Today I took the top end apart on my 96 Ultra Classic. I think it was all stock and with 92,000 miles on it, it needs to be freshened up. The pistons are HD 22091-838, and with my calipers they measure 3.485 at the bottom of the skirt and the cylinder measures 3.5, as close as I can tell with a slide caliper.

I have seen Wiseco and J&E on line, haven't decided which way to go, but it will at least get new pistons and cyl bore.

 

The pistons are 22091-83B. If everything measures under service wear limits you may get by with getting the cylinders honed & a fresh set of rings.

 

Thanks, I am off this next week, so I will take the cylinders and pistons to a local machine shop and have them checked. I am leaning toward news pistons, maybe 9.5 to 1, and maybe the S&S 89" stroker kit. I have a good friend that has a Harley repair/paint shop, and I will have him check his price from S&S for their kit. I will be 69 in two weeks and that would be a nice birthday present from me to me

 

Don't fear 10:1. With a proper squish and some premium gas, knocking isn't an issue.

 

Thanks, I'm seeing more 10 to 1 than 9.5 to 1
I have used mostly J E on inline 4s in the past but don't know which is best for Harley.

 

I've had good results with Wiseco pistons.

 

Wiseco seems to be the piston du jour. It's what I used, and my machinist was a fan as well. Went .20 over and standard stroke.

 

With the 89" your piston brand is limited with S&S cast pistons being mostly the only choice, remember seeing some forged pistons coming out for the 89" but can't remember where.

The guru John Sachs that builds off the charts engines told me a Sportster engine stock forged piston will work for the 89" stroker piston. My 89" has S&S cast pistons and well over 100 hp, it has survived years and years of torture only pulled for a bigger engine but clearly the 89" has my respect.

To get to 10-1 compression with the 4 5/8 flywheel the stock heads need cut down to 76 cc's, with a cam to match this setup, bike weight and riding style is a smile. A adjustable ignition at 10-1 is a must where 9.5-1 is a little more flexible for detonation reasons.

A 80" is a good bang for the buck that fits most needs but starts getting stressed to get it's full potential, a 89" matched with correct components hits 100 hp without killing the engine. The S&S 4 5/8 flywheel is bullet proof and despite everybody thinks a cast piston is the devil witnessed of a set of cast pistons that proves different. Now my current big cube engine is peace of mind with forged pistons because it can cook a hot dog if in a bad situation and a difference between 100 hp and 140-150 hp with physics

 

Im running Wiseco 10:1 pistons and EV46 cam. Even with the crappy California gas and only 91 octane available I have no problems with pinging.

 

With 92,000 miles, you can still see some cross hatching on the cylinder walls, and the bore measures 3.498. I will still take it to the machine and have it checked this week. I will ordered the pistons after that.