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#309-460 ThunderMax® With AutoTune For 2002-2007 Touring Models Double click on above image to view full picture

ThunderMax® With AutoTune For 2002-2007 Touring Models

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Overview

ThunderMax® is an industry award winning, performance ECM designed specifically for EFI equipped Harley Davidson® motorcycles. This highly advanced, stand-alone tuning system utilizes proprietary AutoTune technology specificly designed to interface with wide-band oxygen sensors to automaticly adjust a wide range throttle positions and RPM ranges to deliver unmatched performance and driveability like no other product in the industry. ThunderMax® is made in the USA and comes 100% assembled, ready to install with no wire-cutting or splicing required. Simply replace the factory ECM and oxygen sensors, load a map, and enjoy your new ride!

In compliance with ARB emissions laws, this product is not sold or shipped to California.

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Details

How You Ride, Where You Ride, Every Ride!
Would you like to have full control of your EFI system, freedom to make major 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:

    • Idle Speed & Rev Limit
    • Closed Loop AFR Targets
    • Igniting Timing
    • Accel Pump Simulation
    • Start Fuel Pulse
    • 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!


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.

Download the ThunderMax® software for free! CLICK HERE!

SPECIAL NOTE FOR 2002-2006 TOURING MODELS - ThunderMax® includes wide-band, 5-wire oxygen sensors that thread into 18mm x 1.5mm bungs located near the exhaust port, same thread size and location as stock narrow-band, 2-wire sensors used on 2007 Touring model exhausts (previous year bikes were not equipped with oxygen sensors). For 2007 model bikes, ThunderMax® sensors will install without modification. If the exhaust system on your 2002-2006 model Touring motorcycle is not equipped with oxygen sensor bungs in the 2007 location (near the cylinder head exhaust port), 18 x 1.5mm bungs will need to be added to the existing headers, or purchase an exhaust header with bungs installed. Weld-in bungs are listed above. See the video link for tips on installing exhaust bungs.

SPECIAL NOTE FOR 2006 TOURING MODELS - In mid-year 2006, H-D changed the configuration of the stock 3.91 injector spray pattern for 88" engines, from 8 to 25 degrees. ThunderMax® Maps are available for both 8 and 25 degree injectors used in 2006 bikes. To determine which injectors your 2006 bike is equipped with, search H-D Service Bulletin M-1185 on the Internet for identification instructions.

 

This product is not for sale or use on pollution controlled vehicles.

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Customer Reviews

12 Item(s)

WOW! What a difference. She's AWAKE! Review by D.H.
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“I just got back from my test run. Before the transformation, I would have to downshift into 5th gear to pass anyone. Now, in 6th gear, at 65 MPH behind a car, I can do 90 before passing the car. WOW! What a difference. I think my bike was asleep before. Now, she is AWAKE! Wonderful! Great sound and performance!”

D.H. - TX
(Posted on 9/29/2017)
extra power Review by KD - AL
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“I put a 95" kit in my Ultra® for the extra power on the highway. I had two different systems installed on this bike before and they didn’t get it tuned right. I'm far from being a computer whiz, but thanks to ThunderMax, this runs great!

KD - AL
(Posted on 9/28/2017)
BEST PART I HAVE EVER PUT ON MY HARLEY!! Review by L.P - WY
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“I own a 2002 Electra Glide Ultra with a 96” engine, cams, ported heads, after market exhaust, SE intake and air breather. Needless to say, I have given it to the dyno gods ‘till it hurt!

While on a trip to Kentucky, I visited a friend at Mad City Motor Works and I purchased the ThunderMax setup. I had it sent to my home in Wyoming, where I had already downloaded the program info. I welded in the bungs, put the system onboard, loaded the program and the magic began.

I took a 2300 mile trip, got 5 miles to a gallon better fuel mileage, and a minimum of 10% increase in performance. The motorcycle started easy every time I started it. The conditions were from 3,000 to 10,000 feet altitude, in rain, snow, wind (try riding in Wyoming, Utah and Arizona in April). My experience was nothing but the best. The best part I have ever put on my Harley!! EVER!!

I did call Zipper’s with a question on bung location, they were great to deal with. An honest to goodness great experience!”

L.P. - WY
(Posted on 9/28/2017)
UNBELIEVABLE Review by P.W.
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“I just wanted to say thanks to all the people who make your product available. As advertised, the ThunderMax and 60mm intake with hi-flow injectors did the trick for my Jims 131 with the D&D Boarzilla.

I purchased the Jims 131 in January 2008, one of the first ones they shipped. I've been through 3 transmission main shafts, all bent by vicious starter kickback after hot soak due to too much timing. My local tuners could never get rid of it. My performance was lacking.

The ThunderMax is unbelievable! It has great hot soak re-start, extreme power through all the throttle ranges and last but not least, that serious kick in the pants at full throttle the Zippers 60mm intake gives me over my S.E. 58mm. Also, my stalling problems are cured and my bike is running cooler. The oil cooler temp dropped from 230 to 210 degrees.

As advertised, ThunderMax is unbelievable and worth every penny. The headaches over the last 3 years and thousands of dollars I've spent have come to an end. Thanks to everyone at Zippers!!

P.S. Love that closed loop!”

P.W. – Sent via Email
(Posted on 9/28/2017)
ROCK Review by C.S.
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“You guys rock!! The Power Commander on my bike lost its programing twice - so that was a $297.00 dyno trip each time. I just put my ThunderMax in with a total rebuild – 88” to 103”! I just hope I don’t die from pleasure when I crank the throttle open!"”

C.S. – Sent via Facebook
(Posted on 9/28/2017)
NOTHING CAN BE COMPARED TO IT Review by A.H. - DE
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“ThunderMax is the best product that I have spent money on in a long time. I rate the product on a scale of 1-10, 10, being the best! My bike starts very quickly, idles very good, runs outstanding - nothing can be compared to it.

The Power Commander I had was a waste of money, right along with all the money I spent on dyno tuning it. Having said all this, I will recommend your product to everyone I know. I did my own install, including the o2 sensor bung install. Less than an hour of install time and your riding! Keep up all the great work!”

A.H. - DE
(Posted on 9/28/2017)
CAN'T BELIEVE THE DIFFERENCE Review by K.H. - MA
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“My 2008 Harley FXDF with Cobra AC and SE Slip-Ons running the ThunderMax with Auto Tune is a completely different bike. The more miles I put on it, the better it runs. I can't believe the difference. I look forward to installing new cams and Thunder Headers with the dry nitrous setup. Oh boy!”

K.H. – MA
(Posted on 9/28/2017)
RAN LIKE A DIFFERENT MACHINE Review by P.K.
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“I read the instructions for the install of the ThunderMax with AutoTune on Friday night and did the install Saturday. Needless to say, the most time consumed was in removing the rear cylinder exhaust and relocating the o2 sensor bung. I wrapped everything up according to the instructions, and added some extra wire tie, then took the bike for a test ride.

Throughout the rpm range, the bike started and ran like a different machine. I feel like this was one of the better upgrades that I have done to my bike. Local speed limits and their enforcing agents kept me from really testing the bike very far beyond the "posted" speed limit. It hits the 6 grand numbers a lot quicker now. The wife and I took a short
100 mile ride this morning (Sunday) and the bike ran and performed flawlessly. Thanks again for your help!“

P.K. – Sent via Email
7/24/2011 (Posted on 9/28/2017)
Great Product-Tested and Trusted Review by Hercules-130
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I've had a thundermax on my 2007 Ultra Classic now for over 46,000 miles. I have over 63,000 on my Ultra Classic and its been hopped up with a SE 103 Big Bore Kit, Andrews 26H, RedShift Dual Tensioners, Axtel Plug, SE Stage 1 intake, S&S high performance lifters, SE Racing Clutch, Oil Temp Gauge, Upgraded Twin Power Primary Chain, Fueling 7060 High Flow Oil Pump, Wards Induction Fans, SE Compensator, Accel Stator and Regulator, oh, and my favorite the 1,200 watt pioneer Champion Audio Series (6 speakers).

I'm telling you all this, because I was about to throw away the Thundermax I spent over $700 on, because my bike was running like crap. I was very frustrated and it seemed like every time I finished my commute home the bike was running horrible again! My commute is 124 miles round trip from Fredericksburg to DC every day. My ride is the only way to manage the commute because of the express lanes available to motorcycles and its a fun way to commute to work. I had a SE Racing Tuner and was about ready to put that back on and try to get the bike stable again since it seemed like the Thundermax was making it worse over time... or so I thought. I decided to stick it out with the Thundermax, go to their web site and zippers and research to see if it was a simple fix.

I am very impressed with the Thundermax FAQs, tutorials and easy download of instructions! I'll be honest, I didn't have all the parts I listed above from the beginning (except my audio of course). It's because of the Thundermax, Zippers FAQs, I methodically read and followed the instructions on trouble shooting. I replaced my compensator with the SE one (done).... I cleaned my IAC and checked that it was working properly (done)... I checked my electrical system (done... ops got some problems).... fixed those... I checked my fuel system replaced fuel filter (done)...

Ok, so the bike should run good now... it was running good... for a few days... That's it... I'm getting rid of the bike... I was so frustrated... I decided to take a look one more time, plugged my computer into the thundermax module, read through the error codes... low TPS voltage... hmm.

I replaced my TPS Sensor.... REALLY... THAT WAS IT.... My Ultra Classic has been running fantastic ever since... I am glad I upgraded the Compensator though! That really did make a big difference... Oh and I recently added a 1.4Kv SE Starter... I am extremely happy.... Now I'm looking to upgrade the cams and the cam plate.

So why am I telling you all this? It's because had I taken this to a Harley dealer, it would have cost me more, they wouldn't have really known how to use the Thundermax and once I calmed down and started to go through the Thundermax FAQs... it lead me to diagnosing my problem and getting back to an awesome running Ultra Classic. The problem wasn't the Thundermax at all or any of my performance parts... it was a worn TPS sensor... I did have to replace the Compensator though... Everyone is right on that one... if you have a 2007 or later tourer.

Zippers, Thundermax... Thank you! By the way Pete is great... very patient and explains things very well!! (Posted on 11/22/2015)
HAPPY, HAPPY, HAPPY Review by C.B.
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My son found this 2002 Ultra Classic for me on Craigslist... cheap. It needed repainting which will be done soon. Otherwise he was told by the "original" owner, who was a retired "Certified" HD mechanic… who did all his own work on this bike… that it was a 95 inch motor with a .510 S&S cam, etc. Long story short the seller was the fourth owner. He was never an HD mechanic and did not actually know what was in the bike.

While installing new cam chain tensioners, my mechanic discovered it has an Andrews cam similar to a .510, which he thought would have been bigger for a 95 inch. After new brakes, rotors, tires, tensioners and installation of the ThunderMax, there's still a lot we don't know about this bike. However, what we do know is this thing runs like a batt. Gobs of torque, very smooth... no pings or hiccups, great mileage, etc. We still don't know what's in this bike, but the ThunderMax does and that's all that matters. Great product. Well worth the money. HAPPY, HAPPY, HAPPY. (Posted on 10/13/2015)
Must have if you plan on any mods to your bike Review by Louis
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I have a 2003 Road Glide with a high compression 95” motor and performance exhaust. It was running an aftermarket add on box to help performance but no matter how it was adjusted the bike just did not perform well.
I replaced the whole set up with a Thundermax after Zippers did the base programing.
The bike has never run better. I smile every time I start it up.
Road it to Sturgis last summer then across the Midwest down south and through the Smokey Mountains. Even hit Tail of the Dragon. 5000 miles in 10 days.
No matter the weather, elevation, heat, etc…… The bike ran great!!!!!
No adjustments needed no reprograming anything
This thing works right out of the box!!!!!!!
If you are modifying your bike add a THundermax to the list, get zippers to do the base programing and you will never need to touch it again.
Of course you can if you like to play but I like to ride.

Thanks
Louis
(Posted on 6/8/2015)
Finally - the Cure! Review by Sean
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Since new, I had a rough starting Bike. It would pop and backfire every time when I started it. It got so bad that we installed a different tuning system, which didn't even correct the problem. I tore that out with less then 100 miles on it... Yes, I had to pay for it.

I dealt with the engine issues till I found the ThunderMax. I ordered one from Zipper’s and it was delivered already programmed a day earlier than expected. I installed the O2 sensors and bolted in the ThunderMax.... pressing the start button for the first time, I knew my issues were resolved!! No hard start, no sputter, no backfire when cold. My first ride on the bike was better than when the bike was brand new. I rode 50 miles on my first ride with the ThunderMax and I didn't want to get off the bike. The engine runs great, and it seems to just get better with time. I expected a hard start hot when I finally shut the engine off but when I pressed the button, the engine started right up. No compression released needed, no slow crank - just fired right up! This is the solution for anyone with the 103” engine without compression releases that is experiencing hard starts or any drivability issues. The instructions for install were spot on, and the software is easy to understand and operate. I can’t wait to get more seat time. Why I didn't do this when I first got the bike beats me.

The ThunderMax makes riding fun again!!.. Don't think twice, get one, it will be the best money you ever spent!!!!
(Posted on 6/8/2015)

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Additional Information

Brand ThunderMax®
Fuel / Air EFI
Model Touring®
Engine Type Twin Cam®
Emissions Compliant No
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