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Big Bore or Rebuild

Discussion in 'Motorcycle Tech Talk' started by HD Dragon Slayer, Jan 30, 2006.

  1. HD Dragon Slayer

    HD Dragon Slayer New Member

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    I am working on my 02 Wide Glide. Stock pipes w/a 1" hole rammed thru them. Everything else stock. I am a "Very Aggerssive rider". I blew a gasket and removed the heads and jugs for a detailed inspection of my motor. I discovered a 1/8" thick ring of burned crud or oil along the perimeter of both pistons. I believe this is telling me the rings and/or pistons are worn. Since I'm this far I figured I may as well bore the jugs and go to 95" pistons. Now I am unemployed right now and am trying to go cheap at this time so I'm wondering do I have to do any other head work? Will I have to switch Cams?? Can I get away with just rejetting the carb w/K&N air filter??? Any coments or help.....
    HD Dragon Slayer, Jan 30, 2006
    #1
  3. VYBR8R

    VYBR8R New Member

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    To rebuild or Not Rebuild

    The thick crud you refer to is carbon buildup which is usually there due to an overly rich condition. Generally you will see this buildup get soft and flake off if there is a problem with oil in the cylinders leaving clean patches where the oiling is worst. If the rings are totally worn out and you get oil coming up from the bottom you will see the carbon gone from the outer area of the piston (almost like a halo). The only way to really know if the cylinder is worn out is to measure it with a dial bore guage. How many miles on the motor? If you are totally out of money, clean the top of the pistons, hone the cylinders, install new rings and ride it till you can afford a real top end rebuild. To do it right I'd put in the 95" pistons and barrels, rebuild the heads, leave the exhaust alone and rejet the carb. There's really no good answer until you know if the bores are good.
    VYBR8R, Jan 30, 2006
    #2
  4. HD Dragon Slayer

    HD Dragon Slayer New Member

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    Thanks for the reply.
    I looked at the cylenders a bit closer and found my front jug to have a scratch in it. Not sure what caused it at this time but now I know I must bore to a larger size. I'm thinking 95". Rejetting the carb,adjustable push rods &,when the cash flowpicks up, a cam.
    HD Dragon Slayer, Jan 31, 2006
    #3
  5. hotroadking

    hotroadking Super Moderator Staff Member

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    If you must big bore then get a set of flat top HD SE pistons for about 9 to 1, leave the heads alone because of the budget and have the cylinders bored out by a local shop to fit the pistons.

    It would be cheaper to have them honed and new rings but you "really want that 95" don't you :D That's ok we all do. Check here with DP for pistons as well. You could always look on e bay for used pistons where someone has gone 103, 116 etc, sold my flat tops for $50 to a guy, he bought new rings for $20 and he had a good 95 for several years. Stuffs out there you just gotta go to the boards, check swap meet sections and ebay.

    Be careful what you get on ebay just because it's there doesnt mean it's a deal by price or quality.

    I would leave the cams and heads alone because of budget if the repair must be done. Have a HD wrench stop by and look to give you a second opinon as to if it needs to be bored or not.

    Cams a can be added later, heads should be shipped off and street ported, there are a lot of shops that can do that for $300 to $1300 depending on what you want done. A street port is enough.

    Then you need carb, intake, filter, pipes, tuning all to make it right.

    For now just do the big bore.
    hotroadking, Jan 31, 2006
    #4
  6. HD Dragon Slayer

    HD Dragon Slayer New Member

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    Gotta wonder Hotroadking, why do you reccomend the HD pistons??
    HD Dragon Slayer, Feb 2, 2006
    #5

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