Well, it's been nearly a year since I had my 96 ci modified with a 103 ci kit from Performance Cycles in Baxter, IA, and I still am running stock numbers...but there is hope of resolving the problem. Here's the update.

After putting the 3,000 plus miles on the build that the kit provider suggested, I went on a trip in May where one of my riding buddies had the same year and model bike as mine, only his had a stage-I upgrade. We rolled on at 2500 rpms in both 3rd and 4th gears and it was all I could do to keep up with him. Sad news, huh?

The mechanic tore down the bike and confirmed the cams were installed correctly. He finally took off my stock, '07 SE mufflers and put on a set of Rush open (loud) pipes and the bike ran noticeably better. So, I ordered a set of S&S Quiet Tour Mufflers then set about having the bike dyno'd by who I'm sure is the best techs in the south-east - John Abarr. Here's what he did before even getting to the tuning.

After a disappointing initial run showing 72 hp, he checked for sumping with no problems found. He then did a compression check (190 psi each cylinder). He changed the plugs from iridium to standard to eliminate any interference with the PC III. He did a run without any mufflers at all and got 80 hp, which was still way off the expected 100 to 105 hp. He finally had two techs complete a leak-down test which showed 0% on the back cylinder and 3% on the front. Finally he tuned the bike for the best ride possible...all for $250 and a nice tip from me.

Mr. Abarr is convinced the problem is in the heads, thinking the throat was over-ported. Any feedback?

 

I have a 2008 Ultra Classic that I had the HD SE 103 stage 2 kit put in it (stage 1 AC, and SE 255 cams). It has stock heads with true dual Rinehart header and mufflers. My dyno numbers were around 85hp and 105 torque.

I don't think you will ever get to 100+ hp without headwork and better cams.

my 2 cts

 

Could very well be the heads. Were the heads ever flowed?

 

The heads were ported in the build. No numbers were promised but100 Hp and 110 ft lbs torque was routine for the build...not 72 Hp and 82 ft lbs.

...and the cam is an Andrews 54 H.

 

The heads were never flowed but will be when they are pulled off and sent back to Iowa.

 

If your builder thinks the problem is in the heads, he should try bolting on a set of stock heads to see if that makes any kind of difference. He could also try swapping throttle bodies to see if that's a problem. 190 psi is good compression, the cams are a good fit for your intended mission.

You've eliminated problems with the pistons, jugs, exhaust and cam chest. Got to be either timing, fuel or heads.

 

Fuel delivery was ruled out by the dyno guy, as was the Power Commander; however, one issue occurred whenever he tried adjusting the timing. A knock immediately occurred preventing him from making any adjustments.

 

Just perusing old posts. I know Todd at Revolution Cycle. One of the best in the business. Wondering how everything came out?