It might be too late but cleaning the inner cylinder liners with soap and water is a good thing to do to remove any debris within the cross-hatch. Any debris can prevent the rings from seating properly and can score up the piston skirt.

BTW, this is a recommendation from S&S and there is no doubt they know quite a bit about building engines.

 

I've got the pistons in the cylinders, and sitting on the bench. It's getting the assy to fit over the cylinder studs.

Should I really have to force it?

 

No but you might have a bent stud and that is hanging things up.

 

I have heard that you should not reuse studs more than 3 times.

 

I'm sure I don't have a bent stud, and I'm pretty sure the PO has never been in the engine this far.

It seems I'm in able to get it to the point where I line up the studs with the holes. I got them off though, so I think I may be being a little too ginger with it as I have just painted everything as well and don't want to scar them.

I'm about to head home for the day and give her another try. I guess putting the cylinders back on is like Tetris, only goes one way.

 

...don't stop there

after the soap and water you MUST clean the linings with a white rag and some 10 weight or ATF oil... the soap won't get everything

keep wiping with the white rag and oil until there is no black residue left on rag

 

Finally got her. There was no way the rear cylinder can be installed with the piston in it together at the same time. I took the piston out, put it on the connecting rod, and then was able to get the cylinder in place.

The front jug and piston was able to be installed together.

When using cometic layered head gaskets, do I still need the o-ring that sit on the dowels per the manual(95 softail custom)? Cometic kit didn't come with them.

 

no!

did you deck the pistons, too?

 

Nothing was decked. 9.5-1 comp pistons now. The manual shows an o-ring that sits ON TOP OF the dowels.

So no still?

 

Oh, and a million thanks for all the guidance so far. Thanks.