309-362 Installation V2013.10.15.pdf

8/16/2019 309-362 Installation V2013.10.15.pdf

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www.Thunder-Max.com 309-362 Installation / Setup Guide V2013.10.15 [email protected] 1

#309-362, 2010-13 TBW Tour ing Models

Thank you for purchasing a ThunderMax ECM! Please read through the fo l lowing instruct ions

before beginn ing the insta l la t ion procedure .Following these instructions will ensure that the ECM isinstalled and setup properly for optimal results. If youhave any problems or questions, please refer to theTMax Tuner .pdf Manual, included on the CD (HelpMenu) with this package. Record ser ia l number NOWon your w arranty card, and below for you r records!

Serial # TMWM___________________

Step 1: 1: Insert the TMaxTuner CD into yourcomputer. TMax Tuner willautomatically open theInstallShield Wizard whenthe computer finds the CD-Rom. Follow theinstructions and install thesoftware on your computer. After installing and opening the software the first time,

you will be prompted to install the driver for the USBconnection (see page 4). The TMax Tuner softwarepackage is designed to run on personal computers usingMicrosoft® Windows 2000™, Windows XP™, WindowsVista™ and Windows 7 & 8 operating systems. Thecomputer system must have an adequate amount of freespace on the hard drive for proper operation. TMaxTuner is approximately 140MB when installed. TMaxTuner is not supported by any other operating systems.

Step 2 : Module Installation - Touring ModelsFL-A: Install the ThunderMax ECM. Remove seat andboth side covers. Push up on the bottom of the fuse boxcover to remove the cover (located on the left side of thebike), then remove the ECM fuse from the fuse box.

FL-B: Remove the stock narrow band sensors from theexhaust pipe. Special Note – If you have prev iouslyinsta l led another tun ing device such as a Power

Commander, be sure to remove the device and any

“O 2 Sensor El iminators ” that may have beeninstal led at the senso r harness plug s at that time!

2008-2009 models: 18mm sensors are located at thetop of the head pipe; supplied 18mm wide-band sensorswill replace the stock narrow band sensors. Some stock

2008 model rear bung location may cause interferencewith the transmission lid when using the longerThunderMax oxygen sensor. If this is the case, creasethe pipe next to the bung to change the angle of thesensor for clearance, or relocate the bung for propeclearance. DO NOT pul l or pry on the sensor to gainclearance —the sensor wi l l be damaged i f you do! 2010-13 models: If retaining factory catalyst-equippedheadpipes, 18mm bungs will need to be added to theheadpipes. Bungs should be located no more than 3-4from the head pipe connection (for ideal location, refer tothe factory location on 2009 models). Weld-in bungs are

available from many

sources in straight oangled designs. SeeVideo on adding newbungs on the web a

YouTube.com(search

ThunderMaxAV) othrough your smarphone by scanningthe QR code on page8.Stock 2010-2013

12mm O2 sensors are located downstream on the

factory header pipes, between the engine andtransmission; unplug and remove them as they wilaffect your ThunderMax system performance if leftplugged in. Stock sensor connectors are located undethe bike's right side cover (black and gray plugs). 12 mmpipe bung O2 caps are available from many sources.

FL-C: Install supplied wide-band sensors into the pipesroute the front sensor along the cross brace on theframe in front of the engine and down the lower framerail on the right side of the motorcycle.

Installation / Setup Guide Please Note: This produ ct is Legal in Cali forn ia

on ly for rac ing vehic les which m ay never be used

upon a highw ay. 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 yourapplication and check your local laws before installing.

New! Video Instructions Now Available on You Tube – Smart Phone Users See Back Page


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FL-D:. Route therear sensor leadbetween transmissiontop cover and thestarter, then towardsthe ABS caddy

located under theright side cover.Place the sensorconnector under the ABS caddy.

FL-E: Remove factory ECM from the caddy byspreading the plastic caddy latches at the sides of theECM. Lift the ECM up and to the right to release it fromthe caddy.

FL-F: Disconnect the ECM from the connector as perthe following procedure:Depress button on socket housing of the connector;rotate locking bar until it reaches the full rearwardposition (the index pin on locking bar will engage therear notch in the socket housing).

The connector internal latches are not fully disengageduntil the locking bar on the connector is seated to the fulrearward position to complete removal of the connectorIf you force the socket housing with latches partiallyengaged, it will result in damaging the connector. Onceindex pin is fully seated, with steady yet careful attentionpull apart the connector from the factory ECM andremove it from the motorcycle.

FL-G: With the factory ECM removed, route the AutoTune harness thru the opening on right side of theframe below the down tube for the seat, towards theECM caddy.

FL-H:. If equippedwith factory alarm,detach alarmantenna from ECMcaddy clip by liftingslightly and sliding

to the right of bike(do not disconnect).

FL-I: Locate the package of dielectric grease includedwith communication cable. Spread a small amount ogrease on the AutoTune harness plug inboard of themounting flange to allow the plug to easily slide into theThunderMax ECM, with ThunderMax logo on harnessplug facing up. Attach with screws provided.

FL-J: Install main harness connector to ThunderMaxDe ress button

Rotate locking bar fullytowards rear of bike untilindex pin reaches notch


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ECM. Before installing connector, lightly spread somedielectric grease on harness connector terminals, and onthe inside lip of the connector port opening of the ECMto allow the rubber weather seal in the connector plug toslide into place without binding. Apply a dab of greaseto the (2) upper and lower locating pins on theThunderMax housing as well (arrows). See ‘Tips’ on page 7 for additional dielectric grease instructions.

Before connecting, verify that the locking bar is in thefully open, rearward position (locking bar index pin is

fully engaged with rear notch in the socket housing).

Important Note: If socket housing with grounding pin

are not properly aligned during connector installationdamage to the grounding pin will likely occur, which willrequire you to return the ThunderMax ECM for repair tothe damaged pin.

Rotate the locking bar forward to engage the connector.Observe that the colored cam locks are moving with thelocking bar; proper execution will show both colored camlocks visible in equal amounts on the forward-facing sideof the connector when the locking bar is in its fullyseated position with the button lock engaged, as in theimage below (do not force the locking bar). Index pinwill engage front notch in socket housing.

Important Note: Pin and socket housing of theconnector must be fully engaged before you rotate thelocking bar to the forward position. Forcing the lockingbar forward before the connector is fully engaged wildamage the connector and/or the ECM

FL-K: Place the ThunderMax ECM into the ECM caddy

If equipped, position alarm antenna as shown.

FL-L: Connect the oxygen sensor harnesses to the AutoTune harness. Carefully wire tie the leads to themotorcycle. Take extra care to ensure harness andsensor leads are safe from rubbing or chaffing on themotorcycle. Use all supplied wire ties; add extra ties ineeded to properly secure wiring on your installation.

FL-M: Position the rear connector under the ABS caddyand attach with wire ties provided as shown.

FL-N: Position front connector above lower frame raibetween engine and transmission. Attach to existingharness with provided wire ties. Inspect all wiring tomake sure it is clear of moving parts and excessive heat

FL-O: Re-install the ECM fuse and replace the sidecovers.

Fully closed position:Index pin engagedwith forward notch

Sliding colored cam locksin fully open positiontowards rear of bike

Sliding colored cam locksin fully closed positiontowards front of bike

Fully open position:Index pin engagedwith rearward notch


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I f you purchased a pre-mapped system, you

may skip s teps 3-6; proc eed to Ini t ia l izing (step 7).

Step 3: Choosing and Installing a MapNow it’s time to turn yourattention back to yourcomputer. Open your TMax

Tuner software. There is noneed to link to the module atthis time. To ensure you areworking with the latest versionof TMax Tuner software andhave the most up-to-dateselection of base maps, it issuggested that you establish anInternet connection and click[Configure] on the tool bar,then [TMaxI Software Update] and follow the prompts.

After uploading newsoftware (if found), next

click [EFI Maps] [EFIMap Listings (ThrottleBy Wire)], double-clickany map; when the BaseMap Name Encodingwindow appears, click the [Check Internet ForUpdates] button and follow the prompts. Close windowafter updating.

Loading Interface Drivers and VIN Number _

Next, the TMax Tuner software for the ThunderMaxThrottle By Wire EFI systems contains the correctdrivers required for USB interface with the ECM. Connect the USB cable to the specific port on your PCthat the driver will be configured to, and the ThunderMaxECM, located under theretainer plate (loosenretainer screw, rotateretainer plate and openrubber weather seal).Open the TMax Tuner

software and turn thebike’s ignition andhandlebar switches to theon/run positions. Followthe prompt instructions forinstalling the driver.

Next, go to the menu bar and select [Tuning Maps][+Module Configuration] [Module Service Data].Under the Module Information tab, click [Edit VIN/SRN]

and enter your motorcycle’s serial number (CAPITALLETTERS ONLY), click [OK] then [Close]. Turn ofignition when finished. Once your software, mapdatabases and USB driver are verified as up-to-date, goto selecting and loading your base map.

Selecting A Base Map File from the Database

The TMaxII Tuner EFI Map Database will help youchose a Base Map for your application. To open the MapDatabase, select fromthe toolbar [EFI Maps][EFI Map Listings(Throttle By Wire)].

Available base mapswill be shown (if the[Show All Maps] button at the lower leftof the screen ishighlighted, click it toclear any filtered maps so all maps will be shown).You will now be able to select the closest Base Map foyour engine combination. Please read the followingsection on Key Elements, this will help you quicklynarrow down the selection of available Base Maps andfind the right one for your application.

Base Map “Key Elements”

The reason for selecting a Base Map by “Key Elements”is to find the closest Base Map match available for yourcombination, identified by the most critical componentsThese include:Engine Size. A correct match to the engine’s stroke ismore important than an exact match of enginedisplacement. Stroke and cam timing influence enginepumping pressures. The correct shape of spark curvesin the base map will be best matched by engine stroke.Throttle Body / Injector Size. Choose the throttle bodyand injectors being used for your application (mosapplications will be “stock” unless performance partshave been installed).

Camshaft. Many popular short duration aftermarkecams (less than 240° intake duration) perform well whenusing a stock-cam base map. With broader timing cams(more than 240° intake duration) you may find thachoosing a base map calibration developed for anaftermarket cam to be a better choice.Exhaust System Design. There is no need for concernif an exact brand match does not appear in the BaseMap library. Simply select the Base Map with theclosest style of exhaust system (Slip-ons, 2:1, True


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Duals). Choosing the closest style will yield excellentresults. Group your exhaust system in one of thefollowing three categories:Factory Head Pipe with Crossover: Dual exhaustsystems with a cross over pipe that connects the frontand rear exhaust pipes (includes 'X' pipes). Typicallyused with accessory slip-on mufflers. Bikes withcatalyst-equipped mufflers or headpipes requiremaps designed for use with catalyst-equippedsystems or damage to the catalyst can result. ThunderMax maps for use with 96, 103 and 110” internally stock engines are catalyst-safe maps.

2 into 1: Both head pipes converge into one collector.

(True) Dual Exhaus t: 100% separate exhaust pipes.ThunderMax’s AutoTune system allows you to choose aBase Map that isn’t an exact match of components andstill have excellent results. Even if your combination isn’tlisted, select the closest Map match and let the AutoTune create your custom Base Map while you ride.

The closer match that the Base Map is to yourcombination, the faster the system will achieve thedesired AFR Targets. This simply means less time toestablish and maintain a great tune. Once you haveallowed the system to establish custom AFR fuel-flowadjustments, you can use the AutoMap function tocreate an all-new Base Map based upon the Auto Tunedlearned adjustments. To use the AutoMap feature, seethe tuning manual for the procedure on how to createyour custom base map using AutoMap.

Base Map File Browsing / Selection

With your Base Map Definitions window open, you maybegin narrowing down the list of maps for yourapplication. To sort the map files by a particular keyelement, left-click on the column heading to arrange thecolumn in alpha/numeric order. All of the columns canbe sorted in this manner for filtering purposes. Filter themaps to identify the base map that best matches yourapplication by following these easy steps:

First (in order of importance) place your curser over the‘Family’ heading and left-click to change the sort orderof that column. Scroll down the list and place yourmouse pointer over you bike’s family match and right-click to filter out no-match applications from the list.

Tip - After any filtering, notice that the [Show All Maps] button at the bottom left is now selectable. At any time ifyou want to return to the complete library listing, left-clickthe [Show All Maps] button and you will start over withall Base Map Files in the library displayed.

Second, right-click the engine size under ‘Engine Typethat matches your engine. All maps that do not matchyour selection will be filtered from the screen.

Third, place your curser over the ‘Throttle’ column andright click your match (injector size is more importantthan throttle body size if you have to choose).

Fourth, right-click the ‘Cam’ that closest matches youapplication.

Fifth, right click the ‘Exhaust’ that closest matches you

application.

Keep right-clicking the application columns until youhave located the best map match (in the case ofidentical maps, choose the latest date). Highlight themap you’ve chosen (left-click; blue bar indicatesselected map) and click the [Close] button.

Step 4: This brings you to the ‘Base Map NameEncoding’ page, from which you can review the mapparameters. Once verified, click the [Load BaseMap]

button to load the map into the software.

Note - If you’re still unsure of which Base Map to select, please email the specifications of your Key Elements [email protected]. Please title the emai“Base Map Selection” for a faster response.


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Step 5: Next, go to the [Tuning Maps] Tree and clickthe [+] sign next to [Module Configuration] to revealthe [Basic Settings] command. Open the BasicSettings window and click the [Speedo Cal] button (listwindow appears).

Verify that the Speedometer Calibration is set for youryear motorcycle based on the chart. If it is, click[Cancel]; if it is not, enter the correct value and click[OK], then [Close] the Basic Settings window.

Step 6: Now that the Base Map is loaded into theTMaxII Tuner software; you must ‘Write’ (transfer)the Base Map to your ThunderMax ECM. With thecommunication cable connected, linking to the module isnow automatically performed with the TMaxII Tunersoftware when the handle bar and key switch are in theon/run positions. Turn the ignition switch on; the red[Link] button will turn green to indicate a successful link.

Once linked, from the toolbar click [File] [Write ModuleMaps and Settings], answer [OK] to the 'To RunningPosition' command in the 'Module Configuration WriteOptions' window that opens; the transfer bar thenappears during the map load. Once the Base Map hasbeen written to the module, clear any active DiagnosticCode readings and Learned Fuel Adjustments that mayhave been created during the live module testingsession that each ThunderMax module must pass.While linked, from the Tuning Tree select [ModuleConfiguration] [Diagnostic Codes]. When theDiagnostic Codes window appears, select [ClearDiagnostic Codes]. After completing this step, proceed

to [Map Editing] menu on the tool bar and select [Clear“Learned FuelAdjustments (CLPOFFSET)”]. Thesesteps ensure youwill be starting witha “clean slate” BaseMap.

Step 7: Initialization Procedure

IMPORTANT STEP BEFORE STARTING

This step is required for new module installation, orwhen interruption of 12v power to the ECM takes placeExample: battery change, removal of maxi fuse, etc

Turn the ignition switch on with the handlebar rockeswitch to the run position for 20 seconds, uninterruptedCycle the ignition switch off and on, then start theengine. Let the motorcycle idle on its own for 15seconds. Cycle the ignition off and restart themotorcycle; normal idle speed should be attaineddepending on engine temperature. Warm-up cycle wilhave slightly elevated idle speed (approximately 1200rpm) until engine reaches operating temperature. Todisconnect from the PC, click the Unlink button (turns tored), remove theUSB cable and snapthe weather seal

plug into the USBcable port. Positionthe retainer plateover the weatherseal and tighten theretainer plate screw.

Congratulations! You have successfully installed andset up your ThunderMax ECM. Now it’s time to ride thebike and let ThunderMax optimize your EFI systemSeveral riding sessions that allow the engine to reachnormal operating temperature should be completed withas much variation in terrain and RPM as possibleYour ThunderMax customizes your map based on your

engine, ambient conditions and your riding habits. Onceseveral sessions have been logged, link to yourThunderMax and select [TMax Module Control Centerfor an automatic analysis of the adjustments that havebeen made, and follow prompts for further action if moreoptimization is suggested.

Need Help?We have included manyeasy-to-use features forsupporting and enrichingyour ThunderMaxexperience. A full tuning

manual, links to onlinesupport documents andsites as well as the abilityfor you to easily attach amap or recorded enginemonitoring log to anemail directly to oursupport department arefound here.


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www.Thunder-Max.com Installation / Setup Guide V2013.10.15 [email protected] 7

TIPS AND GENERAL INFORMATION

Several support features are located under the [Help] menu:

A comprehensive tuning manual

Links to allow transmission of module and mapdata via E-mail directly to TMax support

Links to allow transmission of monitor logs(recorded riding sessions) via E-mail directly toThunderMax support

Links to Thunder-Max.com web site forsupport documents and videos

System Updates are available through TMax Tunerwith an internet connection. Software, Firmware andMap updates can be downloaded; check frequently forupdates.

TMax Tuner Module Control Center provides asnapshot of AutoTuned fuel flow adjustments, RPMtime logs in increments of 100 RPM’s, enginetemperature logs and diagnostic codes. Valuable

information about the condition of your tune and howyou ride.

AutoMap feature creates a custom base map basedon AutoTuned fuel flow adjustments. Create a custombase map with just a few clicks!

When the TMax Tuner program is opened, itautomatically retrieves the last map that was open.

Any time you link to your motorcycle: Read the mapthat is installed in the ThunderMax ECM by selecting[File] then [Read Module Maps and Settings] on theTMax Tuner toolbar. This will synchronize the map fileloaded into the ThunderMax ECM with the TMax Tuner

software.Save your edited maps to your hard drive using the[Save As] command. Document the changes in [MapNotes] located under [EFI Maps] on the toolbar.These notes are stored with the saved map; rememberto edit them when making changes for future reference.

When a new map is installed any existing learnedfuel adjustments need to be cleared [Map Editing][Clear Learned Fuel Adjustments]. Linking or editingan existing map within the module does not requireabove steps.

AFR Correction vs. Engine Temperature page isused to adjust warm-up AFR’s. If the engine requires

more fuel during warm-up (start to 200°), use thisfunction to adjust. See TMax Tuning Manual forprocedures..

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 edit AFR targets at

specific throttle positions and RPM’s that will be

learned during closed loop processing. 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.

AFR vs. Engine Temperature - During warm-up, the AFR on both cylinders will show richer than the targe AFR at operating temperatures; this is a normal part othe warm-up map. No permanent changes to AFRtargets and adjustments are made below 200 degreesSee TMax Tuning Manual for applications andprocedures.

Interrupting 12v power to the module (batteryservice/replacement) requires system to be reinitialized (Step 7). Check battery terminal tightness aspart of routine service (like during oil changes)avoid stacking accessory power leads onto maibattery cables. If equipped with dual battery post portsconnect accessories separately.

In-Tank Fuel Filters should be inspected as a part oroutine maintenance. The filter is small and one badload of fuel can clog it. The factory recommendedservice interval is 25K miles.

Fuel pressure should b e c hecked duringperiodic service; this is also the first thing to checkshould you experience sudden or gradual decreasingperformance. For any EFI system to operate properly,your fuel system should build and maintain 55-62 PSIof fuel pressure; your dealer can perform this simpletest quickly.

Oxygen Sensors: Included Bosch wide-band sensorsare very robust and durable; under normal conditionsshould last 50K miles or more. Circumstances that candamage or shorten the life of your sensors include:

Leaded fuel – Race fuel

Oil deposits from oil consumption problems

Excessive moisture exposure

Excessive (extreme) heatThere is no warranty on sensors.Replacement P/N is 309-355.

H-D® released a Tech Tip (#418) regarding improving conductivity atthe throttle body wire connector

(TCA) lug. Carefully remove theharness plug from the throttlebody, clean the male TCA pinswith a swab and alcohol, applydielectric grease to the femaleterminals and reassemble. Werecommend this procedure


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For additional information, scan the QR-codes below withyour smart phone for links to video instructions.

Software Installation Software Update TBW Module Installation

Initializing Instructions Lowering Idle Feature Auto Support Feature

Installing Exhaust Bungs How ThunderMax Works

Documents

309-362 Installation V2013.10.15.pdf