After buying a used 05 FLHPI I had ongoing problems with the EFI. I followed the diagnostic tree in the HD Electrical Diagnosis Manual a number of times, in a number of directions, to no avail. I had read several articles in various forums about other bikers going from EFI to carburetor so I decided to do so myself.

Everything I read was helpful but most postings were incomplete. Below is what I bought and did for a 05 FLHPI. Likely it will not apply to different models/years

HD Parts:
1) 11291 manifold sensor seal
10) 1311D screws
1) 16315-99 top engine mount (with slot for choke)
2) 26995-86C intake manifold seals
1) 27002-89 seal, carb to manifold
1) 27412-99D carb (CV40)
1) 27613-99 intake manifold for CV40
1) 29229-88D enrichment cable
1) 29313-95 gasket, filter element
1) 31655-99 ignition coil
1) 32435-04 wiring harness, ignition
1) 32622-04B ignition control module (ICM)
1) 38723-99 retaining clip, MAP sensor
1) 61163-02 spacer
1) 61402-02 gasket, sending unit
1) 68042-99 screw

DennisKirk Parts:
1) 182865 petcock adapter w/seal
1) H18262 petcock
1) H17224 Slinger Airflow Works jet kit for CV carbs (if your intake /exhaust are not stock)

Auto Parts:
1 foot ź” fuel line
1 foot 5/8” nylon insulator
4 worm gear clamps
2 feet of wire w/appropriate connectors

The parts installation was pretty straight forward. I had the HD manuals and the job basically consisted of part swapping.


In the forum articles I read an admonition that once the system was changed a procedure called “password learn” would need to be done. Directions were often available for the process. However, I never saw that the new system would have to be reprogrammed before “password learn” could be accomplished. The reader will probably guess what’s next – only a Harley-Davidson dealer can reprogram a new system. The reprogramming and “password learn” are fairly inexpensive if the dealer knows what to do. Be sure the dealer knows that the ICM has to be given a carburetor VIN electronically before it can be reprogrammed. I was told that there was something wrong with my work and so after 3 hours of repeated unnecessary diagnostics the service manager called HD. The dealer was then given the knowledge I thought they had when I went there in the first place.

Programmed correctly, she took the password learn and fired right up. The dealer then tried to hang me with another hour because my lights (working fine when I arrived) reportedly were no longer functioning. The whole exchange was a **** story that would have ended up in small claims court but for the fact that the nearest dealer to my home is a 2.25 hour trip one way.

But enough time worrying about sick folk. The bike runs fine and I would not now hesitate to buy an EFI HD to 2006. I think that was the last year for the carburetor models. In fact I recently bought a 05 FLSTSCI (not from the sick dealer of course). Wouldn’t you know? The EFI works like a Swiss watch.

I had about $1,155.00 in parts in the project. The work at the dealer should be no more than 1 hour and may likely be less. Getting the machine to the dealer is another consideration. After changing the jets I have yet to reset the idle mixture and speed, as it seems to be spot on. That, of course, may change with summer time temperatures and so I will monitor the performance for a bit.

I hope this will help others save some money, stress and time.

Questions answered at bhmysc@yahoo.com

Best wishes for thousands of safe and enjoyable riding miles.