FI lines

[Scooter1-2putt]

I just bought a 96 FLHTCUI. Never had fuel injection before. I have a factory service manual for 95-96 FLT models in a MMI binder. The section 9 for fuel injection is missing. (I'm trying to get it now.) My problem is the fuel return hose is leaking at the tank. Dealer parts guy said I need a new fuel line - about $200. The pressure line also drips fuel if I wiggle it - another $200. In the parts breakdown I saw there's o-rings in the ends that go into the tank. New o-rings and fuel lines still wiggle and leak. Are the fuel lines repairable? I'm thinking maybe just yank off FI and put a carb on. Any links on swapping FI for a carb? Is this a good idea? Is there any place that has supply & return lines cheaper? $400 seems like an awful lot. 

[tmwmoose]

The two fuel lines have been obsoleted for years now .

[Hossamania]

Do a search here, quite a few threads on changing out to carb.

[barrybasinger]

I have read a piece on the net about one guy who has a technique for repairing the MM lines, and it seems doable. I personally have never done it. I always replace the factory lines with Goodridge lines. Braided style runs about 200 bucks.

As to conversion, there is another option: These can be converted to Delphi--which is probably what I would do. There is a kit available to assist in this. You can probably find it via google.

Marelli bikes are getting hard to find parts for, unfortunately, and even worse, it is even harder to find anyone who actually knows anything about them--and that's always been kinda tough. As much as I like them, and even though I  have been working on them for a long time, I no longer recommend that the typical new-to-EFI rider in search of a ride actually buy one unless it is absolutely perfect and very low miles.

[Scooter1-2putt]

Thanks Barry. I came up with a way to temporarily repair the oem lines.
  I got two O-rings that fit tight enough between the fitting that goes into the fuel tank and the fuel line, to keep tension between the fuel line and the fitting which keeps the fuel line from wiggling or vibrating. First I drained the fuel tank. Then removed the fittings from the fuel tank, (Be careful there could still be some pressure and fuel in the lines), and cleaned the fitting and the space between the fitting and fuel line real good to remove all traces of fuel & dirt. Then wrapped tape around the fitting to cover the threads and about half of the hex of the fitting . Next I squeezed some fuel & oil resistant silicone adhesive between the fitting and fuel line. I then rolled the O-ring over the fitting so the O-ring would go between the fitting and the fuel line. Then I applied more fuel resistant silicone over the O-ring. I removed the tape from the fitting and installed and torqued the fuel lines. I let the silicone adhesive cure before adding gas to the fuel tank. It's been over a month now and I still have no traces of gas leaking from fuel lines.
  Barry, Was the technique for repairing the mm lines anything like what I've done.?
  So for now I'll stay with the MM fuel injection.  I bought a set of braided style FI lines from J&P Cycles. I haven't had time to install them yet. I have been too busy and my temporary fix is working great.
  Buy the way the bike I bought is a 1996 FLHTUCI with less than 20,000 miles on it, for under $5500.00 which I felt was a pretty good buy. I could have bought a twincam for a few thousand more but I prefer the Evos and have many of the tools for working on them.   

[barrybasinger]

Thanks Barry... Was the technique for repairing the mm lines anything like what I've done.?
  So for now I'll stay with the MM fuel injection.  I bought a set of braided style FI lines from J&P Cycles. I haven't had time to install them yet. I have been too busy and my temporary fix is working great.
  Buy the way the bike I bought is a 1996 FLHTUCI with less than 20,000 miles on it, for under $5500.00 which I felt was a pretty good buy. I could have bought a twincam for a few thousand more but I prefer the Evos and have many of the tools for working on them. 

Not exactly. If I remember, he was able to actually remove the fitting from the hose to replace the seal. Your way is simpler. As to buying an EFI Evo: I too purchased a near-perfect '97 FLHTCUI with 10k miles not too long ago. Suggest that you learn everything you can about them, and start hoarding  the specific parts and tools. BTW, the '95-'96s are unique in many respects. Example: Frame change and ECM change in '97, clutch change in '98... Can't put most tuner devices on a pre-'97 ECM,, so must replace the -94 ECM with a -97 ECM. ETS just seems to "go bad" every couple years on MM EFI. Used to replace way more early ECMs than Delphi, but have replaced several Delphi ECMs in the last year. Guess they're getting old too. S&S is a good bet for either, but remember that the Harley/S&S version internal software ("firmware") is not the same as the aftermarket firmware, as it uses the same TPS/RPM cells as the stock MM, not the unique layout that S&S uses on their own version. Either works, as long as you keep them straight. PM me if you need info as you progress on that thing. I'll help when I can.

[tmwmoose]

I repaired a MM efi years ago I'll lay out the basics you go from there its cheap and not hard to do. You are going to use 1/8" pipe thread fittings at the tank ,ultimately a 90 degree barb to hose clamp to the trimmed oem fuel lines.
You will separate the hose were it swivels at the threaded fitting at the tank. The hole the line was in is what you need to tap to use the 1/8" elbow fitting. Thing is I don't remember what size hole it was and if I had to step up a size with a reducer fitting you might ,might not no big deal just don't remember.
Once you have your tank fittings on you have to cut the metal end off the hoses which will be to short get a couple 3/8" hose splicers and a short piece of fuel inj quality hose and finish it up
You can cover up the hoses and clamps with some of the black plastic wire loom sheathing for instance
Also for the best clamping of hose is to use the crimp type clamps and tool found on all of HDs oil n fuel lines over the typical screw type
I tried the Goodrich line kit once what a POS the clips they supply are cheesy as hell and I called them for some more and was told nope don't sell them seperatly only with the kit ,so this is were the above was conceived from