Hope someone here can point me in the right direction. I bought a 96 FLT three years ago with 65,000 miles on it. Previous owner installed ev27 cam (did not replace pushrods) and primo clutch just before I bought it. At around 100k miles it started knocking. I suspected a wrist pin. Took the top end apart and noticed scoring on the cylinder walls and pistons. I had the jugs punched .010 over and matched to new pistons. Sourced some brand new heads and shaved them .045. When I reassembled the top end I used the original (non adjustable) pushrods again. Bad Idea? maybe, but I was broke. Motor still makes the same knocking noise. Took the primary cover off and checked the compensator nut tourque all was good. Just replaced the front motor mount as well. So what do you think is causing my knock? Doesnt really knock at Idle, It knocks under load. Its louder when its warm.

 

100k on the lower end you have rod knock going on give away is the knock under load & hashed walls . Evo's make a lot of noise with old rods all the alum in the engine just transmits it out . You just put a pumped higher compression upper on a tired lower , it is going out on you just a matter of when . Stock pushrods are fine just a pain to install that's all .
Check around I see later evo cranks ready to run in good shape for $150 regular . Good luck .

 

You need to get the crank pin in the 5 o'clock postion and with the bearings spayed clean with mineral spirits, or the like, gently check the male rod for ANY up/down.
If any is evident, whatsoever, then it's time.
Another thing is, that a service bulletin was issued in regards to the lifters to inspect/replace at 25,000 miles. Your a tick past that level of service interval.
Scott