Newer EFI engine in a 2004-2006 frame, but running a carb???
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Stage I
Joined: Jan 2025
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From: Austria
Newer EFI engine in a 2004-2006 frame, but running a carb???
I see articles about converting later model sportsters from EFI to carb, but what issues would a guy encounter taking a donor EFI engine and putting it in a 2004-2006 chassis with a carb bolted up as the fuel source (and an ignition module appropriate for a carbed bike)? I'm aware about the difference in width for the intake manifold on 2007+ heads (as compared to 2004-2006 models). Are there any other pitfalls or issues with harness or sensors I should be thinking about that would preclude running a donor EFI engine in a early rubbermount chassis that started out life from the factory as a carbureted bike?
HDF Community Team
Joined: Aug 2019
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From: Santa Ana, CA
Sportsterpedia is going to be your friend on this one. The main issue I think here would be the ignition setup. The carb'd bikes use a few different igntion setups over the years. The pre-2004 bikes used a rotator cup on the cam to trigger the spark in conjunction with a VOES switch. The 2004- 2006 bikes with a carb used a crankshaft position sensor and MAP sensor for timing advance. I think in your case it may depend on the year of the donor motor as to how easy it will be to swap over. Sportsterpedia talks about it a bit here. Are you still running the wiring harness from 2004-2006? I think because you are working with a bike that was originally carb'd you might be OK with a swap like this.
Last edited by OCSpringer; Jan 18, 2025 at 09:33 AM.
Road Captain
Joined: Mar 2009
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All you need to do it look in the parts books and identify what's different from a 2004-2006 as compared to a 2007-2022. You can find the parts books here: https://partsfinder.onlinemicrofiche....asp?make=hdmc
For example, look up the part number for the 2004-2006 crank position sensor, and compare it to the 2007-2022.
Do the same for the MAP sensor, the speedo sensor, the oil pressure sensor, and the stator. Those things cover all the electrical connections to the motor.
For any of those that are different, you may have to bring your original pieces over from the old motor to the new.
For example, look up the part number for the 2004-2006 crank position sensor, and compare it to the 2007-2022.
Do the same for the MAP sensor, the speedo sensor, the oil pressure sensor, and the stator. Those things cover all the electrical connections to the motor.
For any of those that are different, you may have to bring your original pieces over from the old motor to the new.
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