Zipper Mowers Max 309-355 ユーザーズマニュアル

3

FXD-B:  Remove the 
stock ECM from the 
electrical caddy.  The 
caddy must be slightly 
modified for additional 
main harness 
connector clearance. 

 

Use a Dremel or Roto-Zip tool to provide additional 
clearance for the harness plug catch; also remove 
approximately 3/8” from the partition support as shown.  

 

FXD-C:  Because of the impossibility of connecting the 
communication cable without disassembly once 
assembled on FXD models, the cable should be 
permanently installed to the ThunderMax, or the optional

entioned in step 2 used.  If using the 

 

‘pigtail’ harness m
communication cable, and
feed it and the AutoTune
ECM plug port of the cadd
caddy as shown.  The ox
exit towards the opposite side of the cad

 

 if equipped with AutoTune, 

 power harness through the 

y and mount the ECM to the 

ygen sensor harnesses should 

dy. 

   

 

 

FXD-D:  If equipped with AutoTune, before reinstalling 
the caddy, feed the front cylinder oxygen sensor harness 
through to the right side of the bike, over the top and to 
the rear of the starter motor.  Reinstall the caddy with 
fuse and relay blocks in place.  Reconnect the TSSM, 
coil and ECM harnesses and main fuse.  

4-pin gray data link on the bike.  It is through the data 
port that data from the AutoTune module is transferred 
to the ThunderMax.  A ‘Y’ harness is available (# 309-
343) to keep an open data port if desired.  After 
programming and setup, the communication cable can 
be coiled up and kept under the caddy cover if not using 
the ‘pigtail’ harness. 

 

 

    If equipped with AutoTune, install supplied wide band 
oxygen sensors in the front and rear exhaust pipes.   

FXD and all 2007-up models are equipped with 

narrow band sensors, which must be removed and 
replaced with the supplie

d units.  The wide 

band sensors are long

factory sensors.  

Installation of the wide

ors into factory 

headpipes presents no

lems, however, 

some aftermarket pipes may require exhaust pipe 
mo

 bung relocation for interference-

free

sors must mount freely without 

contacting surrounding components.  If this is not 

2006 

d wide ban

er than the 

 band sens

 clearance prob

dification or sensor

 installation.  The sen

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).  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.

    Connect the sensors to the closed loop module.  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. 

 The rear harness mounts easily, just coil 

the excess wires and locate them above the 
transmission.  The front harness should travel from the 
AutoTune module, over and to the rear of the starter 
motor, behind the exhaust support bracket and between 
the crossover pipe and the transmission. 

 

Remove the footpeg/brake pedal bracket mounting bolts 
and move the assembly towards the exhaust pipe.  
Route the front exhaust sensor harness under the cam 
cover exhaust support bracket and behind the brake 
pedal; connect it to AutoTune harness.   

 

The sensor plug and harness will drop down to the frame 
rail with a little brake pedal wiggling where it can be zip-
tied to the frame rail, out of sight and out of harm’s way.

Dyna®: ECM installed with 
communication cable attached.