2001 Harley Road King - Build Thread - Marelli Carb to Delphi ECM Swap

Jae · Oct 16, 2024

This build thread will cover an off-topic build.
(I will try to make this a casual 'Read in', Build thread Rather than a 'follow along')

2001 Harley Road King Classic w/ Front Fairing

* This Build thread will also cover, Swapping a Pre-Delphi (Carb) Twin-Cam Harley engine, to a modern Delphi fuel Injection ECM system.

History on the build: (can be skipped to jump straight into the "meat and Potatoes")
I've been through many motorcycles over the years, grew up riding dirt bikes, quads etc. Love it still, to this day. If it has an engine, I'm interested. I have gone through the crotch rocket phase of my life, and it thankfully passed. Now, I dislike just about everything about it. Except maybe to specifically race? Anyways, I knew I wanted a large Touring Harley Model. I have already had and ridden a sportster, except now I wanted lots of luggage room, and make it comfortable for a passenger.
Meet the 2001 Road King Classic. With a Front Fairing and radio kit. Which Basically turns it into a full Touring Model.
I purchased it used pre covid with around 3000 miles.

Harley Delphi Swap & Build Thread
Section 1 Pre-Build-Info

A few Q&A's:
What is a Magneti Marelli Fi?
A Magneti Marelli Fuel Injection system is basically a carburetor, that uses a fuel injector. The so called "Tune" is 2D. TPS vs RPM. It does not factor in speed Density or Load.
It is essentially, almost exactly the same as having a carb, with a few bonus features, such as ignition timing. with ZERO feedback.

What is a Delphi Fuel System?
A Delphi Fuel injection system is a more modern approach to fuel injection. Rather than having zero feedback, Delphi has multiple feedback points, from Temperature sensors, Manifold pressure, advanced crank cam position, etc. a Class 2 Data BUS system. Basically, exactly what GM offered in the v6 family with the advancements of OBD2. It offered fuel injection, with full feedback Loops, including the option later, for switching o2 Sensors.

What is TTS MASTER TUNER?
Well, if you can remember the early days of GM tuning including the 3800 series 2 and Specifically the DHP Tuner. We had access to certain tables, to adjust the feedback loops and calculations from within the ECM/PCM. Once you get the data cracked on the OBD bus, you can have endless fun, changing the feed back calculations from your ECM/PCM. Well, Harley wanted the leading edge on performance, and the owners preferred the Carb's so they can adjust for specific AFR. TTS MASTERTUNER. A.K.A The Turbo Shop's MasterTuner (Steve Coles Shop)

How tuning got started with Harley:
They worked with a software engineer Steve Cole, who helped Harley build the "Harley Screaming Eagle Race Tuner". Steve Cole worked DIRECTLY with Harley and Delphi, to create a tuning system to work directly for and with Harley Engines. Rather than crack the code like DHP/HPT was/is stuck doing, they had the advantage of behind-the-scenes access to Delphi code. Offering a "Harley Tuner" straight from the factory.

Harley and the EPA?
As you can imagine... The Tree Hugging EPA found out about a few thousand Motorcycle owners, that were skewing their AFR's, And to quickly avoid the conversation of Taylor Swift and her Jet pollution ( joking) they had to make some examples of their new regulations. Harley was Fined, and ordered to halt the practice of offering customers what they wanted, Proper Engine Management. Harley then split the relationship with Steve Cole, and he started his Own private route of offering a tuner for Harley engines named, TTS MASTERTUNER. A.K.A The Turbo Shop's MasterTuner (his shop)
Link to the suit: Harley to Pay 12 Million over EPA emissions Lawsuit

What are the Harley Models, or families?
Sportster, And Touring are the main lines.
Sportsters came with 800cc and or 1200cc engines, The engine and trans are one case. Much lighter motorcycle, very easy to ride around on. Limited room for passengers and or luggage.
Touring, models are your large frame harleys. Touring Model Harleys are your Road king, Road Glide, Street Glide, Dyna(Touring Model without luggage to make more of a sportster feel).

Harley Engines?
The most common Harley engine is the BIG TWIN Starting from the Late 90s. With the Twin Cam Coming out around 98 with a run life until 2018. And now, they are released with the Milwaukee-Eight engine aka The M8 from 2017 - Until present. Still, within the Big Twin Family. Of course these Harley released models. Custom builds go well over 130ci.
Twin Cam: 88ci = 1450cc, 95ci = 1550cc, 96ci = 1584cc, 103ci = 1690cc, 110ci =1801cc
M8 107ci = 1750cc, 117cu =1920cc

My 2001 Harley Road King Engine:
My bike came with the 88 twin cam, and was upgraded to a 95ci.
This included New Cylinders, Heads, Pistons, Cams, Cam plate, etc.

Jae · Oct 16, 2024

Harley Delphi Swap & Build Thread.
Section 2 The Fuel Injection Swap

Why ditch the Marelli?
With the Magneti Marelli we have 3 options...
One: Leave it alone, or Swap to a traditional carb,
Two: Get a Complete Custom system like a mega squirt or
Three: Do what Harley did, upgrade the bike to a Delphi.
In my opinion the best option is to do what Harley did, Upgrade to the Delphi system.
Having a 3D View of the engine vs 2D without Feedback is huge. I also wanted o2 switch sensor control. Open loop / Closed Loop.
I thought about a few other ECM/PCM Options Such as ThunderMax.. However, it seems they will soon be not supported, and I didn't want to go down that road, and I wanted to be unique, and try something different, plus I love bone yard shopping for upgrades. Reminds me of the Early grand prix days... Junkyard Hopping and Shopping.
I am hoping this will be a future tech article for anyone that wants to switch from a carb to EFI. Or Marelli to Delphi. Not having to mess with Carb Jet kits and being able to hit any elevation without the thought of Speed Density is much appreciated.

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 ): ( MAKE SURE YOU ORDER THE CORRECT ECM! )
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
** Depending on your situation, you may need a new Air Filter and Mount.

Some Information about TSM or TSSM ( Turn Signal Security Module )
*** If you have Key Fobs.. Or you want Security. You have.. a few options.. try to follow along. If you Order a new TSSM & ECM Combo Already married. You are set, just program your keys and your done. If you want to only order a ECM, and marry your ECM and TSSM, you must follow the procedures. Ill try to find a link.
**** Now.. If you don't care about security. Just order a regular TSM and ECM. no marriage process, and no key fobs.

Good Old Before Photo. No Fairing, Stock

( ..:: 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 coil will need a custom fabbed bracket or some type of mounting ( you can use the newer bracket if you have it ).
You will also need to mount the insides of the side panels, ( ECM, Fuse boxes, etc ). It's important for these items to be properly secured, as close to factory as possible.

Also, Their may be shortcuts depending on your year, However. this swap will give you the full Data system between the harness, Speedo, TSSM, ECM, etc. Much better to do the complete correct swap.

Jae · Oct 16, 2024

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

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.

Here is a photo of the black area removed. I will still need to blend both sides, and polish the exhaust side.

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. as listed above.

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!

Also for tomorrow Figuring out how to handle photos on here!

Here is a shot of taking apart the fuel tank, getting ready to install the new fuel assembly. Notice its getting dark, and my shaggy outside setup is not suite for it!

Here is a photo of the marelli harness removed. Just missing the Throttle body to go with it. Soon will be on ebay!

Jae · Oct 16, 2024

(THE BUILD):

Here is a little update on how the heads are looking

while I have it apart. figured a great time to knock out the handle bar bushings. they were definitely cooked.

Something Don pointed out that's extremely important. after the 2001 era Harley ditched the old school "Circuit Breaker". Shown in the photo. new style uses the large 40amp fuse. not pictured

when you get a speedometer. make sure you get the lock ring included. as the older speedo is thicker

Throttle Body is out! adjustment on the new throttle body will definitely be needed. wot gets me about %75

s&s Cam Plate. Andrews gears and chain.

baker 6 speed

sorry for the bad photo. roller rockers.

okay if you are able to get the coil with a bracket. I found if you slightly vend the open end of the bracket inwardm it's able to fit in between the tank mounts. now we will find out later if this fitment works good or not

Jae · Oct 16, 2024

(THE BUILD CONT.):

throttle body in place. connections in place. still need to tuck the harness after I finish

you can see the new crank position sensor in place. the old harness uses a 3ft long position sensor wire. the new harness has the length in the harness side. so the sensor only has a 6" wire with connector.

sensor installed. old one being removed

here is the routing of the new harness crank sensor wire. old one will be removed.

some advice for your guys doing this.. try and have an empty fuel tank. don't be silly like me.. and "Fill R' Up". handling that sucked. haha

.
also. remember if you previously has this rig running.. you will have positive pressure in the fuel feed line. as it uses one way valves.

be careful if you plan to cut this line pictured

the fuel connection from the pump assembly will land here.

you'll be replacing the lines with your new setup

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 will edit the main post for updated part numbers

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 Jenga is tough. you'll struggle here

once you get her aligned properly while also sideways and upside down. 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.

also a great tip from Don. very good practice to replace the fuel assembly screws with new screws. only a few bucks. they have seals on each screw. really worth it.

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 will attach a finished another time.,

This is pretty much the Entire Magneti Marelli System. Everything that makes the entire system up. and everything you will be swapping out if you did the project. This might be easier to get a perspective of what's involved.

Jae · Oct 16, 2024

(THE BUILD):

Cant remember if i posted this. Try and order a Speedo with a Bracket. As you can see the older and generation newer styles are different. The older version is much thicker. as seen here

Installing the new speedo into a Road King is a breeze. Pop it from the bracket and your home free. Obviously other Models will be different as you will be working inside the Fairing. I do use a fairing currently, but only for the radio and speakers.

I think i forgot to add this photo. This shows how the throttle cables get connected to the new throttle body. Dont forget to adjust it.

These are the Fuel tank mounting screw Gaskets. Notice the old one verses the new ones in my hand. It's only $10 for the screw set, and better to replace them while you are in there.

In my situation, I ordered the 2006 year Fuel pump, as i was going to go the 2006 route ( All parts must be from 2006 when using a 06, 07, or 08 model ). The 08 also requires handle bar wire harness to be replaced, among other things. Since i really got held up on the 06 harness, i ended up going 2005. Considering i already purchased the 2006 Fuel pump, I had the convert the connector to match the 05 to 06 pump.

*Notice the connector on the top, is from the previous years.

Putting everything basic back together, routing and mounting everything in place.

I ran out of single connectors, so i used this for the regulator wire. Soldered and Shrink wrapped on both ends. it will be covered with wire loom. This is the Red regulator wire running from the regulator to the battery area, that you wire into the new harness.

After finishing the swap ( minus side covers and touring pack ). I had a crank no start. Boy was that fun. Thank you @TwoLaneRider for guiding me to the fix! WRONG ECM! Ooops. Damn Ebay.

Turned out to be something silly on my part. I ordered a "2006 Touring ECM" From ebay. Turns out.. the ECM was from a VROD!.. After I ordered a new ECM and TSSM Combo ( Already Married ). She fired right up.

.....Well except for the issue of mixing up the spark plug wires!

Make sure you get those right too! oh, and make sure you order the correct ECM!

I also want to ad.

If you have Key Fobs for security your bike has a TSSM. And if you don't order an ECM TSSM married Combo, you will have to marry your TSSM ( Turn SIgnal Security Module ) to your new ECM. ( your keys will stay programmed to the TSSM )

However, if you order a new ECM and TSSM Combo.. you will need to program your FOBS to the new TSSM.

OR..

you can skip the Keyfobs.. and the security and just get a TSM module, rather than a TSSM.

** Photo is the TSSM

Jae · Oct 16, 2024

(THE BUILD CONT.):

Something i forgot to ad to the main post.. and unfortunately i am not able to edit the post! You will need to figure something out for the air intake depending which one you have. If you already have a Filter you could just order a back plate from ebay for a few bucks. I just ordered the Arlen Ness Big Sucker Air cleaner Kit.

Everything is going back together smooth! Once i have her fully set back up, i will start the tuning process. Although i must say she already Run, Starts, and Feels better!! ( Yes i drove with no seat, really touched my inner... Iron Butt... )

Got the Bungs welded onto the exhaust. Twin scan and TTS both installed. (Both USBs are in the saddle bag, I can just pop the side cover to swap connections, I have thought about using a Y splitter to leave both connected at once, not sure if that would cause disruptions). Got the O2s Ordered, and have the wideband installed, going to try and figure out how to scan with Twin scan, and program with TTS. I have been trying to find the correct Excel Sheets, unfortunately none of them are correct! the cells are off 14x21.

Good old marketplace. Found a random gentleman online that was doing some random weld jobs, Asked if he wanted to try to weld a bung. He Agreed, awesome guy. Welded the stainless in, worked awesome!

o2 Switching Sensors are in. Along with wiring and pin Sensors. Time to add Narrowband Switching SEnsors onto the bike, and flash a newer file with o2s

The bike as it sits.. it runs awesome! Generally speaking, i still need to dial in the tune. it was extremely lean, i dialed that in manually.. Which.. im not sure why as the o2 sensors came in and the bike needs flashed again haha.... as they say idle hands are the devils hands.

So. I started to build the Wiring harness for the o2 sensors. Now i must say, you can use the default connector that comes with the o2 sensor, and just find a male end.. But honestly.. i have used those and they are junk when it comes to weather and abuse. Delphi connectors are always the way to go. You can grab them from amazon.

Here is the old connector in the background. also i prefer to get the delphi connectors with the barrel compression pins.

If you need to disassemble a connector, there are plastic stoppers inside, simply push them down, to release the crimped wire.

Accessory harness . I ordered 2 pin and 4.

Here is my finished harness for the oxygen sensors. I just need to installed them on the bike, and route the wiring. And ofcourse, open the PCM harness up, and stick the pin in.

Just a reminder.. If you do Not want to go with adding oxygen sensors ( o2 ), all you need is a tune and your done. Otherwise, continue on

Jae · Oct 16, 2024

Here is a shot of the connector rear. Notice those little clips on the outside, you'll have to simply pop those off. and cut the zip tie. Then your home free.
There are little plugs blocking the holes you need.
TERMINAL #8 == FRONT o2 SENSOR WIRE.
TERMINAL #23 == REAR o2 SENSOR WIRE
TERMINAL #26 = Sensor Ground wire ( this may have a wire just splice into it )

Notice in this photo, i removed that clear plastic cover with a screw driver. This made pulling the pins through the connector easier. I HIGHLY recommend 20 AWG wire for this connection. My 18 was fat and JUST FIT.

As i mentioned terminal #26 the ground was already taken,,, so i spliced into it.

Connector closed up
You can see the clear cover easy in this photo. I used shrink wrap, sheathing... and tape. oh. and zipties.

Dont forget anti seize on those threads

Front o2 wire harness in its home spot.

Zip Tie and she looks clean

And here we have the finished product. ( as far as o2 sensors installed and pinned to the ECM )

o2 sensors are installed! ( Please excuse the PCM and the mess under the right side cover), i have been trying to fabricate a perfect fitting peice of metal, but she keeps coming out wrong, as i keep adding things. I will update when i finish it.

Anyways, here she is. ready for a tune!

Now.. as for the tuning.. TTS manual stated.. "you need a 176 Calibration file". After staring at that sentence for hours, and searching around.. it seems ANY 176 file will work.. which covers multiple bikes from many years.. say.. 2006-2009.. actually it may run 2006-2011 for the safe range, Just do not quote me on that. I found a suitable file from the 2007 year category from the TTS library.

Something to keep in mind.. and make sure you change. "ECM Constants" Displacement size, injector size, etc. I also copied over every table from my previous tune as a starting point. And this my friends.. gave me a MAP to start out with.

I will report back, after i get a few logs, and make a few changes.

** Some more info on the tuning part ****
I will upload the original TUNE file, and my tuned/Changed file just incase it is able to help anyone.

*Being the narrow bands can only measure that "narrow band" of 14.1-15. I feel its better to dial the entire VE table in, using the "band" the sensors are able to measure (14.67). So to get a good tune: I set the entire AFR table to 14.6, Tuned the entire VE table until i got within %5. Then Smoothed it. Then set the AFR table back to where i wanted it ( in your case stock ). That should pretty much get you exactly where you want. If you follow this method, don't forget to zero out any adders or decel tables.