Originally Posted by email@example.com
My son just bought an electra glide with a 88 cu.in. Can't remember if he said 2002 or 2006. I've got a set of 96 cu.in. jugs, pistons and a stock cam. I'm wondering if we can swap them or do we need more. Such as the heads, fuel injection system and different ecu.
That's a loaded question but I will take a shot.
Jugs will need to be bored; the 96" cylinders are the same bore as the 88" cylinder; the 96" comes from the increase in stroke from 4.0"" to 4.38". So, bore to 3.875" to fit a set of new SE cast flat top pistons.
Don't know why you would want to install the stock 96" cams; I don't know the differences in profile but if you are going to change cams, change to some that will make a difference. Cam selection will depend on riding style and other modifications.
Headwork will always help. Your options run from a BigBoyz "street" port job for $299 toi a set of fully ported Baisley (or other) heads for more than $1000; depends on performance goals and budget. A BigBoyz street port, plus machine work for chamber balance and decking for compression will run about $500 and, IMHO, a great value. If you can get your hands on those 96" heads, you could install them without any headwork and see some gains; they flow much better than the earlier heads.
If you increase displacement, upgrade heads and cams, you will need a fuel mangement system. Your options are Thundermax with, or without, autotune to the TTS Mastertune. You should check in your area for a tuner with a rep for good work and find out what he/she likes to work with. If there is no dyno tuner readily available, the Thundermax may be the way to go as it has an auto tune feature and, from what I read, pretty user friendly. I have no experience with the TMax but everyone I know that has is quite happy with it. The TMax has it's own ECM but others will retain the use of the stock ECM.
You did not mention exhaust or intake. To complete the package, you will need to open up the air intake with the SE air cleaner and convert the exhaust to a good 2:1 exhaust sytem like the V&H Propipe or the Python 3; both are good value and hard to beat for the money.
BTW, the FLHT, particulalry if an '02 is a solid machine with a strong bottom end. H-D cranks were still forged that year and the Timken crank bearing was still in use; boht have been downgraded, IMHO, since that year.