Thundermax Electrical Issues - Marelli and Early Delphi Syste Uživatelský manuál stáhnout pdf

New, Unusual Running Conditions on

1995-2001 ThunderMax Marelli Touring Models

and 2001-2005 Delphi Type Models

v.07172012

Since 1995, H-D® has been building fuel injected models. Now that

these vehicles are starting to age, new and unusual operational

problems are appearing, which are worth discussion.

As the oldest cycles in the fleet, 1995-2001 Magnetti-Marelli®

equipped models were the first to experience symptoms. Additionally,

many aging sensor and wiring problems are present in 2001-2005

Delphi models.

A data collection should be performed with a running log. This will

allow the data to be properly analyzed using new tools in the

ThunderMax software. ThunderMax diagnostic efforts have uncovered

issues related to wiring, degraded sensors, or faulty IAC motors which

will make your engine perform poorly. Careful inspection of these

areas and components is critical to locating and correcting the

problem.

Throttle Body Branch Inspection

The fuel tank must be removed to inspect the engine harness and

clips which attach to the m/c backbone on the frame. Many

harnesses installed on motorcycles between 1995 and 2003 were

tied too tightly to the backbone. When the engine shakes in the

chassis, the wiring is pulled which slowly degrading the integrity of

the wires. Additionally, the original wiring has already been

subjected to 10 to 15 years of stress, heat and vibration, making

this area a big target for locating problems. The harness must be

released from the last frame clip to allow enough slack to reposition the

connectors for the Delphi throttle body. Stress from

constant tension could be pulling strands of wires out of the engine

harness, creating intermittent and inconsistent engine operation.

(See image of harness clip/wiring branches below)

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New, Unusual Running Conditions on 1995-2001 ThunderMax Marelli Touring Models and 2001-2005 Delphi Type Models v.07172012 Since 1995, H-D® has bee

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Through monitoring of gauges in the SmartLink software, we have discovered abnormal readings for throttle position, manifold air temp and erratic

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Note- A working, yet faulty, IAC motor will provide erratic A/F readings and poor performance. Replacing the IAC motor is a quick process worth tr

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SENSORS Abnormal operation could also be related to degradation of sensors. Partial failure of a sensor may not trigger a diagnostic code. If no

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Very Important Note- The following wiring color codes are provided to help identify the Data Link connection on Marelli Models which is used by th

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