Thunder Heart EA4250D Owner'S Manual Download Page 8

Thunder Heart Performance Corp.

615-672-8811

www.thunder-heart.com

4

EI4250

1.3

Connector Assembly

The following information highlights proper assembly procedures for the AMP 
connectors included with the Micro Harness Controller system:

1.

Strip approximately 3/16” of insulation off of the end of the wire to be 
terminated.

Figure 5—Proper wire strip amount

2.

Clip a terminal from the supplied “tree” of terminals.

3.

Using either a “W” or an “AMP” tool, crimp the terminal onto the end of 
the wire. The following figures show examples of “good” and “bad” 
crimps:

Figure 6—Good Crimp; insulation retained by outside tabs, conductor 

retained by inside tabs

Figure 7—Bad Crimp; too much wire stripped; strands exposed outside 

of terminal

Figure 8—Bad Crimp; too much wire stripped; insulation not retained 

by outside tabs

Summary of Contents for EA4250D

Page 1: ...Owner s Manual Electronic Harness Controller P N EA4250D Thunder Heart Performance Corporation MANUAL P N EI4250 120 Industrial Drive Revision 5 26 11 White House TN 37188 www thunder heart com...

Page 2: ......

Page 3: ...Options 9 2 5 Harness Assembly 9 CHAPTER 3 INDICATORS AND INSTRUMENTATION 10 CHAPTER 4 OPERATION 11 4 1 Diagnostics 11 4 2 Turn Signals 11 APPENDIX A FREQUENTLY ASKED QUESTIONS 11 APPENDIX B OPTIONAL...

Page 4: ......

Page 5: ...deline for installing the Electronic Harness Controller system on your motorcycle However each motorcycle is different Due to the universal nature of this system a certain level of technical skill is...

Page 6: ...gun makes quick work of shrinking the tubing as it provides a broad even source of heat No other means of shrinking the tubing is recommended Figure 1 Heat Gun x A good quality wire crimping tool is...

Page 7: ...but a test light will not tell you if you have a short to ground or a resistance problem In other words a pinched wire may provide enough current for the test light but not enough to power the horn i...

Page 8: ...wire to be terminated Figure 5 Proper wire strip amount 2 Clip a terminal from the supplied tree of terminals 3 Using either a W or an AMP tool crimp the terminal onto the end of the wire The followi...

Page 9: ...hear a click Gently pull on the wire to ensure that the terminal is fully engaged in the housing 1 4 EHC Component Overview Throughout this manual you will be referred to the various components of th...

Page 10: ...ion for the Electronic Harness Control Module Split Tank Bikes The Electronic Harness Controller EHC is designed to mount to the top frame tube between the gas tanks The black plastic mounting base is...

Page 11: ...rial 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...

Page 12: ...eir mounting points cut the excess length from the ends of the wires leaving them approximately 3 too long for final fitment 2 3 H D 1996 2003 Hand Control Connections Starting in 1996 Harley spliced...

Page 13: ...x Turn signals functioning as a turn signal and brake light see Figure 21 x Turn signals functioning as a turn signal brake light and tail light this option requires dual filament turn signal housing...

Page 14: ...is attached to a terminal use the black 1 pieces supplied with the kit 10 Repeat the process for the other three harnesses CHAPTER 3 INDICATORS AND INSTRUMENTATION Indicator Options The EHC is design...

Page 15: ...ound such as the battery negative terminal or a paint free boss on the frame 4 2 Turn Signals Table 1 Summary of commands and the corresponding turn signal function APPENDIX A FREQUENTLY ASKED QUESTIO...

Page 16: ...rcycles than 1996 2003 motorcycles See Section 2 3 and Appendix D for more information APPENDIX B OPTIONAL AND REPLACEMENT PARTS Table 2 EHC Optional and Replacement Parts Component Thunder Heart P N...

Page 17: ...Right Handlebar Connector Pin Assignments PIN FUNCTION COLOR pre 1996 AWG COLOR 1996 2003 AWG 1 RIGHT SIGNAL SWITCH POWER GREEN 18 ORANGEw WHITE STRIPE 18 2 BRAKE SWITCH POWER ORANGE 18 ORANGEw WHITE...

Page 18: ...Thunder Heart Performance Corp 615 672 8811 www thunder heart com 14 EI4250 Figure 17 Front Harness Wiring Diagram Wire Side of Connector Shown...

Page 19: ...Thunder Heart Performance Corp 615 672 8811 www thunder heart com EI4250 15 Figure 18 Pre 1996 Hand Control Wiring Diagram Wire Side of Connector Shown...

Page 20: ...Thunder Heart Performance Corp 615 672 8811 www thunder heart com 16 EI4250 Figure 19 1996 2003 Hand Control Wiring Diagram Partial Diagnostics Wire Side of Connector Shown...

Page 21: ...Thunder Heart Performance Corp 615 672 8811 www thunder heart com EI4250 17 Figure 20 1996 2003 Hand Control Wiring Diagram Full Diagnostics Wire Side of Connector Shown...

Page 22: ...Thunder Heart Performance Corp 615 672 8811 www thunder heart com 18 EI4250 Figure 21 Rear Harness Wiring Diagram Turn signals functioning as a turn signal and brake light Wire Side of Connector Shown...

Page 23: ...615 672 8811 www thunder heart com EI4250 19 Figure 22 Rear Harness Wiring Diagram option requires dual filament turn signal housings Turn signals functioning as a turn signal brake light and tail lig...

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