Zipper Mowers Thunder-Max 309-365 User Manual

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309-365  Installation / Setup Guide V2009.04.23 
Part # 309-365 for Sportster® Models 
Thank you for purchasing a ThunderMax ECM! 
Please read through the following instructions before 
beginning the installation procedure. Following these 
instructions will ensure that the ECM is installed and 
setup properly for optimal results. If you have any 
problems or questions, please refer to the SmartLink 
Tuning .pdf Manual, included on the CD (Help Menu) 
with this package.  
Step 1
Inse the SmartLink 
CD into your computer.
SmartLink will automatically 
open the InstallShield 
Wizard when the computer 
finds the CD-Rom. Follow 
the instructions and install 
the software on your 
computer. If you do not have a serial port on your 
computer for the communication cable, you will need to 
use a USB to Serial converter (an inexpensive converter 
is available from Zipper’s, #372-000). Install the included 
driver disc at this time; follow the instructions given by 
the manufacturer of the converter for installation.  
Install the Thunde
rMax and AutoTune modules.  
Step 2
Due to the mounting location and space constraints on 
the Sportster® for the ECM, your ThunderMax system is 
supplied with a separate AutoTune module.  The 
ThunderMax ECM mounts in the same location as the 
factory ECM under the seat; the AutoTune module must 
be mounted separately. 
Step 2a 
the seat. Open the 
left side frame 
cover (opposite the 
oil tank) to expose 
the fuse panel. 
Locate and remove 
fuse labeled “ECM 
POWER” (top left 
fuse; sticker with 
fuse identification is 
located on the inside of the frame cover).   
Step 2b
 Unplug and remove the factory ECM from the 
motorcycle (located on top of the rear fender under the 
seat).  Plug in and install the ThunderMax ECM in the 
same location over the locating pins shown.  
Step 2c 
Install the AutoTune module.  Mount the 
AutoTune module to the frame backbone using supplied 
wire ties (right side view below).  Position housing so 
wires exit to the left as shown below.   
Installation / Setup Guide
Please Note:  This product is Legal in California 
only for racing vehicles which may never be used 
upon a highway. 
The user shall determine suitability of the 
product for his or her use. Installation and use on a pollution-
controlled vehicle constitutes tampering under the U.S. EPA 
guidelines and can lead to substantial fines. Review your 
application and check your local laws before installing. 

Summary of Contents of user manual for Zipper Mowers Thunder-Max 309-365

  • Page 1: Part # 309-365 for Sportster® Models Installation / Setup Guide Please Note: This product is Legal in California only for racing vehicles which may never...
  • Page 2Step 2d Insert AutoTune power/communication 4-pin Step 2g Rear sensor: Route wiring down the left frame plug into the bike’s...
  • Page 3Step 3 Load a Base Map to your SmartLink software. Second, place your curser over the ‘Throttle’ column Selecting a...
  • Page 4: Speedometer Calibration SettingsStep 4 From the ‘Tuning Maps’ Tree, click the + sign From the toolbar, click [File] [Write Module Maps and...
  • Page 5Step 8 Before restarting the engine, from toolbar click the IAC position, the engine will idle above the idle rpm...
  • Page 6volume at all points by creating learned “offset” points and a vertical bar will show the actual throttle position. from...
  • Page 7 TIPS AND GENERAL INFORMATION • Several support features are located under the • Air/Fuel-TPS @ RPM These pages reflect...