Zipper Mowers Max 309 360 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 # 309-360 for Big Twin Models  
Touring Models  
FL-A. Unplug the ECM wiring harness from the factory  
ECM.  
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.  
FL-B: Remove the factory ECM from the motorcycle,  
the ECM is held to the electrical caddy by socket head  
cap screws. The screws have a locking agent on them  
and can be difficult to remove. Work the screws back  
and forth slowly to break them loose.  
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.  
FL-C: Install the ECM wiring harness to the  
ThunderMax ECM. Do not install the ECM onto the  
motorcycle at this point. If the ECM is mounted onto the  
electrical caddy at this step, it is difficult to get the fuse  
box in place.  
Step 2 Install the ThunderMax and AutoTune (if  
equipped) modules. Special Note: Module location on  
some model motorcycles (notably all Dyna® and  
Softail® Rocker® models) makes it difficult to insert the  
communication cable once the module is installed. An  
8” ‘pigtail’ harness is available (# 309-324) that can be  
permanently connected to the bike’s ECM harness plug,  
allowing a remote port for the communication cable if  
FL-D: Route the AutoTune harnesses (if equipped)  
through the frame opening before positioning the ECM  
for installation. Re-install the ECM fuse and secure the  
fuse box back into position on the electrical caddy.  
FL-E: Mount the ThunderMax ECM onto the electrical  
caddy using the two factory socket head cap screws.  
Plug the AutoTune harness into the 4-pin gray data  
port (shown).  
desired.  
Compatible with ThunderMax ECM serial  
number 114000 or higher (starting August 2008).  
All Models - Locate the fuse box that contains the ECM  
fuse, remove fuse labeled “ECM POWER”.  
309-360 Installation / Setup Guide V2009.04.23  
1
FXD-B: Remove the  
stock ECM from the  
electrical caddy. The  
caddy must be slightly  
modified for additional  
Oxygen Sensor Installation (AutoTune)  
If equipped with AutoTune, install supplied wide band  
oxygen sensors in the front and rear exhaust pipes.  
2006 FXD and all 2007-up models are equipped with  
narrow band sensors, which must be removed and  
replaced with the supplied wide band units. The wide  
band sensors are longer than the factory sensors.  
Installation of the wide band sensors into factory  
headpipes presents no clearance problems, however,  
some aftermarket pipes may require exhaust pipe  
modification or sensor bung relocation for interference-  
free installation. The sensors must mount 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. Weld-in bungs 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 2007-up models). Weld-in bungs are available from  
Zipper’s (#272-200, straight; #272-202, angled). After  
installation, route the sensor harness away from the  
engine and along the frame when possible, above the  
lowest frame point to avoid the possibility of dragging  
ground during operation. Avoid routing harnesses where  
engine movement or moving parts can contact and  
damage the harnesses or connector plugs.  
main  
harness  
connector  
clearance.  
Use a Dremel or Roto-Zip tool to provide additional  
clearance for the harness plug catch; also remove  
approximately 3/8” from the partition support as shown.  
FXD-C: Because of the impossibility of connecting the  
communication cable without disassembly once  
assembled on FXD models, the cable should be  
permanently installed to the ThunderMax, or the optional  
‘pigtail’ harness mentioned in step 2 used. If using the  
communication cable, and if equipped with AutoTune,  
feed it and the AutoTune power harness through the  
ECM plug port of the caddy and mount the ECM to the  
caddy as shown. The oxygen sensor harnesses should  
exit towards the opposite side of the caddy.  
Connect the sensors to the closed loop module. 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 and rear  
use. It is very important to install these correctly or the  
engine will perform poorly! Tie the harnesses to the  
frame or existing 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.  
FXD-D: If equipped with AutoTune, before reinstalling  
the caddy, feed the front cylinder oxygen sensor harness  
through to the right side of the bike, over the top and to  
the rear of the starter motor. Reinstall the caddy with  
fuse and relay blocks in place. Reconnect the TSSM,  
coil and ECM harnesses and main fuse. If equipped  
with AutoTune, plug the closed loop module into the  
4-pin gray data link on the bike. It is through the data  
port that data from the AutoTune module is transferred  
to the ThunderMax. A ‘Y’ harness is available (# 309-  
343) to keep an open data port if desired. After  
programming and setup, the communication cable can  
be coiled up and kept under the caddy cover if not using  
the ‘pigtail’ harness.  
FXD Tips: The rear harness mounts easily, just coil  
the excess wires and locate them above the  
transmission. The front harness should travel from the  
AutoTune module, over and to the rear of the starter  
motor, behind the exhaust support bracket and between  
the crossover pipe and the transmission.  
Remove the footpeg/brake pedal bracket mounting bolts  
and move the assembly towards the exhaust pipe.  
Route the front exhaust sensor harness under the cam  
cover exhaust support bracket and behind the brake  
pedal; connect it to AutoTune harness.  
Dyna®: ECM installed with  
communication cable attached.  
The sensor plug and harness will drop down to the frame  
rail with a little brake pedal wiggling where it can be zip-  
tied to the frame rail, out of sight and out of harm’s way.  
309-360 Installation / Setup Guide V2009.04.23  
3
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. From the  
‘Tuning Maps’ Tree, click the + sign next to [Module  
309-360 Installation / Setup Guide V2009.04.23  
4
Configuration], then double-click ‘Basic Settings’.  
The basic settings page opens. Check to see if the  
For closed loop (AutoTune) operation, click the ‘Closed  
Loop Processing’ box. For open loop operation, this box  
should not be not be checked (click checkmark to un-  
check). Close the window. Once linked, the system  
detects if an AutoTune module exists on the bike and will  
inform you via screen message if there is a mismatch.  
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  
[Speedo Cal] calibration setting matches your year and  
model; if not, click the button, enter the correct value as  
shown, then click [Close].  
certain that the cable is routed away  
from any part of the motorcycle that  
generates heat.  
Speedometer Calibration Settings  
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  
2004-2005 FXD  
2006-2007 FXD  
2007-up CVO  
2008-up FXD  
2001-2003  
2004-2006  
2007-up  
40960  
45900  
42450  
42450  
4352  
Dyna®  
Softail©  
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 the “Link” Button in 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.  
40960  
42450  
4352  
2002  
2003  
20480  
Touring  
2004-2006  
2007-up (16”)  
2007-up (17”)  
40960  
42450  
42000  
Step 4 Next is to configure the module for open or  
closed loop operation (closed loop operation requires the  
AutoTune module and wide band sensors). Most maps  
will initially open as ‘Closed Loop Configured’ by default.  
To change or edit these settings, select [Configure]  
[Closed Loop MODULE Settings] from the toolbar to  
open the dialog page. This page is divided into two  
halves, the left side controlling the ‘Module’ settings  
while the right side controls the ‘Map’ settings. The  
‘Map’ side is used to store the settings you desire the  
base map to dictate to the module. The ‘Module’ side,  
editable only when linked to the module, can be used  
later to override the map settings if desired.  
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 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].  
309-360 Installation / Setup Guide V2009.04.23  
5
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 and if the bike is a 2007 or later model the 6th  
gear indicator settings are correctly set (Final drive ratio  
[87] for Touring & Softail®, [84] for Dyna® models) Gear  
6 Min TPS [40]). 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.  
gauges that you deem important; if too many are chosen  
your screen may appear cluttered.  
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.  
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.  
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.  
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 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  
section of the toolbar), Section  
3
(Tuning the  
ThunderMax ECM) for further adjustment procedures.  
309-360 Installation / Setup Guide V2009.04.23  
6
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.  
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].  
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  
and a vertical bar will show the actual throttle position.  
See the SmartLink manual for further tuning instructions.  
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  
MAP’s settings).  
ldle 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.  
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.  
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;  
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  
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.  
range is 10-25%).  
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.  
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.  
309-360 Installation / Setup Guide V2009.04.23  
7
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  
8

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