2014 Elkridge, MD - U.S.A. - ZippersPerformance.com - Zippers@ZippersPerformance.com v.20140320
P E R F ORMANC E PRODUCTS GUIDE
MAXimum Performance From Your EFI When You Ride, Where You Ride, Every Ride!
Would you like to have full control of your EFI system, freedom tomakemajor or minor engine changes or tuning adjustments without a master’s degree in electronics and computers? Here is a simple solution—ThunderMax® with Wave Tune AutoTune! The ThunderMax ® is a completely new product that replaces the factory electronic control module (ECM), not an add-on box or post-fuel signal modifier. The ThunderMax ® is purpose-built to deliver uncompromising performance with advantages not possible with post-fuel or flash systems - but you don’t have to be a rocket scientist to install, program or make adjustments to it. Just how easy is it? Installation is a straightforward plug-in replacement of the factory module and oxygen sensors* 1 . The ThunderMax® TMax Tuner software contains hundreds of base maps that cover most popular factory and aftermarket combinations, dyno-developed on real motorcycles. Choosing a map is a quick and easy process thanks to TMax Tuner’s sorting filters; loading a map takes less than a minute. After that, you’re ready to let the ThunderMax’s Wide-Band AutoTune system dial in idle and warm- up settings for your engine and you’re ready to ride! During your ride, every time you ride, ThunderMax’s ® Wave Tune AutoTune analyzes, adjusts and anticipates the air/fuel ratio read by the wide-band oxygen sensors at warp speed during every cylinder fire and makes any necessary adjustments to the injector pulse width to
achieve the desired air/fuel ratio while compensating for variations in injectors, fuel pressure and exhaust flow. With every tank of fuel, at every temperature or elevation. That’s it! All you have to do is ride. As simple as it is to install and use, don’t be fooled into thinking that this not one of the most sophisticated systems you can buy for your Harley ® . Using the supplied Tuner software, you can adjust or monitor virtually every parameter of the system:
• Decel Pop Control • Speedometer Calibration • Read Diagnostic Codes • Running Statistics / Logs • Engine Temp Alarm
• Live Engine Tuning • Live Monitoring & Recording • Dealer Digital Tech Compatible • Warm-up Settings • And More!
• Idle Speed & Rev Limit • Closed Loop AFR Targets • Igniting Timing • Accel Pump Simulation • Start Fuel Pulse
While this system does not require a dyno to achieve a smoother, cooler, excellent running engine, that does not mean it’s not a dyno-friendly device! Experienced tuners will appreciate its live-tuning capabilities with real-time monitoring and the ability to control all of the systems tuning parameters, knowing that AutoTune will keep the final tune from deteriorating as ambient
conditions change. Advanced level software is available for technicians wishing to create a custom tune, add nitrous or install a forced-induction intake. ThunderMax ® also employs industry-leading tech support though its internal data-collection system that quickly communicates directly with the ThunderMax ® support team should there ever be a need. ThunderMax ® Technicians can quickly review recorded data streams, data stored within the module and information about the bike and system with just a few clicks of a mouse!
The ThunderMax ® makes more sense in the long run as the system can grow and change as your engine does—just load a new map! ThunderMax ® software, firmware and maps updates are accessible 24/7 with an Internet connection so you’re only a mouse-click away from the latest available data. Each ThunderMax ® includes an ECM, 2 wide-band oxygen sensors with harness, communication cable, software disk and comprehensive instructions. The ThunderMax ® is designed and manufactured right here in the USA and backed by a 3-year warranty! *1 ThunderMax® uses 18mm Wide-Band oxygen sensors, which unlike the factory narrow-band sensors read over the engines full rpm range for constant full-time feedback and adjustments. Certain year bike exhaust systems are equipped with 18mm sensor ports, others may have 12mm ports or none at all. Check application notes for compatibility. ThunderMax® is not legal for sale or use on pollution-controlled vehicles; see ThunderMax 50 for California ARB approved applications.
Zipper’s Performance Products ● 6655-A Amberton Dr. Elkridge, MD 21075 ● (410) 579-2828 Some products on this page are not for sale or use on pollution controlled vehicles.
ThunderMax ® Applications
#309-562 #309-362 #309-460 ThunderMax ® for Touring Models PART NO. APPLICATION
2014 Touring (Throttle by Wire) 2008-2013 Touring (Throttle by Wire) 2002-2007 Touring (Cable Operated)
ThunderMax ® requires 18mm exhaust sensor ports as used on 2007-2009 models. 2010-14 (12mm) Touring models must use a 2009 style exhaust or modify the 2010-2014 exhaust to accept 18mm oxygen sensors if not equipped with dual sensor ports. 2002-2006 models require exhaust with 18mm oxygen sensor ports or be modified for same.
ThunderMax ® for Softail ® Models
#309-382 #309-562 #309-363 #309-361 #309-485 *1 #309-460 PART NO.
2012-2014 Softail ® (Cable Operated) except FXSB Breakout ® * 2 2014 FLSTNSE Softail ® (CVO TBW models) 2011-2013 FLSTSE 2011 Softail ® (Cable Operated) Except 2011 FXCWC Rocker ® C 2008-2010 Softail ® Rocker ® and 2009 CVO FXSTSSE 2001-2010 Softail ® (Cable Operated) except Softail ® Rocker ®
* 1 Includes Pigtail communication cable adapter due to limited module access. * 2 Breakout ® models under development
ThunderMax ® requires 18mm exhaust sensor ports as used on 2007-2011 models. 2012-14 (12mm) Softail ® models must use a 2007-2011 style exhaust or modify the 2012-2014 exhaust to accept 18mm oxygen sensors if not equipped with dual sensor ports. 2001-2006 models require exhaust with 18mm oxygen sensor ports or be modified for same.
ThunderMax ® for Dyna ® Models PART NO. APPLICATION
2012-2014 Dyna ® Models 2004-2011 Dyna ® Models #309-382 #309-485 *1 * 1 Includes Pigtail communication cable adapter due to limited module access.
ThunderMax ® requires 18mm exhaust sensor ports as used on 2006-2011 models. 2012-14 (12mm) Dyna ® models must use a 2007-2011 style exhaust or modify the 2012-2014 exhaust to accept 18mm oxygen sensors if not equipped with dual sensor ports. 2004-2005 models require exhaust with 18mm oxygen sensor ports or be modified for same.
ThunderMax ® for Sportster ® Models PART NO. APPLICATION
#309-382 *1 #309-485 *2 #309-464 *2 #309-460
2014 Sportster ® XL Models 2010-2013 Sportster ® XL Models 2008-2012 Sportster ® XR1200 ® Models 2007-2009 Sportster ® XL Models
* 1 2014 XL models require an exhaust system equipped with 18mm oxygen sensor bungs or be modified to accept 18mm sensors in place of the factory 12mm sensors (not required for 2007-2013 XL/XR models). * 2 Includes Pigtail communication cable adapter due to limited module access
ThunderMax ® for V-Rod ® Models PART NO. APPLICATION
2002-2014 V-Rod ® Models #309-366 *1 * 1 #309-366 communicates via serial port. PC with serial port or USB-Serial adapter required ThunderMax ® requires 18mm exhaust sensor ports as used on 2008-2011 models. 2012-14 (12mm) V-Rod ® models must use a 2008-2011 style exhaust or modify the 2012-2014 exhaust to accept 18mm oxygen sensors if not equipped with dual sensor ports. 2002-2007 models require exhaust with 18mm oxygen sensor ports or be modified for same.
Visit Us On-Line! www.ZippersPerformance.com Some products on this page are not for sale or use on pollution controlled vehicles.
ThunderMax EFI Intake Systems Building A Performance Big-Inch EFI Engine? These oversize CNC-machined castings replace the factory designs used on Delphi ® -equipped 2001 and later models, and are designed to accept the factory electronic components so assembly is a snap. Manifold width available for most popular engine kits from 95” up to 131”, with oversize (1.780” ID) intake port opening. High flow design requires MaxFlow air filter with spread bolt pattern (see below). Our MaxFlow Air Cleaner includes a beautifully CNC-machined billet backplate, 2-3/4” deep high flow filter, breather plumbing and heavy-duty support brackets, and fits all years of ThunderMax ® throttle bodies. 2006-UP THROTTLE BODY/MANIFOLD Body/manifold are 1-piece, unit construction; includes billet intake flanges and seals. 54MM 60MM
PART NO. ‘01-‘05 DELPHI ® -STYLE THROTTLE BODIES Throttle body and manifold are sold separately, but must be used together. Includes intake seals; uses original 1984- 2005 intake flanges (not included).
#109-709 #109-713 #109-716 #109-718 #109-723 #109-700 #109-654 #109-655 N/A #109-658 N/A PART NO.
#109-660 N/A #109-662 #109-664 #109-666
Throttle Body/Manifold, std length For 4.980” long cyls, JIMS 120”/131” For 5.013”-5.016” long cylinders
2001-2005 54mm EFI Throttle Body only
For 5.037” long cylinders For 5.100” long cylinders
2001-2005 THUNDERMAX MANIFOLDS For stock length (4.937”) cylinders. Fits Zipper’s 95 & 107” H-D 88, 95, 96, 103, 110, 113”, JIMS-SE H-D® 120
For 4.975”-4.980” long cylinders For 5.013”-5.016” long cylinders
For 5.037” long cylinders For 5.100” long cylinders Max length, for cyls longer than 5.100”; machine to fit
MaxFlow Air Cleaner for ThunderMax ® Throttle Bodies Our MaxFlow Air Cleaner for ThunderMax throttle bodies includes a beautifully CNC-machined, radius inlet billet backplate, 2-3/4” deep MaxFlow filter, breather plumbing and heavy-duty support brackets. This air cleaner has the wider ThunderMax throttle body
bolt pattern and substantially raises intake airflow capabilities for impressive performance gains. Choose between two designs that accept either the stock Twin Cam ® “football” cover or a traditional round EV-style covers.
PART NO. DESCRIPTION #117-150 #117-154 #172-112 #162-303
Accepts stock TC-style ‘football’ cover (5-1/2” end diameter) Accepts 8” round EV-style cover (7” end diameter)
Replacement Air Filter Element for #117-150 Replacement Air Filter Element for #117-154
Covers for ThunderMax Air Cleaners Customize your ThunderMax air filter with one of these custom covers. PART NO. COVERS FOR #117-150
5-1/2” round open air filter cover, chrome smooth 5-1/2” round open air filter cover, chrome scalloped
PART NO. COVERS FOR #117-154 #150-291 #150-400 #172-794 #172-795 #172-770 #172-800 #172-771
(A) 8” full air filter cover, chrome (B) 8” full air filter cover, gloss black (C) 8” open cover, chrome scalloped (D) 8” open cover, chrome smooth (billet) (D) 8” open cover, chrome smooth (steel) (E) 8” open cover, chrome ball milled (F) 8” open cover, wrinkle black (steel)
Zipper’s Performance Products ● 6655-A Amberton Dr. Elkridge, MD 21075 ● (410) 579-2828 Products on this page are not for sale or use on pollution controlled vehicles.
ThunderMax ® Gen III & TBW Communication Accessories (USB) ThunderMax ® Communication Cables
Replacement communication cables in standard or extended lengths for Generation III, TBWand CAN-BUS ThunderMax ® with mini-USB/USB connection 6’ w/90° end #309-326 15’ w/straight end #372-150 ThunderMax ® Gen III/TBW Pigtail Harness #309-424 Allows a second USB port for the communication cable connection to the ThunderMax ® Throttle-by-Wire and Gen III models. It is installed to the bike’s wiring harness at the ECM connector; handy for motorcycle models with tight clearances around the ECM. Works with ThunderMax ® part numbers 309- 460 and included with # 309-485. Will not work on Gen I & II ThunderMax ® , (#309-361) ’11-up cable Softails ® or (#309-380) ’12-up Dyna ® models with CAN- BUS data systems.
ThunderMax ® Gen II Communication Accessories (Serial Port) ThunderMax ® Communication Cable Replacement communication cables in standard or extended lengths for Generation I & II ThunderMax ® with Mini-DIN/serial port connection. #309-321 6 foot #309-322 12 foot USB/Serial Port Adapter
#372-000 If your laptop or PC does not have a serial port, this inexpensive adapter will instantly add a serial port to your computer for communicating with Gen I & II ThunderMax ® EFI controller (36 pin connector models only). Supports 1.0 and 2.0 USB ports, Windows 98/2000/ME/XP/Vista/7. Includes driver installation software. ThunderMax ® Gen II Pigtail Harness
Serial Port Style
#309-324 Allows a second port for the communication cable connection to Gen II ThunderMax ® , serial number 114,000 or higher. It is installed to the bike’s wiring harness at the 36-pin ECM connector. Handy for motorcycle models with tight clearances around the ECM such as Dyna ® , Softail ® Rocker ® and 2002- 2005 V-Rod ® models. Will not work on Throttle-By-Wire or Gen III USB Models. Included with ThunderMax ® systems #309-364 and #309-385. ThunderMax ® Gen II AutoTune-Data Port ‘Y’ Harness #309-343 The Gen II, modular ThunderMax ® AutoTune module gets its power and communicates to the ECM through the motorcycle’s 4-pin factory data port plug. This ‘Y’ harness allows the AutoTune module to be plugged in with an additional plug remaining open for other tasks. Not applicable for TBW or CAN-BUS models.
ThunderMax ® Accessories
ThunderMax ® Bench-Top 12 Volt Power Supply Allows for off-motorcycle, bench-top programming of the ThunderMax ® controller. Power supply includes
power supply, switch box adapter, plug for ECM. # 309-325 For 36-pin Gen I / Gen II T-Max
#309-328 For 73-pin TBW T-Max
AutoTune Harness Repair Kit #309-352 This kit includes components required to make repairs to a damaged AutoTune wire harness and connector plug. Included is a replacement connector, connector terminals, replacement wires with terminated ends and shrink tubing. Use to repair a damaged, but functioning, AutoTune module harness. 2-Bar Map Sensor for Supercharger or Turbo Applications #309-315 Required when using a ThunderMax ® in a boost application.
Replacement Wide Band Oxygen Sensors
Weld-In Oxygen Sensor Bungs with Caps For exhaust systems without installed 02 sensor bungs. Drill pipe and weld in; choose straight or angled bung. Sold each, two required.
#309-355 ThunderMax ® replacement oxygen sensors for all ThunderMax ® EFI withAutoTune modules (no service parts available). Sold Individually.
#272-200 Straight bung with cap, each #272-202 Angled bung with cap, each
#272-204 12mm Bung Cap set. For ’10-up Touring, ’12-up Softail ® , Dyna ® and V-Rod ® & ‘14-up XL/ Sportster ® models with stock sensors removed
Zipper’s Performance Products ● 6655-A Amberton Dr. Elkridge, MD 21075 ● (410) 579-2828 Products on this page are not for sale or use on pollution controlled vehicles.
Fuel Injection Components Injectors (Weber Pico) for ’01-’05 Delphi ® injected models and ’08-up TBW Touring models. Sold Each.
PART NO. DESCRIPTION #150-609 #150-665 #150-796 #150-741 PART NO. DESCRIPTION #150-709 #150-654 #150-742
4.22 gr/sec (Big Twin stock replacement) 4.81 gr/sec (V-Rod ® stock replacement) 5.30 gr/sec (high flow replacement) 6.70 gr/sec (high flow replacement)
Injectors for ’06-up Delphi ® injected models with cable-actuated throttle body. Sold Each.
3.91 gr/sec (25° Big Twin stock replacement) 4.89 gr/sec (high flow replacement) 6.2 gr/sec (high flow replacement) Manifold Absolute Pressure (MAP) Sensor Fits ’02-’07 Touring, ’01-’09 Softail ® , ’04- ’09 Dyna ® , ’02-’09 V-Rod ® models. #150-316 Fits ‘07 Touring, ’99-’00 and ’07-up Softail ® , ’99-’03 and ’06-up Dyna ® , ’04-’06 XL models. #150-317 Fuel Pressure Regulator Stock replacement. Fits ’02-’07 Touring, ’01-’07 Softail ® , ’02-’09 V-Rod ® models. #150-408
Fuel Pressure Checking Gauge Fuel injection systems rely on consistent fuel pressure for proper operation. When fuel pressure drops due to a clogging
filter, pinholes in the in-tank fuel line or a faulty fuel pump, performance suffers. This is the FIRST tool you should grab for diagnosis. Quickly installs in-line at the fuel tank outlet and allows you to verify pressure is within spec. #772-457
Fuel Rail Kit Stock replacement. Fits ’06-up Delphi ® injected Big Twin models with cable- actuated throttle body. #150-651
Cylinder Head Temperature Sensor Fits ’99-’09 Touring, ’01-’09 Softail ® , ’04-’09 Dyna ® . #395-062
Wiring Harness Connector Kit 2001-2005 Delphi EFI Includes
Manifold Air Temperature (MAT) Sensor Stock replacement, 1995- 2005 injected models . #150-270
connectors and terminal ends for IAC, TPS, MAT and injectors for 2001-2005 components. Allows fitment of 2001- 2005 throttle bodies to 2006-up Big Twins with cable-actuated throttle bodies. Wiring instructions included. #117-124
Throttle Position Sensor (TPS) Stock replacement, 2006-up Delphi ® injected models with cable-actuated throttle body. #395-065 Throttle Position Sensor (TPS) Stock replacement, 2001-2005 Delphi ® injected models. #395-064 Idle Air Control (IAC) Motor Stock replacement, 2001-2005 Delphi ® injected models. #395-060 Idle Air Control (IAC) Motor Stock replacement, 2006-up Delphi ® injected models with cable-actuated throttle body. #395-061 Manifold Air Temperature (MAT) Sensor Stock replacement, 2006- up Delphi ® injected models w cable- actuated throttle body. #150-381
Wiring Harness Connector Kit 2006-up cable-type throttle body. Includes connectors and terminal ends for IAC, TPS, MAT and injectors for
2006-up cable-type throttle body components. Allows fitment of 2006-up cable-actuated throttle bodies to 2001-2005 bikes. Wiring instructions included. #117-125
Intake flanges, 1984-2005 These are the offset type flanges that are front and rear specific (flanges stamped F & R). Sold each, order 2 for one engine. Front # 198-032 Rear # 198-033 Intake flanges, 2006-Up Big Twins These are the symmetrical type flanges that can be used on the front or rear head (equal distance between the mounting holes and the intake port). Sold each, order 2 for one engine. # 150-993
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