The ThunderMax booth inside...
The ThunderMax booth inside Destination Daytona at 2010 Bike Week was packed with eager enthusiasts.
Indepth
Zipper's Performance is the cure-all for horsepower enthusiasts looking for more getup and go. The company has been in the motorcycle performance business since 1978 and a manufacturer of some of the highest-quality engine and transmission components around.
In 2002 Zipper's teamed up with Thunder Heart Performance, which manufactures the system, and launched the ThunderMax with AutoTune. The ThunderMax system is a wide-band, closed-loop system that continually and automatically adjusts the air-fuel ratios whenever you ride, even when there are changes in ambient temperatures or elevation. This system also claims quicker throttle response, increased power, and cooler operating temperatures, and is backed by a three-year warranty.
After several years of development, the ThunderMax is now available for Throttle-By-Wire Harleys. Basically, a throttle-by-wire setup utilizes a throttle actuation sensor to move the throttle blade in place of a throttle cable setup. So instead of operating the throttle mechanically, throttle positioning is now operated electronically on some motorcycle models. The ThunderMax with AutoTune for Throttle-By-Wire motorcycles was developed specifically to handle this new throttle system.
We caught up with the guys from ThunderMax installing these modules like gangbusters at 2010 Daytona Beach Bike Week. Fortunately, we were able to snap some pics of the ThunderMax TBW going on an '09 Harley-Davidson CVO Electra Glide Ultra Classic. The best part, it only took about 30-40 minutes to get the module hooked up and the software installed.
01.
The TBW ThunderMax with...
01.
The TBW ThunderMax with AutoTune kit comes with the ECM module, two 18mm wide-band oxygen sensors, thorough installation instructions, and software to download the base map (software works with PCs utilizing Microsoft Windows 2000, Windows XP, Windows Vista, and Windows 7 at this time).
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Installation of the ThunderMax...
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Installation of the ThunderMax TBW is very easy. The Zipper's tech started the installation by removing the seat and side covers from the '09 CVO Electra Glide Ultra Classic. He then located the main fuse box in order to Pull the ECM fuse (arrow).
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...Pull the ECM fuse...
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...Pull the ECM fuse (arrow).
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The ThunderMax module...
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The ThunderMax module replaces the stock ECM. The tech removed the stock ECM from the wiring harness to make room for the ThunderMax TBW module.
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He then simply plugged...
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He then simply plugged the ThunderMax ECM module into the wiring harness.
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Next, the tech applied...
06.
Next, the tech applied a good amount of dielectric grease to the AutoTune harness plug and ECM connector, then plugged it into the ThunderMax ECM with the logo face up. Next, it was time to install the wide-band oxygen sensors into the front and rear head pipes.
07.
Here's a shot of ThunderMax...
07.
Here's a shot of ThunderMax wide-band oxygen sensor (top) and the factory narrow-band oxygen sensor (bottom). The narrow band sensor is limited in that it only tells the computer if the air/fuel mixture is rich or lean, but not how rich or how lean. The wide-band sensor tells the computer exactly how rich or lean the air/fuel mixture is, and as a result, sends the computer a series of air/fuel mixture readings to compensate and deliver the most optimal performing mixture.
08.
The ThunderMax tech removed...
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The ThunderMax tech removed the factory oxygen sensors from the front and rear head pipes. He then installed the wide-band sensors covering the threads with anti-seize.
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He then routed the rear...
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He then routed the rear ECM harness lead down toward the rear plug coming from the rear pipe bung between the trans top cover and starter, and plugged them together.
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The front ECM harness...
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The front ECM harness lead was routed along the bottom of the frame rail to meet the front bung wiring harness and they were hooked up. After the front and rear oxygen sensors were installed and plugged in, the ECM fuse was returned to its housing and the motorcycle's side covers were replaced. Installation was just about done at this time.
11.
Lastly, a base map was...
11.
Lastly, a base map was downloaded onto the new ThunderMax ECM and the installation was complete. After a few miles, the AutoTune function of the ThunderMax will adjust the air/fuel mixtures to give the bike an optimal mixture for the best performance in all riding conditions.