...... and i do believe you are correct on this
.... 95" was as large as the MoCo went on the original TC, any bigger & you had to stroke it.

 

the 103 on the older CVO models was a bored and stroked 88.

the original CVOs (called SEs at the time) were 95" (a bored 88)
then the CVOs became 103, a bored and stroked 88 (or a stroked 95, however you want to look at it) stroker kit available in P&A catalog

the 96 was a stroked 88
88/96 same bore
95/103 same bore

 

Without boring the case, Axtel or new SE 110 thin spigot cylinders would work but there are few piston choices for them with 88 crank. I'd stick to 98...

 

4"x4" is 100 cubes

 

If you insist on a 'square' engine the closest you are going to get is an S&S 111", which is 4 1/8" square. With a stock H-D crankshaft the largest bore available will give you 98", falling short on bore diameter by a mere 1/16". Surely that is close enough?!

 

I'd call S&S or another manufacturer and get their opinion . . . I believe that I read in one of Donny's books that 107 ci is the largest displacement without case modification. For a 103 ci like mine, that wouldn't be a large enough increase to justify the expense and hassle. But for 95/96 ci I would think it worthwhile . . .

Mark!

 

Harley just came out with a bolt on 110" kit that has a steel sleeved jug that has a thin wall jug that allows for a 4" bore without modifying the cases. I just had the first run over my lunch hour on this configuration after the techs got it installed. The info on this kit is attached. If you need one of these kits my dealership has them in stock. Message me if you'd like to get one.

 

Nice, but it wont fit his bike.

 

That's exactly what I said on the first page. Put the new big bore kit that makes 96's into 110's, on an 88, and you should have a perfect 4x4 100 inch motor. But was told it won't work.

 

The jugs would, pistons would have to be custom fit for the 4" crank. I'd guess someone will come with a piston in the near future.