MM EFI to Carb conversion done!

[chnpostal]

All done last Saturday, and I just have to say wow! What a difference! :banana:

This is on my '99 FLHRCI with Andrews 26, stage 1, true duals with Thundercone slipons (yea, I know :D).

Total cost (did my own labor) was $365........a blend of used and new parts, plus I went with the Crane HI-4TC for the ignition. A used 8-3150 (uses cam sensor) that Crane reflashed for free to a 8-3170 (ignores cam sensor, only uses crank sensor). All gaskets, seals, and map sensor were new. Basically, I found a good deal on a cv40 with manifold and SE intake kit on ebay. It already had a dynojet kit in it set to just dump gas, so I changed the 195 jet to a 185 and dropped the needle drastically (mine's only a tc88 with andrews 26).

Biggest problem was getting the '99 model gas tank with that welded in tall bung/line fitting cut down neatly enough for the Pingel adapter and petcock. I don't think the later model tanks have this problem.

Second problem on the '99 model is the wiring harness.....if you use the '01 model's harness, there is no way to run the wires down to the crank sensor and oil sending unit without either: (1. building another patch harness (2. cutting and splicing that section from your old harness. I'm a cheapskate....I just cut and spliced. :D

Other than those two problems, everything else was just plug-and-play.The bike cranked up in about 2 rotations when I first tried it, and only took a minimal amount of tweaking the carb and ignition to get it right. Low end torque, cruise, roll on power, and WOT have all improved noticeably over the MM efi. The ride is now well mannered with no funny transition points or glitchy behavior that was prevalent with the efi system before. No backfires, coughs, spits, or sputters, and the sound is even better.......especially with the return of the carb's "lopey" idle!

I've been working a lot of overtime lately, so I haven't really rode it enough to check the fuel mileage yet......put on about 300 miles since it was finished, but most of that was playing with the throttle......it just wouldn't be a fair assesment of fuel economy. When the weather warms up, I'll get a baseline dyno run just to see where it's at.

All said and done, I would recommend this mod to anyone that has problems with their Magneti-Marelli efi! :wootdance:

[chickenman]

I agree as I did the same swap. Much better response at any rpm.

[flhpi-ohio]

Congrats. I did the conversion on my 01 RK police and all my effort was well worth it. The best thing was my local dealer said it cant be done. I ended up selling the bike to a local guy and it is still running strong. Enjoy the ride.

[cznmike]

chnpostal,
I'm a semi-wrench. I used to have an 80 shovel and got reeal good with it. I've now got an 06 FXSTI and want to convert it over to carb. Any thoughts or problems on doing it?

[chnpostal]

Welcome to the forum, cznmike.

I'm not really an authority on carb swaps.....just kinda dove in and did mine due to the issues on a lot of the older magneti-marelli style fuel injections. There's only a handful of guys that understand and can tune that system, and the MM itself is notorious for just "losing" the tune afterwards.

Your ride has the later Delphi injection system, and it can be set up to run better than any carb by a competent tuner using SERT, PCIII, DTT, ect. The carb swap could still be done, but unlike the MM efi, you'd be hard pressed to find a real harley tech that would recommend it. The Delphi efi is a way better system. The real problem with efi's in general is trying to find a competent tuner in your area.

That being said, in order to do the swap, you'd have to:

Swap out the throttle body for intake and carb, including carb/air filter mount (I think the '06 models have a different intake/flange than earlier ones).
Map sensor for intake.
Get a mount for the choke.
Bypass/remove fuel pump in tank.
Modify/adapt gas tank for petcock (I think both harley and pingel have this).
Replace wiring harness with one for carb ignition.
Replace ECM with carb ignition module, either harley or aftermarket.
I'm not sure, but I think there's also an issue of getting the TSSM (blinker module?) to talk with the new ignition module?
Might have to replace throttle cables too.

Not a complete list, but it should give you a general idea. My personal advice would be to stick with the efi on a late model bike, get all builds/mods done at one time (big bore, cams, exhaust, ect.), then take it to a good tuner even if it requires a road trip. Maybe wait for the new V-tuner to come out as mentioned in this thread (clickey here). (http://www.doofclenas.com/forums/showthread.php?t=142152)

[bigjailerman]

good work there guys!!

[cznmike]

Thanks chnpostal,
I've got the PCIII on it already and had the stealer dyno it after I put straight pipes on it. Runs pretty good, but still seems like it could be better. The only other option in this area is to go to the suzuki shop.

[MegaGlide]

If you're running straight pipes anywhere but the dragstrip, we've found your problem.

[Berserker]

You can have my EFI when you pry it from my cold dead hands.

[chnpostal]

Thanks chnpostal,
I've got the PCIII on it already and had the stealer dyno it after I put straight pipes on it. Runs pretty good, but still seems like it could be better. The only other option in this area is to go to the suzuki shop.

If you're running straight pipes anywhere but the dragstrip, we've found your problem.

Have to agree with Mega here........what was cool on a shovel is just obnoxious and performance killing on a twincam.

For loud and cheap, you'd been better served with Cycle Shack or Python slipons.

For loud and performance, a 2-into-1 like Thunderheaders or RB Racing. IMHO.

And 'serker.........MM efi still sux..........:Poke:

[8-Ball]

Cool....!!!

Man, I sure want to do this. I'm wondering if it is worth it with the Delphi... obviously the Morelli was a piece of crap.

Thanks for the thread...