuse identification is  
located on the inside of the frame cover).  
309-365 Installation / Setup Guide V2009.04.23  
1
Second, place your curser over the ‘Throttle’ column  
and right click your match.  
Step 3 Load a Base Map to your SmartLink software.  
Selecting a base map for your ThunderMax is easy  
thanks to the filtering system in the SmartLink software.  
Open SmartLink; from the toolbar choose [EFI Maps]  
[EFI Map Listings / Definitions]. You should first  
update the Map Definitions file to ensure you have the  
latest available maps.  
Close the [Base Map  
Definitions] window, then click the [Check Internet For  
Updates] button (requires internet connection; follow  
prompts). After updating, select [Select BaseMap]..  
Third, right-click the ‘Exhaust’ type that closest matches  
your application.  
Fourth, right click the ‘Muffler’ column if further definition  
of the exhaust system is required (depends on exhaust  
application). Keep right-clicking the application columns  
until you have located the best map match (in the case  
of identical maps, choose the latest date). Highlight the  
map you’ve chosen (left-click; blue bar indicates  
selected map) and click [Close] button. This brings you  
to the ‘Base Map Name Encoding’ page, from which you  
can review the map parameters. Click the [Load  
BaseMap] button to load the map into the software.  
Available base maps will be shown (if the [Clear Filters]  
button at the lower left of the screen is highlighted, click  
it to clear filtered maps so all maps will be shown).  
Filter the maps to locate a base map that best matches  
your application by placing your curser first over any  
‘Engine Type’ that matches your engine and right-click it.  
All maps that do not match your selection will be filtered  
from the screen.  
From this page you can load the base map into the  
software by clicking the [Load Base Map] button.  
[Close] this page to view the open map page.  
309-365 Installation / Setup Guide V2009.04.23  
3
From the toolbar, click [File] [Write Module Maps and  
Settings], answer OK to the message that informs you  
that you are about to overwrite the current map in the  
module; the transfer bar appears during the map load.  
Step 4 From the ‘Tuning Maps’ Tree, click the + sign  
next to [Module Configuration], then double-click  
‘Basic Settings’. The basic settings page opens.  
Check to see if the [Speedo Cal] calibration setting  
matches your year and model; if not, click the button,  
enter the correct value as shown, then click [Close].  
Step 7 Verify Module Settings. Before performing this  
step, clear any active Diagnostic Code readings. While  
linked, from the Tuning Tree select [Module  
Configuration] [Diagnostic Codes].  
When the Diagnostic Codes window appears, select  
[Clear Diagnostic Codes]. After completing this step,  
select Basic Settings from the Module Configuration  
menu and verify that the speedometer calibration is  
correct. After verifying these settings, click [Write Basic  
Settings]. If the installation is to be operated in closed  
loop  
mode  
(with  
AutoTune  
module),  
select  
[Configuration] from the toolbar menu and click  
[Closed Loop Configuration]. Verify that the [Closed  
Loop Processing] and [AutoTune] boxes are checked  
on the left (module) side of the window.  
Speedometer Calibration Settings  
XL 883  
2007-up  
2007-up  
48400  
46000  
XL 1200  
Step 5 Now you are ready to ‘Link’  
and ‘Write’ the map to the ECM.  
Attach the communication cable  
from your computer to the  
ThunderMax  
module,  
making  
certain that the cable is routed away  
from any part of the motorcycle that  
generates heat.  
IMPORTANT STEP BEFORE STARTING  
Next, ‘Initialize’ the ThunderMax ECM. Initializing  
synchronizes ‘home’ positions for the TPS and IAC, and  
is a required step any time battery power has been  
interrupted or established to the ThunderMax ECM.  
With the handlebar switch in the ‘ON’ position, cycle  
the key switch on and off 3 times, leaving the  
ignition on for 30 seconds, then off for 30 seconds,  
each cycle. DO NOT start the engine or move the  
throttle during this process. After 3 on/off cycles, make  
certain that the motorcycle is in neutral and start the bike  
2 times, letting it settle at idle for 10 seconds; the idle  
should be smooth and steady. Some engines may  
require several on/off engine starts to initialize properly.  
This initialization process  
must be performed any time  
battery power is interrupted  
to the module (after battery  
servicing/winterization, etc).  
After initialization, shut off the  
engine, but stay linked for  
step 8.  
Special Note for International Model Bikes with  
Active Exhaust Enabled: If your bike is equipped with  
a working Active Exhaust Valve, you must unplug the  
active exhaust harness before linking to the module, as  
the AEV circuitry conflicts with the communication  
stream. You can re-connect the harness after unlinking.  
If the stock exhaust has been changed, disregard this  
step. ThunderMax does not support active exhaust  
Step 6 To link to the module, turn the key switch to the  
“Ignition” position, making certain the “RUN / OFF”  
rocker switch (Kill Switch) on the handlebar controls is in  
the “RUN” position.  
Select  
Button  
the  
in  
“Link”  
the  
SmartLink software.  
The button turns  
green to indicate a  
successful link. Answer [No] to the “Do you wish to  
READ the module map now” question at this time.  
309-365 Installation / Setup Guide V2009.04.23  
4
the IAC position, the engine will idle above the idle rpm  
specified in the idle speed vs. engine temperature page.  
If it determined that these automatic adjustments have  
not resulted in satisfactory operation of the engine,  
consult the SmartLink Manual (available under the Help  
Step 8 Before restarting the engine, from toolbar click  
[Monitoring] [Show Gauges]. The “Engine Speed”,  
“Engine Head Temp”, “IAC Position”, “AFR Front”, AFR  
Rear” and “AFR Target” gauges are automatically  
formatted and are shown on the screen. Additional  
gauges can be created if desired (see SmartLink Tuning  
Manual under Help menu), but the above gauges are  
most helpful during initial set up. You may select any  
gauges that you deem important; if too many are chosen  
your screen may appear cluttered.  
section of the toolbar), Section  
3
(Tuning the  
ThunderMax ECM) for further adjustment procedures.  
CLOSED LOOP PROCESSING  
When equipped with AutoTune, your SmartLink software  
will allow you to set Air/Fuel tuning parameters for your  
ThunderMax and its installed base map. To set the  
AutoTune Limits, go to the toolbar and click [Configure]  
[Close Loop MODULE Settings].  
Step 9 Select the “Monitor” button to active the gauges.  
It is located beside the “Link” button and will turn green  
when the monitor gauge functions are live. The gauges  
will be displayed if they were not already on the screen.  
The Closed Loop Configuration dialog page opens; the  
right side shows the default MAP settings stored in the  
MAP file (settings are applied to the installed base map  
during the ‘Closed Loop Format’ conversion performed  
by SmartLink), while the left side shows what the module  
is currently set to (unadjusted, these settings will mirror  
Step 10 Now select the IAC Stops vs. Engine  
Temperature page from “IAC Curves” menu within the  
tuning  
tree.  
Strike  
the  
spacebar to show the actual values of the tuning block  
(use left/right arrow keys to move the block marker).  
Make certain that the motorcycle is in neutral and the  
engine is cold, and then start the engine. Once the  
engine idle is stable after 15- 20 seconds, select the  
“IAC-Auto” button (Idle Air Control Auto Adjustment).  
Allow the “IAC-Auto” function to run at idle until the  
engine head temperature reaches 275 degrees. After  
reaching temperature of 275 degrees, the “IAC-Auto”  
function automatically shuts off. You can terminate this  
function at any time, and re-run it at a later time if you  
wish.  
MAP’s settings).  
Step 11 Unlink the SmartLink software from the ECM,  
turn off the ignition switch and remove the  
communication cable from the ThunderMax ECM. Use  
the ‘Save As’ command to create a folder and save the  
map to your hard drive. The motorcycle is now ready to  
be ridden. Several riding sessions that allow the engine  
to reach normal operating temperature should be  
completed. During this process, the IAC virtual stops will  
automatically be adjusted to the IAC target values set  
within the map’s basic settings. This feature  
automatically adjusts how the engine comes back to the  
specified idle speed. If the IAC stops are set too low, the  
engine will dip below the specified idle speed during  
certain transient conditions. If the IAC stops are above  
The un-highlighted left ‘MODULE’ side of the page  
allows editing of those settings within the MODULE for  
tuning purposes, while unaffecting the MAP settings. To  
edit module settings, click the [Link/Read (Module)]  
button (left side highlights/active). You can now edit  
these settings within the live module should you want to  
change any of the settings from the MAP default  
settings.  
Closed Loop Processing (Module) – Check [ON] to  
enable closed loop AutoTune processing. During closed  
loop processing, the ThunderMax module processes  
feedback from the oxygen sensors to adjust the fuel  
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5
volume at all points by creating learned “offset” points  
from the installed ‘base map’ fuel points. The ‘static’  
base map is dynamically used by the ThunderMax  
module and the AutoTune’s active (closed loop)  
feedback system. This system optimizes the fuel points  
to fit the target air/fuel ratio through ‘learned offset  
points’. These ‘learned offset points’ are stored within  
the ThunderMax and are used in conjunction with the  
base map. The ‘base map’ fuel points are not being  
adjusted by either the AutoTune or ThunderMax  
modules.  
and a vertical bar will show the actual throttle position.  
See the SmartLink manual for further tuning instructions.  
Idle Air Control Override (Module) - Check [OFF].  
This setting should not be checked on except for  
diagnosing a particular type of supported problem or  
during tuning on a load cell dyno. Changing this setting  
will lead to starting and idling problems.  
Maximum CLP Offset (Module) [Session (Module)]  
button sets the AFR maximum learning correction from  
the base map’s fuel setting per session by percentage  
(range is 0-10%). A ‘session’ is defined as the period of  
time from engine on to engine off (per cycle).  
[Maximum (Module)] button sets the total AFR  
maximum learning correction from the base map’s fuel  
setting by percentage (regardless of number of sessions;  
If AutoTune Closed Loop Processing is un-checked, fuel  
points will be adjusted to the last learned offset points, or  
if no learning has occurred, to the original base map  
points. Stored offset points remain within the module; in  
the event that power is interrupted for any reason, the  
learned offset points remain until re-learned or cleared  
under the [Map Editing] toolbar menu.  
range is 0-25%).  
Unless your application is a  
considerable mismatch to the installed base map, the  
default settings of 5 and 20 percent are sufficient for  
most AFR corrections.  
Air Fuel Ratio Override (Module) – A single Target  
AFR setting can be applied using this command.  
Clicking this box and changing this number overrides  
ALL ‘Air/Fuel Ratio vs. TPS’ pages at all RPM’s. To  
target specific Air/Fuel Ratio RPM ranges and throttle  
positions, leave this box unchecked and edit the  
individual ‘Air/Fuel-TPS @ RPM’ map pages located  
under the [Tuning Maps] tree. Individual Air/Fuel  
targets are pre-set within the base map to provide a  
good balance between power and economy. Individual  
cell throttle position/rpm AFR targets can be viewed and  
adjusted on these pages. Use the left/right arrow keys  
to navigate the individual blocks (strike the spacebar to  
view the values); use the up/down arrow keys to adjust  
the values. Click the [Monitor] button when linked live  
You should always pick the best possible map match  
during the selection of your base map. The theory  
behind this is to reduce the range and time the closed  
loop system needs to learn offsets (corrections) for the  
target AFR. If your map selection is a poor match to the  
application, the amount of learning needed will be  
significant. Review the parameters of your base map vs.  
available base maps under ‘Base Maps Listing’ to  
ensure you have the best map match and the latest  
version of the map.  
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6
TIPS AND GENERAL INFORMATION  
Several support features are located under the  
[Help] menu; some require an internet  
connection.  
Air/Fuel-TPS @ RPM These pages reflect  
desired targets of AFR to throttle position at  
every 256 RPM. Example: if you desire a leaner  
mixture for added fuel economy then you can  
easily make multi-tiered AFR targets at specific  
throttle positions and RPM’s that will be learned  
during closed loop processing.  
A comprehensive Tuning Manual in PDF  
format is included on the CD for viewing and  
printing from your desktop.  
When the SmartLink program is opened, it  
will automatically retrieve and open the last map  
that was open.  
During warm-up, the AFR on both cylinders will  
be richer than the target AFR at normal  
operating temperatures; this is a normal part of  
the warm-up map. AutoTune and its targets are  
inactive below 200 degrees.  
Any time you link to your motorcycle: Read  
the map that is installed in the ThunderMax  
ECM by selecting [File] then [Read Module  
Maps and Settings] on the SmartLink toolbar.  
This will synchronize the map file loaded into the  
ThunderMax ECM with the SmartLink software.  
Target air/fuel ratios can be viewed on the  
Air/Fuel-TPS @ RPM pages.  
When these  
pages are open, you can view the target AFR by  
clicking on a dot and tapping the space bar to  
view the target at a specific throttle position for  
that RPM. Use arrow keys to raise/lower targets.  
2003 FLT/FLHT models: H-D® used 2 different  
speedometer calibrations during the extended  
2003 model production. Which calibration you  
may need is easily identified by checking the  
part number on the back of your factory ECM.  
Calibration 20480 is used if the part number  
ends in -03, while 4352 is used if the ECM p/n  
ends in -02. If your turn signals don’t cancel on  
a 2003 model, try the alternate setting.  
Writing new or modified maps to the module  
requires the system to be re-initialized (Step 7),  
and any existing learned fuel and IAC  
adjustments to be cleared (Map Editing, clear).  
Linking and editing an existing map within the  
module does not require above steps.  
System Updates are available through  
SmartLink with an internet connection.  
Software, Firmware and Map updates can be  
downloaded; check frequently for updates.  
2007-up Big Twin models: There are two  
settings in the [Module Configuration] [Basic  
Settings] page that should to be set to the  
following to enable the 6th gear indicator light to  
function:  
In-Tank Fuel Filters should be inspected as a  
part of routine maintenance. The filter is small  
and one bad load of fuel can clog it. The factory  
recommended service interval is 25K miles.  
Final drive ratio [87; 84 for 06-07 Dyna®]  
Gear 6 Min TPS [40].  
Sportster® models: The [Main Relay Loc]  
must be set to “1” under the [Basic Settings]  
[Module Configuration] page, or the engine will  
not start.  
Save your edited maps to your hard drive  
using the [Save As] command. Document the  
changes in [Map Notes] located under [EFI  
Maps on the toolbar. These notes are stored  
with the saved map; remember to edit them  
when making changes for future reference.  
Accel Fuel is be used to tune throttle response  
(go to [Module Configuration] [Basic Settings]).  
AFR Correction vs. Engine Temperature page  
is used to adjust cold start AFR’s. It is active yet  
should be used with extreme caution. Any  
changes made to this page affects all maps, at  
every throttle position, every 256 RPM’s! See  
SmartLink Tuning Manual for procedures.  
Oxygen Sensor Care: Items that can damage  
or shorten the life of your sensors:  
Leaded fuel – Race fuel  
Oil deposits from oil consumption problems  
Excessive moisture exposure  
Excessive (extreme) heat  
There is no warranty on sensors. Replacement  
P/N is 309-355.  
AFR vs. Engine Temperature is active yet at  
this time you should be discouraged from  
making any changes to this page.  
Installation / Setup Guide V2009-04.23  
7

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