Owner's manual

ManualsBrandsZipper's Performance ManualsFor motorcyclesThunderMax Marelli EFi

Installation

Instructions

For Marelli EFI

Conversion

With AutoTune

Closed Loop

READ ALL INSTRUCTIONS FIRST! If you do not have a H-D® service manual for the year and

model of the motorcycle you are working on, get one before starting the installation to use for

reference. The factory ECM you are replacing is triggered by signals from the cam position and

crankshaft position sensor (CPS), while the ThunderMax, like the later Delphi® system, uses only

the signal from the crankshaft position sensor. We recommend disconnecting the cam position

sensor and installing a new crankshaft sensor and in-tank fuel filter on your (at least) 13-year old

motorcycle during installation. Verify charging system operation and battery condition; check

both ends of battery cables for clean, tight connections. See Pages 7&8 for special procedures

regarding certain model years. This product is legal in California only for racing vehicles which

may never be used upon a highway.

1. Disconnect the battery

positive terminal before

proceeding to step one. Remove

the Marelli intake assembly from

the engine. Remove also the

top engine mount with the

stabilizing link attached to it.

2. The new ThunderMax throttle

body and manifold assembly are

pre-assembled as delivered.

Remove the intake manifold

assembly from the throttle body.

3. Install the manifold assembly

using lightly lubricated new

intake seals (supplied) and the

original intake flanges.

4. Remove the stabilizing link

from the top engine mount,

noting which side of the link was

attached to the engine mount.

Re-mount the link to the chassis

mount using the supplied 3/8-24

button head bolt, 12pt nut and

original washer under the nut as

shown (nut up). Tighten to 40

ft/lbs.

5. Attach supplied special high

pressure 5/16” EFI hose to fuel

rail fitting using supplied EFI

hose clamp (the hose and

clamps supplied are special high

pressure EFI compatible

components, NEVER replace

these with standard hose or

clamps).

6. The original fuel lines will be

retained, but the banjo ends

must be removed. Using a pair

of dial calipers, mark the

crimped factory fitting .210” from

the crimp housing.

7. Using a tubing cutter, cut

through the crimped end.

8. Grasp the fitting with pliers

and twist the line loose from the

fitting and separate it.

Summary of content (8 pages)

PAGE 1
Installation Instructions For Marelli EFI Conversion With AutoTune Closed Loop READ ALL INSTRUCTIONS FIRST! If you do not have a H-D® service manual for the year and model of the motorcycle you are working on, get one before starting the installation to use for reference. The factory ECM you are replacing is triggered by signals from the cam position and crankshaft position sensor (CPS), while the ThunderMax, like the later Delphi® system, uses only the signal from the crankshaft position sensor.
PAGE 2
9. Remove the remaining ring from the rubber hose. Repeat nd this process on the 2 hose. 13. Install throttle cables and throttle body assembly. Attach harnesses for TPS, MAT sensor and IAC motor. Adjust throttle cables for proper closed freeplay and idle to wide-open operation. 10. Attach the fuel supply and return hoses to the manifold using the supplied EFI clamps. 14. Verify clearance between buttonhead stabilizing link bolt and IAC motor plug. 11.
PAGE 3
Your AutoTune module is designed to communicate with the ThunderMax through the bike’s Data Link connector. This port is also where the AutoTune draws its power. However, on 1997-2001 model Big Twins, the 12 volt terminal (#4 in the Data Link plug) is “hot” at all times, not upon “key-on” as are 2002 and later (Delphi) bikes. The Data Link must be rewired to provide power for the AutoTune module only when in the “keyon” position or battery drain will result.
PAGE 4
in both the MAP and MODULE sides of this window. 24. “Initialize” 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 each cycle. DO NOT start the engine or move the throttle at this point. During this time, the fuel pump will also prime and pressurize the system. Check the system for fuel leaks again.
PAGE 5
CLOSED LOOP PROCESSING Your ThunderMax was programmed for closed loop processing during the map loading process. Your SmartLink software will allow you to set Air/Fuel tuning parameters for your ThunderMax and its installed base map when the AutoTune module is installed and AutoTune program is enabled. To set Target AFR and AutoTune Limits, go to the toolbar and click [Configure] [Close Loop MODULE Settings].
PAGE 6
TMax Control Center provides a snapshot of AutoTuned fuel flow adjustments, RPM time logs in increments of 100 RPM’s, engine temperature logs and diagnostic codes. Valuable information about the condition of your tune and how you ride. AutoMap, located within the TMax Control Center, feature creates a custom base map based on AutoTuned fuel flow adjustments.
PAGE 7
Special Procedures For Certain Year Installations 2000 and Early Model 2001 Motorcycles – Page 7 1995-1996 Model Motorcycles – Page 8 2000 and Early Model 2001 Motorcycles For the year 2000 and some early 2001 FL models, the Vehicle Speed Sensor (VSS) signal output wire from the speedo terminates at the 8-pin main harness connector (see illustration below), #8A, pin 5. There is no connection from there to the ECM and therefore no VSS signal to the ECM.
PAGE 8
Special Procedures For Certain Year Installations 1995-1996 Model Motorcycles 1995 and 1996 model motorcycle must have a ground wire added to the main ECM terminal connector at Pin 33 (standard on 1997-2001 models). Parts required are (1) terminal connector H-D # 72326-95 and a length of black wire. Crimp the terminal end to the wire and add the wire to the open port #33 on the main harness connector.