Thunder Heart Performance Corp.
615-672-8811
www.thunder-heart.com
EI4250
7
Saddle Tank Bikes
When using a saddle tank, an alternate mounting location must be found.
The most common areas are near the oil bag and under the transmission.
The mounting base may not fit in these locations. Zip ties can be used to
attach the EHC to its mounting location. If possible, the EHC diagnostic
instructions should face in a direction that will make them visible with little or
no disassembly for service. Care should be taken to keep the EHC a safe
distance from the exhaust system.
Note: Though the EHC module is moisture and vibration resistant, care should be
taken in mounting the EHC so that it is not subjected to excessive amounts
of vibration, heat, and moisture. The EHC should be mounted at least four
inches away from the engine to avoid radiating engine heat.
WARNING: FAILURE TO MOUNT THE ELECTRONIC HARNESS CONTROLLER,
WIRES, OR CONNECTORS AWAY FROM EXCESSIVE HEAT SOURCES
(SUCH AS THE ENGINE AND EXHAUST PIPES) MAY RESULT IN
FAILURE OF THE ELECTRONIC HARNESS CONTROLLER SYSTEM.
2.2
Trial Fitment of the Harness to the Bike
The following steps outline the process of trial fitting the harness to the bike.
The installer may experiment with different routings to achieve the best
results:
1.
With the EHC mounted, plug the rear harness connector into the EHC.
Note: Each wire is labeled according to its function. Refer to the wiring tables and
diagrams in APPENDIX D. “Auxiliary Power” sources can be used to power
brake lights, license plate lights, etc.
2.
Route each wire to its destination, but do not cut them yet. Keep wires
bundled together until they need to break off to their destination. Use
electrical tape to construct branch points and to temporarily attach the
harness to the bike while fitting is performed. Wires not used should be
terminated at the connector to prevent short circuits.
Tip: Try to minimize the number of branches from the main harnesses by
combining wires that branch off closely in one larger branch, as this will make
the heat shrink easier to apply later.
Tip: Remember to allow extra length for suspension movement or strain relief
when locating the harness-to-bike attachment points.
WARNING TAKE CARE TO ROUTE THE HARNESS AWAY FROM SHARP EDGES
OR SURFACES THAT MAY PINCH THE HARNESS. ROUTE THE
HARNESS AWAY FROM SOURCES OF HIGH HEAT, SUCH AS THE
ENGINE AND EXHAUST SYSTEM.
3.
Start again at step 1 for the front harness and the left/right control
harnesses.
Note: For 1996-2003 hand controls, see Section 2.3.