ThunderMax PN#309-380 Sportster - Manual (Page 3)

FX/FLST-N:
Securely tie all harnesses to the frame
and/or other harnesses. Avoid routing harnesses where
engine movement, sharp edges, exhaust systems or hot
engine components can contact and cut into the
harnesses or connector plugs. Be aware that swingarm
movement at full suspension compression reduces the
clearance opening at the rear of the oil tank where the
front oxygen sensor harness is routed (tie harness
inboard of swingarm).
FX/FLST-O:
Install
steel fuse box
mounting bracket.
Plug in the tail light
harness plug,
re-
install the battery
(positive cable first).
Re-install the main
fuse. Replace the
fuse box cap and
attach the fuse box to the plastic fuse box bracket.
Step 2 - Module Installation - Dyna® Models
FXD-A: Remove seat.
Disconnect fuel line from fuel
tank by carefully pushing up the
quick disconnect ring on the
tank fitting while gently pulling
the fuel line down. Loosen front
fuel tank mounting bolt; remove
rear mounting bolt, prop up tank
rear 4-5” with a wood block.
FXD-B: Remove left side cover
to
expose electrical caddy.
Remove fuse box cover and
remove Maxi-fuse.
FXD-C: Remove factory
ECM
from caddy by
pushing up ECM from
bottom and sliding it out
towards you. Depress
locking tab
on
connectors and remove
the ECM from the wire
harnesses.
FXD-D: Remove the three
caddy mounting bolts (do not
remove caddy from bike) to
allow caddy to drop down
slightly towards primary cover.
Pull caddy slightly towards you
to allow room for oxygen
sensor harness routing.
FXD-E: Starting
at the rear cylinder
head,
route the
oxygen sensor
harness behind
the coil and ECM
caddy up through
the frame opening
as shown, then
back down
through the frame
opening, through
the back of the
ECM opening of
the ECM caddy.
Pull the
harness
through far
enough to allow it
to be attached to
the
ThunderMax
ECM. Apply di-
electric grease
(see page 2, G&H)
and
attach the
harness to the
ECM using screws
provided;
plug
black and gray
harness plugs into
ThunderMax ECM.
W ith ECM still
“out” of its home
position as shown,
reinstall (3) caddy
mounting screws.
Verify that oxygen
sensor
harness
moves freely (not
pinched by caddy
reattachment).
Enough
slack
must be left in
harness to allow
ECM to be pulled
out far enough for temporary attachment of the ECM
communication cable for map programming and
adjustments.
FXD-F:
Unplug and remove factory oxygen sensors from
the exhaust pipes. Remove any previously installed
ancillary tuning device including oxygen sensor
eliminators that may be plugged into the factory
oxygen sensor harness. If using an exhaust system
equipped with 18mm sensor bungs (‘06-‘11 style), install
the supplied sensors into the exhaust pipes and tighten.
If retaining factory exhaust headpipes, 18mm bungs will
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Guide V201
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