ThunderMax PN#309-385 - GenII Sportster User Manual
Page 5
www.Thunder-Max.com
309-385 Installation / Setup Guide V2012.06.28
5
Rocker® and FXSTSSE
2
Models
ST-A: Unplug and remove
the
factory
oxygen
sensors.
Thread
the
supplied front sensor up
from the bottom through
the
gap
between
the
engine
and
kickstand
mount in front of inner
primary cover; install into
front pipe. Install sensor in
rear exhaust pipe; route
sensor lead under oil tank
to
right
rear
of
transmission. Leave leads
loose for connection after
ECM installation.
ST-B: Locate and remove
the ECM fuse. Remove
rear fender assembly and
rear wheel to access ECM
mounting caddy. Remove
the plastic shield, then the
ECM
caddy
mounting
bolts.
ST-C: Remove the caddy
from the chassis, then remove
the factory ECM from the
caddy. Mount the T-Max ECM
using two mounting bolts.
ST-D:
Install
pigtail
communication harness to 36-
pin ECM plug as per included
instructions. After applying
dielectric grease (step 2),
connect the 36 pin connector
to the ECM. Re-install the
ECM caddy with the oxygen
sensor harnesses routed over
the top of the swingarm pivot
bolt; connect the rear sensors
and coil the excess harness
for the rear sensor (shown red) and tie it up under the
transmission housing, clear of the suspension and any
other moving parts.
ST-E: Route the front sensor lead along the right frame
rail, position connector as shown behind brake pedal; tie
harness to top of frame rail (avoid hot or moving parts).
ST-F: Connect and tie
front
oxygen
sensor.
Route
4-pin
AutoTune
communication
harness
and pigtail to the factory
grey data-port connector
located at the battery and
plug
in
the
AutoTune
harness. Replace the ECM
fuse, position the pigtail for
convenient access and re-
install the rear wheel and
fender assembly; proceed to step 3.
Oxygen Sensor Installation Notes
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 from many sources in straight or angled
versions if current bungs present clearance issues.
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]..
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).