ThunderMax Electrical Issues - Marelli and Early Delphi Systems - Manual

New, Unusual Running Conditions on
1995-2001 ThunderMax Marelli Touring Models
and 2001-2005 Delphi Type Models
v.07172012
Since 1995, H-D® has been building fuel injected models. Now that
these vehicles are starting to age, new and unusual operational
problems are appearing, which are worth discussion.
As the oldest cycles in the fleet, 1995-2001 Magnetti-Marelli®
equipped models were the first to experience symptoms. Additionally,
many aging sensor and wiring problems are present in 2001-2005
Delphi models.
A data collection should be performed with a running log. This will
allow the data to be properly analyzed using new tools in the
ThunderMax software. ThunderMax diagnostic efforts have uncovered
issues related to wiring, degraded sensors, or faulty IAC motors which
will make your engine perform poorly. Careful inspection of these
areas and components is critical to locating and correcting the
problem.
Throttle Body Branch Inspection
The fuel tank must be removed to inspect the engine harness and
clips which attach to the m/c backbone on the frame. Many
harnesses installed on motorcycles between 1995 and 2003 were
tied too tightly to the backbone. When the engine shakes in the
chassis, the wiring is pulled which slowly degrading the integrity of
the wires. Additionally, the original wiring has already been
subjected to 10 to 15 years of stress, heat and vibration, making
this area a big target for locating problems. The harness must be
released from the last frame clip to allow enough slack to reposition the
connectors for the Delphi throttle body. Stress from
constant tension could be pulling strands of wires out of the engine
harness, creating intermittent and inconsistent engine operation.
(See image of harness clip/wiring branches below)