HELP!! Bad knock. Have video
Road Warrior
Joined: Nov 2014
Posts: 1,962
Likes: 140
From: NY
Well I had my local indy look at it (trusted friend, was lead service tech at local dealer for 10+ years, then went rogue and opened his own shop)...
Bad news. Somehow my banjo bolt did break (perhaps over-torqued at some point?) and flew into the intake, tearing up pretty much everything in its path. At that point, there was bits of shredded metal that continued to do damage, making it all the way down to my flywheel. Heads need to be replaced, flywheel needs to be replaced, and crank case needs to be split to do that and clean all the debris out to try to salvage it. He is recommending a complete motor swap.
Well, I was planning on doing a Stage 3 on her anyway. She already has the SE-203 cam (confirmed) that I can pull from her existing box.
So next question: Should I buy an 06 used 88ci (this year had the better valve heads), slap my cam in and call it a day til I can bore it out? (approx: $1800)
Or should I dabble in trying to throw a 07-08 96ci and 6-speed tranny on it? (approx $2300). Heard this can be done.
I've only got $4000 to spend between parts and labor, so no way I can afford the S&S motor...
Bad news. Somehow my banjo bolt did break (perhaps over-torqued at some point?) and flew into the intake, tearing up pretty much everything in its path. At that point, there was bits of shredded metal that continued to do damage, making it all the way down to my flywheel. Heads need to be replaced, flywheel needs to be replaced, and crank case needs to be split to do that and clean all the debris out to try to salvage it. He is recommending a complete motor swap.
Well, I was planning on doing a Stage 3 on her anyway. She already has the SE-203 cam (confirmed) that I can pull from her existing box.
So next question: Should I buy an 06 used 88ci (this year had the better valve heads), slap my cam in and call it a day til I can bore it out? (approx: $1800)
Or should I dabble in trying to throw a 07-08 96ci and 6-speed tranny on it? (approx $2300). Heard this can be done.
I've only got $4000 to spend between parts and labor, so no way I can afford the S&S motor...
OCh,sorry to hear that.
On replacement motor,i read that TC 96" in your older bike cam be done requiring some fab and or bracket work etc and is not by any means a simepl swap.
So if you dont want to deal with that i'd go wit a decent use 88" ,install your cams and move on for $1,800 & do lrg bore upgrade at a later date ad $$$$ allows.
BTW,unless its a hvy dty app " Blue Loctite " is an HD's friend,esp anything close to the intake that could get sucked in if was to come loose so try to use it when ever wrenching the bike.
I keep blue/medium strength loctite in the bike tool kit too.
Scott
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Cruiser
Joined: Jul 2012
Posts: 146
Likes: 9
From: 'Merica
Very true, wscott. That is looking more and more like my best option unless another CVO 103 pops up. I haven't done any work to the air cleaner before-hand so I know it wasn't my wrenching. Unfortunately, the bike has had 3 sets of hands on it in the past 6 months, so I'm thinking that's what happened. I lock-tight everything and keep plenty in my tool bag also. The hunt continues!
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Cruiser
Joined: Jul 2012
Posts: 146
Likes: 9
From: 'Merica
Well with the help of everyone in this forum and a few other sources, I finally came up with a solution. Basically Frankensteined the motor, BUT I feel like I did it right and without buying the full used, expensive, hard-to-find CVO motor.
Kept my 1999 RK transmission and primary.
Used '06 CVO crank case from a Screamin' Eagle Ultra Classic
Used stock 1999 cam plate and tensioners (new boots) (will go hydraulic later, couldn't afford now.)
Went with new S&S 551 Easy Start cams (for added compressino and stock starter)
2015 stock bore (103ci) cylinders and heads from a dealer take-off of a 2015 Electra Glide (literally no miles on them other than whatever start-up test the MoCo does)
New Wiseco 9.6:1 high compression pistons
All new gaskets with .030 cometic head gasket
New stock stator (mine was pretty caked up, so went ahead and replaced)
All new gas and oil lines
Waiting on new hoses to get here and we'll see if she starts up! If she does, I'll have effectively turned a trashed 88ci motor into a mostly new 103ci! And still have my cylinders, heads, crank case, and SE 203 cams to sell to make back some money! Overall, project cost me about $1500. WAY better than the $3200 quote to fix what I had, and $5200 quote to have S&S build out the motor.
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Kept my 1999 RK transmission and primary.
Used '06 CVO crank case from a Screamin' Eagle Ultra Classic
Used stock 1999 cam plate and tensioners (new boots) (will go hydraulic later, couldn't afford now.)
Went with new S&S 551 Easy Start cams (for added compressino and stock starter)
2015 stock bore (103ci) cylinders and heads from a dealer take-off of a 2015 Electra Glide (literally no miles on them other than whatever start-up test the MoCo does)
New Wiseco 9.6:1 high compression pistons
All new gaskets with .030 cometic head gasket
New stock stator (mine was pretty caked up, so went ahead and replaced)
All new gas and oil lines
Waiting on new hoses to get here and we'll see if she starts up! If she does, I'll have effectively turned a trashed 88ci motor into a mostly new 103ci! And still have my cylinders, heads, crank case, and SE 203 cams to sell to make back some money! Overall, project cost me about $1500. WAY better than the $3200 quote to fix what I had, and $5200 quote to have S&S build out the motor.
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Cruiser
Joined: Jul 2012
Posts: 146
Likes: 9
From: 'Merica
To anyone following this thread or that might see it in the future, I've solved the problem and did a complete overhaul with the motor. I posted a pretty detailed write-up on the following thread, and have/will post pictures of the whole process. You can check it out here!
https://www.hdforums.com/forum/touri...ad-king-3.html
https://www.hdforums.com/forum/touri...ad-king-3.html
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