Decisions Decisions
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6th Gear
Joined: Mar 2020
Posts: 13
Likes: 2
From: Hawaii
Decisions Decisions
I have a 2003 EGS (Police) that I bought a little over a year ago. I've been staring at it for months now and making small changes/upgrades. I took it for a long ride yesterday and can hear what sounds like some valve train noise in the top end. Doesn't sound too serious. Nothing super crazy, just a little noisier than usual. It has a couple of leaks here or there. Nothing too ridiculous. I know very little about the bike as far as what motor work has been done to it. The VINs match so its the original bottom end, at least, but I know nothing about cams or top end work that may have been done. This is the first Harley I've ever done any real work on so, I don't know a ton about Harley motors, but I am a motor guy (hot rods and crawlers). I does have an old PCIII on it.
My questions are....
1. Is it time for a rebuild? (65,000 miles on it, but it may have been rebuilt already)
2. Or, does it just need some rocker adjustment?
3. This motor came with both FI and carb... can I switch it over to carb and get that old school sound without risking too little oil flow?
4. If it is time for a rebuild, I think I'd like to make it a beast. Cams, new exhaust, new fuel tuner, etc. What are your recommendations? I generally ride this one alone, although, the wife will join me on occasion. She prefers the EGC. I like to cruise it around 55-65, but I want it to move out when I twist the bars and I want it to sound like it will eat your first born.
5. What should I expect to pay for this kind of work? (Would it be a better idea to buy another motor with this work already done and do the swap myself?)
What are your thoughts?
My questions are....
1. Is it time for a rebuild? (65,000 miles on it, but it may have been rebuilt already)
2. Or, does it just need some rocker adjustment?
3. This motor came with both FI and carb... can I switch it over to carb and get that old school sound without risking too little oil flow?
4. If it is time for a rebuild, I think I'd like to make it a beast. Cams, new exhaust, new fuel tuner, etc. What are your recommendations? I generally ride this one alone, although, the wife will join me on occasion. She prefers the EGC. I like to cruise it around 55-65, but I want it to move out when I twist the bars and I want it to sound like it will eat your first born.
5. What should I expect to pay for this kind of work? (Would it be a better idea to buy another motor with this work already done and do the swap myself?)
What are your thoughts?
Banned
Joined: Dec 2017
Posts: 4,506
Likes: 2,361
Plenty of options and it all depends on your budget, I just put a bunch of money into my bike with no regrets, I bought it new and wanted to keep the original engine, sometimes I wish I would’ve just went with a new S&S engine, it would not have cost that much more. I have no advice except spend the money once and do it right. Nice looking bike too.
Advanced
Joined: May 2007
Posts: 79
Likes: 17
From: N.E. Fl.
Air cooled V twins are inherently noisy. 03 efi is the first year Delfi, a good system, as far as the old potato-potato- potato idle, you will have to ditch efi / electronic ignition etc... what you will gain is a less reliable bike that won't last very long before it needs a new lowerend. Your call
Tourer
Joined: Jan 2012
Posts: 419
Likes: 60
From: Central IL
That motor has hydraulic lifters so there are no rocker adjustments that can be made-unless motor work has already been done and an adjustable pushrod has come loose. Those top ends are noisy even when everything is right.
I would first recommend that you pull off the cam cover and check the cam chain tensioner shoes. They are a well known weak point. And if it has an aftermarket cam plate then you know work has been done on it.
For a total rebuild, Fuelmoto has a 98" kit that I was looking at when I had my twin cam. Very tempting.
I would first recommend that you pull off the cam cover and check the cam chain tensioner shoes. They are a well known weak point. And if it has an aftermarket cam plate then you know work has been done on it.
For a total rebuild, Fuelmoto has a 98" kit that I was looking at when I had my twin cam. Very tempting.
Seasoned HDF Member
Joined: Sep 2008
Posts: 14,144
Likes: 11,219
From: San Diego, CA
Do you know if the engine is OEM, or if their have been mods/upgrades done to it...???
Do you have the tools to do a leak-down test to check how tight the engine is at 65K miles... That could give a hint to any issues, or potential issues...
As mentioned... on that year twin cam bike (up to 2007) the spring cam tensioners are a weak spot... At 65,000 miles, if they haven't been changed, you are on borrowed time.....
Open the cam chest and check the tensioners.... It should also be a clue if any work has been done... If everything is OEM...
1) Replace the cam tensioners (many options from $ to $$$$),, search this forum, you will have a bunch of reading for cam tensioner replacements
2) While in the cam chest, change the inner cam bearings from the INA Brand caged bearings to the Koyo-Torrington captive needle bearings..
3) While you have the better HD lifters.... they have 65K miles on them.... replace them with a good aftermarket lifter (I use Johnson-Hylift from WFO Larry at Larry's motor machine online)
You might also remove the rocker box covers and inspect the rocker arms... check the tolerances, maybe add Rockouts (search there is plenty of info), and upgrade to the better, stamped style breather assemblies....
Many of these things MAY have been addressed on that bike due to it's mileage... if not, they are overdue...
Do you have the tools to do a leak-down test to check how tight the engine is at 65K miles... That could give a hint to any issues, or potential issues...
As mentioned... on that year twin cam bike (up to 2007) the spring cam tensioners are a weak spot... At 65,000 miles, if they haven't been changed, you are on borrowed time.....
Open the cam chest and check the tensioners.... It should also be a clue if any work has been done... If everything is OEM...
1) Replace the cam tensioners (many options from $ to $$$$),, search this forum, you will have a bunch of reading for cam tensioner replacements
2) While in the cam chest, change the inner cam bearings from the INA Brand caged bearings to the Koyo-Torrington captive needle bearings..
3) While you have the better HD lifters.... they have 65K miles on them.... replace them with a good aftermarket lifter (I use Johnson-Hylift from WFO Larry at Larry's motor machine online)
You might also remove the rocker box covers and inspect the rocker arms... check the tolerances, maybe add Rockouts (search there is plenty of info), and upgrade to the better, stamped style breather assemblies....
Many of these things MAY have been addressed on that bike due to it's mileage... if not, they are overdue...
Sponsor
Joined: Jul 2015
Posts: 8,538
Likes: 1,646
From: SF Bay area
Have a look around my website, might be just what you need... thousands of happy Rockout customers 
Also try changing oil. When it comes to noise, there is nothing better than Spectro 25-60 NON-SYNTHETIC.
Good luck in the hunt!
John @ Rockout
__________________________________________________ ____
For ROCKOUT information & purchasing please click HERE For all Twin Cams and Evo Big Twins & Sportsters
Also try changing oil. When it comes to noise, there is nothing better than Spectro 25-60 NON-SYNTHETIC.
Good luck in the hunt!
John @ Rockout
__________________________________________________ ____
For ROCKOUT information & purchasing please click HERE For all Twin Cams and Evo Big Twins & Sportsters
__________________
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Ordering & info http://www.rockout.biz On ebay! ... CLICK HERE
Also on amazon.com...
Imitated, never equaled... ROCKOUTS!
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