I am finally ready to assemble the motor in my 08 Road Glide with a 103 big bore. Just received my cylinders and pistons from the machine shop. Piston kit is SE 22942-00 with ring kit 22431-00, forged flat top.
I do not have the tools to mike the cylinders or pistons so I do not know if I have proper piston/cylinder clearence of .0015-.0025 but I do have a feeler gadge and can check ring end gap.
Both top rings are at .025, both middle rings are at .035, and oil control rails are at .033.
Top should be .009-.015
middle should be .019-.029
oil control rails should be .010-.030.

Its too late in the day to call the machinest so I thought I would ask your opinion. The way I see it I have 3 options:
1) Don't worry about it, put it togather and go
2) Order oversized rings and file like crazy? HD does have a .005 oversize set (22432-00)
3) Machinest cut cylinders too big, get with him tomorrow and see how to make this right.

The machinest had me send him the pistons along with the cylinders so he could get proper piston to cylinder fit.

Please advise, I was hoping to have this beast together in time for Daytona but I am wondering if my cylinders are shot!

Thanks for your time and any and all input

Doug

 

What method did you use to position the rings in the cylinder when you checked the end gap?

 

I'm not an expert , but have done many rebuilds. I would be ok with .025 on compression rings. The oil and scraper rings are not as crititical. But Maybe someone with more knowledge can offer you some advice. I would be more worried about too little clearance as the pistons will expand more on start-up then the cylinders. Just my .02

 

I pushed them down with the top of the piston, about 1 inch down from top of cylinder.

Thanks,
Doug

 

I'd call the machinest tomorrow.

 

Thats the answer I would like Honestbob. I have a bit of money in this build and although I really want to put it together I am a little afraid, but you make a good point.
Thanks,
Doug

 

So the machinist bored the cylinders too big?
Did he tell you this?
I would not assemble until the machinist replaces the cylinders.

 

without a mic and a bore gauge to check it there is no way to know....

 

He did not tell me this, it is just my assumption. I have not talked with him since I checked the gap tonight. He does not know I have a problem. I will call him in the morning and see what he has to say.
Damn, this sucks!

Thanks guys,

Doug

 

So you think the bores are oversize because of the ring gap?
If i'm correct,a crued way to check is to place a piston in the cylinder and use a feeler gauge.Start with a .0015 and then a .002",etc-.
Check at different points around the piston.