Thunder Heart EA4250D Manuale utente
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
TABLE OF CONTENTS
CHAPTER 1 INTRODUCTION ...............................................1
1.1 General Information....................................................................1
1.2 Special Tools Required..............................................................2
1.3 Connector Assembly..................................................................4
1.4 EHC Component Overview........................................................5
CHAPTER 2 SYSTEM INSTALLATION.................................6
2.1 Finding a Suitable Location for the Electronic Harness Control
Module.................................................................................................6
2.2 Trial Fitment of the Harness to the Bike.....................................7
2.3 H-D 1996-2003 Hand Control Connections ...............................8
2.4 Rear Lighting 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 AND REPLACEMENT PARTS...12
APPENDIX C TROUBLESHOOTING...................................12
APPENDIX D WIRING TABLES AND DIAGRAMS .............13
CONTACTING THUNDER HEART PERFORMANCE CORP.
Mailing Address................................120 Industrial Drive
White House, TN 37188
Shipping Address .............................120 Industrial Drive
White House, TN 37188
Phone ...............................................615-672-8811
Fax....................................................615-672-1353
Tech Support E-mail.........................techsupport@thunder-heart.com
Website.............................................www.thunder-heart.com
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CHAPTER 1 INTRODUCTION
1.1 General Information
The Electronic Harness Controller consolidates all of the electronic functions
of a motorcycle (with the exception of instrumentation and engine
management) into one, easy-to-hide system. The Electronic Harness
Controller avoids the wiring “bird’s nest” of other systems so you spend less
time wiring your bike…and more time riding!
Perfect for split tank bikes, the Electronic Harness Controller system includes
a self-diagnostic electronic harness controller, un-terminated “fantail”
harness, shrink tubing, and all necessary connectors, a comprehensive
instruction and troubleshooting manual for a durable, professional
installation.
The information included in this manual is intended to provide a guideline 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 required to assure a complete,
trouble-free installation.
Please read through this entire manual before attempting any part of the
installation. If you are uncomfortable with the level of skill required to
complete the installation of this system, either contact a Thunder Heart
Performance technical specialist, or hire a professional to complete the install
for you.
Note: The EA4250C and EA4250D differ in the function of the turn signals when
the brakes are applied. The EA4250C flashes the turn signals three times
prior to keeping them illuminated for 30 seconds, or until the brakes are
released (whichever comes first). It can only be installed on bikes with a
center taillight. The EA4250D does not flash the turn signals when the brakes
are applied. It can be installed on bikes with and without a center taillight.
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1.2 Special Tools Required
Most of the installation of the Micro Harness Controller can be completed
with basic hand tools. However, a few special tools make the job much
easier:
xAheat gun (such as the unit shown in Figure 1) is required to shrink
the heat shrink tubing onto the harness. The heat 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
xA good-quality wire-crimping tool is also required. The “W” style
(shown in Figure 2) is available at www.digikey.com (Digikey part
number WM9999-ND).
xThe AMP style (shown in Figure 3), while considerably more
expensive, will produce better results. The AMP style is
recommended if you plan on wiring many bikes using the AMP
connectors included with the Electronic Harness Controller system.
Figure 2—“W” crimping tool
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EI4250 3
Figure 3—“AMP” crimping tool
xAmulti-meter is useful for diagnosis. A common “test light” is OK,
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,
ignition, etc. A multi-meter allows you to check current, and you can
check the suspect circuit for any grounding issues.
Figure 4—Multi-Meter; useful for circuit diagnosis
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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
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4. Insert the wire through the blue seal into the connector body until you
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 the
EHC system. Use the following figures to aid in component identification:
Figure 9—EHC Module Front Panel
Figure 10—EHC Module Rear Panel Components
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Figure 11—Handlebar Harness Connectors
Figure 12—Included Terminals
CHAPTER 2 SYSTEM INSTALLATION
2.1 Finding a Suitable Location 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
molded to fit the tube radius and slotted to accept “zip tie” fasteners. The
EHC snaps onto the mounting base via three mounting tabs so that the
diagnostic instructions are visible with the dash removed.
Indice
