CVO Technical > Intake/Exhaust/ECM
Magnetti Marelli conversion to more modern EFI ?
martys:
Hi Fella's, My 2000 SERG is getting a bit tired, it now has 102,000 km (65k) on it and I don't believe the motor has ever been opened. I am considering doing a bore kit from 96 to 103, and also switching my EFI on my 2000 Road Glide Triple Red from MM to Delfi or some other system without having to take out a mortgage ;) Any feedback on this project would be appreciated .
Marty
Twolanerider:
--- Quote from: martys on January 28, 2018, 11:47:20 AM ---Hi Fella's, My 2000 SERG is getting a bit tired, it now has 102,000 km (65k) on it and I don't believe the motor has ever been opened. I am considering doing a bore kit from 96 to 103, and also switching my EFI on my 2000 Road Glide Triple Red from MM to Delfi or some other system without having to take out a mortgage ;) Any feedback on this project would be appreciated .
Marty
--- End quote ---
There are options Marty. I've converted a few M&M bikes to carbs. That's an easy solution if you want to lose fuel injection. If you want to keep fuel injection (and I did) there are options there too.
A few aftermarket harness additions that add to or kludge on top some part of the M&M harness and keep some/all/or a little of the original M&M hardware. I've messed with some of those and don't like any that I've seen. Especially if you break down on the road somewhere and have to rely on someone else for service. That shop will some what they'll only perceive as a Frankenstein's combo and walk away.
Just make the bike newer. It'll take a parts collection but it's all parts you can collect used (eBay or wherever) relatively inexpensively if you're willing to be patient. Get the parts you'll need from an 04-05 bike and make the old M&M bike straight up Delphi.
When I did mine a few years ago got all the pieces from a wrecked donor bike for $250. Have done the same thing to a few others and helped the owners search eBay for awhile. They each spent anywhere from $400 to $700 depending on how patient they were. All the parts are bolt-on though so it's not a tough chore.
martys:
--- Quote from: Twolanerider on January 28, 2018, 08:52:33 PM ---There are options Marty. I've converted a few M&M bikes to carbs. That's an easy solution if you want to lose fuel injection. If you want to keep fuel injection (and I did) there are options there too.
A few aftermarket harness additions that add to or kludge on top some part of the M&M harness and keep some/all/or a little of the original M&M hardware. I've messed with some of those and don't like any that I've seen. Especially if you break down on the road somewhere and have to rely on someone else for service. That shop will some what they'll only perceive as a Frankenstein's combo and walk away.
Just make the bike newer. It'll take a parts collection but it's all parts you can collect used (eBay or wherever) relatively inexpensively if you're willing to be patient. Get the parts you'll need from an 04-05 bike and make the old M&M bike straight up Delphi.
When I did mine a few years ago got all the pieces from a wrecked donor bike for $250. Have done the same thing to a few others and helped the owners search eBay for awhile. They each spent anywhere from $400 to $700 depending on how patient they were. All the parts are bolt-on though so it's not a tough chore.
--- End quote ---
Thanks Don I was sure you would advise me on this project and I do appreciate it. I guess my first step would be to search for a wrecked 04/05 up hereand try to secure the entire system from it . If that isnt possible I maypick your brain a bit more for a list of what to search for.
Marty
Twolanerider:
--- Quote from: martys on January 28, 2018, 09:38:57 PM ---Thanks Don I was sure you would advise me on this project and I do appreciate it. I guess my first step would be to search for a wrecked 04/05 up hereand try to secure the entire system from it . If that isnt possible I maypick your brain a bit more for a list of what to search for.
Marty
--- End quote ---
Glad to help any time. It's a bit of a parts list. The donor bikes are getting old enough that most of the stuff can be had relatively cheaply though. Will try to work from memory here and see how complete of a parts list can come up with on short notice:
Battery try
ECM bracket
ECM from 04-05-06
Main harness from 04-05
Engine harness from 04-05
Interconnect harness from 04-05
02-05 throttle body
Fuel pump and float assy (all the guts in the tank) 02-07 (think that's right)
gasket and screws for fuel pump assy above
Gauges from 04-13 bike
charging system
Options on the charging system: You can make the original Marelli era charging system work. Not recommended.
Can use the 02-05 charging system parts and it'll be plug and play to the harness you'd be using. Easiest option and works ok unless you load the bike up with lots of lights, heated riding gear and saddles, etc.
If you want all the charging capacity you can get use the 06-09 three phase charging system parts. Not quite plug and play but almost. One pigtail change and you're home.
It's been awhile since I've done the charging system swap on a 01 and earlier bike. I think I remember having to open up the holes in the legs of the regulator just a bit to make it mount.
If you do this you no longer use (and good riddance) the old cam position sensor. You'll also need a plug for one of the two holes in the gas tank a new fuel line from the tank to the throttle body. I think I remember the coupler in the tank needing to be changed to match the new line as well. Not sure there but, if so, Drag Specialties has that fitting with a new hose attached for cheap.
It's a large enough collection of parts that if you just goes balls to the wall and by whatever you can find first it can get expensive. Be patient though and a lot of this stuff can be had cheap. eBay is your friend if you're patient.
Pay special attention to harnesses on eBay. I did exactly this job to a bike from a buddy in Tulsa a year or two ago. The harness had a bad wire in it for the serial bus data signal so the tach and speedo didn't work. Took me longer than it should to isolate the problem then a half hour to pull a new wire from someplace where the data signal was still good at the TSSM to up inside the fairing. Cheap fix in a six foot piece of wire and a couple connectors but it took time.
Get all the pieces in hand and it's a fun Saturday job to change it all out. Then when done the old bike is all the vintage of Delphi parts that has such a large fleet in service that parts will still be available for a long time.
v-rod:
Here is a setup that works great...http://www.zippersperformance.com/all-products/performance-kits/thundermax/filter/cat/thundermax-marelli-conversion/engine_type/twin-cam-r.html
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