Zipper Mowers Thunder-Max 309-365 Manuale Utente

  Insert AutoTune power/communication 4-pin 

plug into the bike’s data port (gray), located at the base 
of the battery, left side of the bike. 

 

 Remove the factory oxygen sensors and install 

the wide-band units in their place. 

 

 

 

 Front sensor: route wiring along frame rail 

(double up harness if necessary), position harness plug 
at lower front primary cover area. Connect the sensor to 
the closed loop module, secure with wire ties. 

 

 

 Rear sensor: Route wiring down the left frame 

rail behind the primary housing, with the plug located 
along the frame turn.  Double-back the wiring to the rear 
sensor.  Connect the sensor to the closed loop module, 
secure with wire ties. 

 

    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 for exhausts systems not equipped with 
bungs or if current bungs present clearance issues.  
Bungs should be located no more than 3-4” from the 
head/pipe connection (for ideal location, refer to the 
factory location on 2007-up models).  Weld-in bungs are 
available from Zipper’s (#272-200, straight; #272-202, 
angled).  Chase the threads after welding with an 18 x 
1.5mm tap (available from auto parts stores) and verify 
that the oxygen sensor threads in easily without the pipe 
wall interfering with the sensor tip.  After installation, 
route the sensor harness away from the engine and 
along the frame when possible, above the lowest frame 
point to avoid the possibility of dragging ground during 
operation.  Avoid routing harnesses where engine 
movement or moving parts can contact and damage the 
harnesses or connector plugs.

    The  AutoTune  harness for  the rear cylinder sensor  is 
shorter and can be easily identified by black tracers on 
all of its wires; both plugs are clearly marked for front 
and rear use.  It is very important to install these 
correctly or the engine will perform poorly!  Tie the 
harnesses to the frame or existing component 
harnesses, taking care to avoid contact with any 
vibrating component that may chaff the sheathing or 
wires.  Some disassembly of bike components may be 
required for best harness routing. 

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