EFI Swap - Harley Forum

sinolav · #1 03-23-2009, 09:12 PM

Good day to all......

Well my winter project has gotten out of hand! Thanks Donnie, you and your fantastic books!

I added installing 06 heads on my 03 Ultra Classic, and also picked up the entire 06 EFI unit and flanges. Figures I'd go with a better design there also.

Well......... I have three minor problems, so far. The plugs on the injectors and throttle position sensor and different than those on my 03.

Does anyone have a solution for this, besides not installing the 06 EFI?

I AM going to get that unit on my bike, even if I have to solder the wires together ! Well, I won't go that far.

But I AM DETERMINED to install the 06 EFI somehow. Is there a source for just the connectors?

Tbone · #2 03-23-2009, 09:20 PM

Try these for starters.

Delphi Connectors Systems

NAMZ Custom Cycle Products

Is the '06 EFI off an '06 Ultra or the test bed '06 Dyna?

Whichever one it is, you can get someone to give you the part numbers for the corresponding connectors that you need if they have a parts manual. Then you can order them from the dealer or ZanottiMotors online by part number.

shovelmike · #3 03-23-2009, 10:01 PM

The injector connectors are the same as on GM cars. I had the counter man at O'reilly Auto Parts dig out his catalog. The TPS connector may be the same story, you'll just need to browse through the catalog and see.
I hope all goes well on the project, I know you will persevere.
Ride safe and God bless, Sincerely: Shovelmike.

sinolav · #4 03-24-2009, 10:20 AM

Thank you......both of you.... big time thanks, I'll research these tips.

I am looking for reliability, and after reading both of Donnie's books, I figured that since I had my bike skinned down to replace the cam, I wouls put on a better designed set of heads and EFI unit.

sinolav · #5 03-24-2009, 10:23 AM

TBone,

It's actually off a 07 FLHX. Got the heads first, then noticed the seller was also selling the entire EFI throttle body unit, and flanges.

sinolav · #6 03-24-2009, 08:45 PM

Looks like I won't be installing the O6 throttle body after all. After I also located the connectors in the J&P catalog I just received, I wrote the numbers down off the injector plug. The injectors are the 8 degree injectors, not the new 25 degree injectors, so there goes that upgrade, unless I want to spend more money and get the 27625-06A style injectors.
I'll be putting my 03 throttle body back onto the 06 heads. RATS.............. well maybe next year. Want to get this project done.

VRYQUIK · #7 03-24-2009, 11:00 PM

Quote:

Originally Posted by sinolav

Looks like I won't be installing the O6 throttle body after all. After I also located the connectors in the J&P catalog I just received, I wrote the numbers down off the injector plug. The injectors are the 8 degree injectors, not the new 25 degree injectors, so there goes that upgrade, unless I want to spend more money and get the 27625-06A style injectors.
I'll be putting my 03 throttle body back onto the 06 heads. RATS.............. well maybe next year. Want to get this project done.

I haven't read Donnie's article on this subject but, I would be interested in what he said. Maybe you can give to the short version.

I am always experimenting with different things at the shop. I have recently Installed 07 heads and 07 T/B on my wife's 02 Ultra. I also upgraded the injectors. I haven't had time to dyno tune and find out the results with the addition of the new injectors but I can tell a good bit of difference in the seat of the pants.

I would go ahead and use the new style throttle body and upgrade the injectors. The stock injectors will only provide enough fuel for about 98 HP (knowing this from previous dyno tuning of the bike). The injector upgrade should be good for about 120 HP.

sinolav · #8 03-25-2009, 02:48 PM

VRYQUIK,

According to Donnie's books, swapping heads and the EFI throttle body has several advantages.

The new 06 heads have smaller valves, better springs, better flow due to reshaped ports and smaller valve guides. Make sure you get heads with an 06 casting date, not an 04 casting date.

The 06 EFI has better designed injectors. The new injectors have a 25 degree spray pattern, as compared to the older style injectors, which have an 8 degree spray pattern.

I am after reliability, so I installed an Andrews 21G cam, and oil cooler. I also installed a ThunderMax controller with auto tune, and exhaust from an 08 Road Glide so I would have the O2 sensor bungs.

Of course, I got Donnie's books in the middle of my project, and first asked why the heck did I buy into this bag of problems. I can't believe you pay so much for a bike, and then have to spend even more money to make it reliable! That's not counting the money to be spent for getting better performance!

All that being said, you have to get the injector part numbers right to get the 25 degree spray. According to what I found, even on the newer throttle bodies, some older 8 degree injectors have been installed. They have a part number of 27625-06. According to what I found you want part number 27625-06A. If you need to buy them, plan an $100.00+ more spending.

Also, the plugs on the throttle position sensor and injectors are different. You will need to modify your wiring for the new plugs.

TBone and Shovelmike gave some good sources, and I also found plugs in the J&P catalog, under the electrical section.

I'm going to forgo the newer throttle body this year. My working capital is nearly gone, and I need to buy new tires.

cntrhub · #9 04-27-2009, 01:19 AM

If they angle the pitch of the spray from 25° from 8° is more like they are aiming in the center of the port and not bounce off a wall so soon, sounds like.
A spray patter are still straight out in a line shots of fuel mist patterns. But the angle of that straight line of the injector is all important and that is the degree it is set in of that throttle body. Sure, if they use the same body style of the injector and the head for the snap connector is the same = Go swap out the best mist shooter and the manifold with the best angle is the best of both parts. So I would run the '06 manifold and the more holes in the injector, the more fuel out > Could be the better mist.

This is really a simple wiring job. It is sorta complex to discuss and long in detail if I start writing theory. But the deal is this...

If we have a 3-Wire Sensor:

1. One wire off a sensor goes to = Ground*
2. One wire off the sensor goes to = The ECU.
3. One wire off the sensor goes to = The neutral light or the kill switch or the fuel pump, or the injector signal or the spark box and now the " * " for the footnote...

If we have a 2-Wire sensor:

1. One wire = Goes to ground.
2. The second wire = Goes to the ECM.

*You mess up with what junction boxes to ground > Is what set of sensors are in a basket and the next set of, "ground junction posts" are those basket of sensors separate from one ground toppled on the next set of grounds.

You are going to code all over the place in so many words. I could almost [I think I could maybe write a pamphlet and not] write a book about, EFI/DFI/ECM/EcU/Codes/Backup/Limp Mode and all that are 2 and 3 wire sensors... And those variables are enormous and complex I do not know that much about the subject. Just enough to become dangerous as they say.

But it can be done and that TPS has to work both in the low and high fuel signals. It defaults to the high throttle position and without looking in the factory service manual, I would guess the generic fuel injection limp mode to happen that way = "Not Ride-Able" unless you use it at the drag strip. Think how high they set the rpm' before they release the clutch? That is limp idle > In other words, the TPS is in limp mode and your project is at a stop for the street more or less.

If you do not code the ECU with any of the swaps, of course you are home free. Some codes you can get away with. That is for another day or another thread or post.