Let me ask the question right up front. What could be wrong with my upgrade?

The guy who wrenches my bike talked me into a 103 upgrade when I went to him for just a cam change. His promise? Increase in the power band, a 50% increase in HP and 40% in torque, all without any real change in mileage. The cylinders and heads were sent for the rework and damaged in shipment. Although the damage was supposedly done during shipment to the shop, the shop replaced them with "fresh pulls" because the damage was not reported in time to make a valid shipping insurance claim. The cylinder was bored and the heads ported. New cams, gaskets, and pistons accompanied the modified heads and cylinders, then re-installed.

Right away I noticed a positive change in the torque range from the cam upgrade (what I asked for to begin with); however, the power was just not there and the mileage sucked royally (as low as 29 mpg vs. the 44 I was getting). My problem is that a post break-in dyno revealed numbers in the stock range w/stage I changes - 74 max hp and 79 torque. If I really baby the ride by not getting over 3,000 rpm or above 55 mph, I can get 37 mpg on a 150 mile ride.

I knew there was a problem when I took the bike back to have a compression and bleed down test done. The mech (I don't consider him a full blown mechanic now, so I just refer to him as "mech") had to borrow a compression gauge and the fitting was the wrong size (automotive vs HD). He could not do the compression test and I'm not sure what he planned for the bleed down. He checked the cam timing which looked okay. The mech wants me to take the bike by another shop to have the tests done at my expense. I don't plan to do that. As a matter of fact, if the mech does not step up to the plate to fix this problem, then I'm probably going to another mechanic and then to small claims court to get back some of what I'm out.

All I want is for my bike to perform at or near expectations. My question is what could be wrong with the upgrade that lends itself to what I described above?

 

I saw your thread over in the touring forum, but you'll likely get better responses to your question on this forum.

Your mechanics estimate of power increases of 50% hp and 40% torque for a cammed, ported 103 vs a stock 96 should mean a final number of something like 100 hp and 115 ft lbs, easily within reach of your planned mods.

Your problem, though, is impossible to diagnose without more information. You need that compression and leakdown test. If nothing else, it will start eliminating possible problems.

There's many things that could be costing you power, including having a crappy tune, improperly installed cams or pushrods, valves not seating properly, wrong parts installed, etc, etc.

Post up the dyno chart and get the compression check done and you'll have a better chance of getting good advice from the forum.

 

What's the best way to post a dyno chart? My pdf is too large. Should I convert it to a bmp?

 

My "free magazine sponsored" 103 upgrade ended up costing me well over 3k to get fixed up and running right. Also some of the parts photographed and published in the magazine were removed and not present when the engine was taken apart for repairs. Don't tell me how I'm still to the good cause I never would have done this had I known where I was gonna end up. I wanted a cam change, thats all. Guess I shoulda known there is no free lunch.

 

Dyno sheet attached. Thanks.

 

cam timing??????????

 

My 2011 with a stage 1 ONLY SE A\C, PC-V, V&H Hi Outputs & a dyno-tune rolled 76 hp & 90 tq. There's definitely something wrong... That was on my 2011 103 Ultra Limited.

 

What Andrews cam?

 

I believe it was the 54H cam.

 

Dyno sheet is posted and my son-in-law is reminding me of more details, so here goes.

1. Pipes should not be a big issue; however, I'm running true duals with SE stock slip-ons (that came off a SE getting aftermarket slip-ons).

2. I'm running a PC III USB w/o O2 sensors. Could this be a limiting factor? If so, why?

3. I have a loud tapping noise on the top end that the mech said is not unusual. I'm/we're wondering if a broken valve spring or out of adjustment push rod could play a role.

4. I never see this because I'm on top of the bike, but my son-in-law has told me several times that smoke comes out of the exhaust when I'm pulling off. This may be that it is running rich at idle.

Commentary: The cam seems like it is doing what it is supposed to do because of the curve characteristics, so maybe the problem is in fuel delivery or compression loss.