Alright.. I will just jump straight into it. I have a 2001 Road king. full SE kit. When i purchased it, i was tricked into thinking it was a CVO.. Unfortunately not. But it is defiantly a great bike I just can't stand the Magneti Marelli System. I come from a background of Tuning Vehicles so the tuning access is a niche for me. After i complete the Delphi swap, i will then be doing a Road Glide Conversion. That will COme after. Maybe i will keep it all in this thread. Unsure yet. Also. I am in the middle of a Flip house. And unfortunately no garage. It will soon be on the market, and maybe ill get my garage then . So if you see...... "Rigged" "Mickey Mouse" looking photos.. please Concede and Proceed.

With the magenetti Marelli.. We have 3 options really.. 1x Carb. 2x. Complete Custom like a megasquirt. or 3x. Do what harley did, upgrade the bike to a delphi.

In my opinion the best option is to absolutely go with what harley did, Upgrade to the Delphi system. Having a 3d View of the engine vs 2D ( TPS vs Speed) is huge. I also want o2 sensor control.
I thought about a ThunderMax.. However it seems they will soon be not supported and i didnt wanna go down that road. Plus i want OPen CLosed loop functions. and i'm sure other reasons I cant think of righty now
This build will be a great tech article for anyone that wants to switch from a carb to EFI. Having that %15 Fuel trim can vary for elevation and many changes without needing the mess with your carb.

Now I am in no way an expert, and i want to say all the credit of the Magneti Marelli or Carb To Delphi Swap, Goes To Don. ( TWOLANERIDER) Without him, this would never have happened.


Onto the Delphi Swap:
First thing's First. The parts list:

Parts List:
2002-2005 Throttle Body
2004-2005 Main/Engine Wire Harness - 70233-04A
( If you have a front fairing you'll also need the interconnect harness ): 70232-04 if Electra Glide. - 70274-04 if Road Glide.
04-05 ECM(Engine Computer ):
04-05 Speedo Sensor: - 74430-00D
04-05 Delphi Ignition Coil: - 31743-01
04-05 Delphi Coil Bracket - 70348-02
04-05 Crank Pos Sensor : - 32707-01C
04+ Speedometer : - 67410-04A
04-05 EFI External Fuel LIne: - 62900-01D
04-05 EFI Fuel Check Valve Tube :- 62228-03
04-05 ECM Bracket: - 70348-02
04-05 Battery Tray: - 66281-02A
04-06 Complete Fuel Pump Unit : - 75127-06

( Notes )
I believe that is the full list, i will update it if needed, it;s getting pretty late and the beers are getting few, must mean bed time is near.
If you plan to swap to a 2006 or 2007, all the parts must match that exact year. And a few more steps come into play.
There is also an option to upgrade the Charging system to the 3 phase system.
The Delphi ignition will need a custom fabbed bracket.



( The BUild ):

First.. we had to get all the orders in.. eBay and amazon single handed, I received all my parts from. Took about 2 weeks of scouring. I'm not sure what happened to the 02-05 throttle bodies recently, but when i first started this project, i was deciding to go the 06 route.. and once a decided to land back to the 02-05.. all the throttle bodies listed on ebay were GONE. Yes.. i seen 10+ listed for as little as $30.. and now.. NONE. occasionally i will see that one crazy person show up with the $500 Throttle body.. of course that is a pass.. Mostly patience.. and you'll score the parts. unless you have a local harley salvage yard. that would be great to get a donor bike.

In total , i think i have spent $350 without the Fuel pump. I couldn't score one, so i paid the tax fee of $250. Brining my personal total to $600.

Picked up a TTS tuner, to tune the bike once complete.. I am not %100 sure how to resize these photos.. to make them smaller and clickable.. maybe i will figure it out and edit this.


Before The Swap.
Photo of the Road King


Baker 6spd


Parts Incoming
Parts starting to roll in. O fcouse filling up the kitchen and wife asking questions!


Parts 2


Gasket Match porting Area shows in black
I am Cleaning up and gasket matching to heads. Some call this porting. Note all the black area, that is what can be removed. it is basically a wall that the air is hitting.


Cut and CLean Ported
Starting to come together.








Yesterday, I removed some of the basic items from the bike. I ordered a set of 2006 Heads, and began cleaning them up. Gasket matching the ports basic stuff.
Today, The wife helped. We got the bike down to the basics, removed the old wiring harness completely, and started to route the new harness to its living place. Once its through the battery tray, and you get the Y in place under the tank, it seems to be home free.
The Cam position sensor gets cut, and left out as harley did away with it.

Tomorrow will be connecting the Coil, CPS, and getting the new fuel tank guts put in!

 

How did you get tricked ? By the way I'm selling my yacht.

 

not sure if it was tricked or the guy just didn't know. . Luxury yacht? look legit.

 

If you get stuck with anything during the conversion get ahold of Ed Ramberger here on the site. He converted his MM bike to Delphi back when he worked for the Motor Company.

 

that would be fantastic. Don has pretty much walked me through the process maybe.. 10x in a row. I'm sure he's getting exhausted of it haha. any and all help is wonderful. pay it forward. if he would want to chime in that'd be great. there are a few different connections and wire locations I am questioning. trying to find photos of stripped bikes with wires intact. . thanks again

 

S

&S Cam plate. Andrews Timing Gears and Timing chain

 

roller

roller rockers

 

wit

​​​​​​with the new coil. if your able to get the bracket with it. I found you can slightly bend the bracket inwards. and position it to straddle the fuel tank bolts.

 

Here is a set of new Fuel pump assembly screws. Its always best to replace these new, as they have seals on them, seen in the photo. I can add the part number to the thread


I made a short mistake on the part number for the intake fuel line. from what I just learned from Don. Harley had 2 sizes. and 00-02 have the smaller of the two. I'll try to edit the main post for updated part I for ation.


when removing the fuel pump assembly and then installing the new assembly with the new fuel line, be careful because this pump goes in ONE WAY. if you think Jinga is tough. you'll struggle here

once you get her aligned sideways upside down and the. in place. it's a breeze. .

new pump assembly installed. the second quick connect fittings. you may remove and install a plug. I will add the part number to the main thread. Don has it. thanks again Don!!!!!!

 

OKay so remember, doing this swap The circuit breaker located within the battery box gets Deleted. It will not be used anymore. The Wire Circled in BLUE goes to your regulator ( Your Regulator has two wires GROUND AND +), the + will need spliced together to the regulator wire from the harness. Its a red wire with a black round connector. Both wires have the same size wire gauge. The 2nd wire from the regulator goes to ground, pictured circled in the bottom yellow circle. The wire in GREEN will go to your positive terminal (I believe. DON correct me if i'm wrong). I will attach a finished Photo tomorrow.


Photo above is the regulator connection that must be made. You can splice them together with shrink wrap, or order a delphi Single connector from ebay very cheap, and go that route. The + Regulator wire from the new wire harness will be the red wire with the large black connector. And the second wire photo'd is the Wire directly from the regulator. This is the wire the used to live on the circuit breaker that is being removed. Splice these together nice and neat. I will post a photo complete tomorrow.

This is the new crank position sensor., Notice it's oinly a few inches long, vs the 36" old version.