Okay guys. I could use some helpfull thoughts and opinions with the occasional pun or joke.
I currently have a 2009 ElectraGlide with 96 inch. 35k miles. I really need to keep this bike reliable and I treat it that way. Wife and I do a lot of long distance travels on it with confidence and it has to stay that way.
So I take it in for the 35k service and notice it appears to have a Base Gasket leak. Still under extended warranty so the expense of the repairs is just my deductible. Other leaks found at Stator plug and Clutch cable. No big deal and not really concerned as this stuff happens.
My dilemma is; now is the time to do a mild 103 upgrade and maintain reliability at the same time. Most parts and labor will be covered thru warranty other than pistons, rings, Jugs and clutch spring and probable compression releases.
My buddy has 2 sets of 103 jugs and pistons (used) which he took off his 2008. Pistons r wiseco 10.5:1 My tech is gonna have to Mic the jugs and see if they are usable.
1 set is Diamond Cut the other is not.
My question is; should I go thru this drama of having the Tech evaluate the freebies or just pull the trigger and buy the complete 103 kit??
I have no intention of a drastic upgrade but may add mellow cams for low end torque.

 

I just was reading somewhere else Don that Headquarters offers a new 107 kit for under $900 and that would be the route I would go if I was you. Looks like a real reliable powerhouse. How much were you looking at paying for the 103 kit?

 

The kit is listed at $950.00 with 255 cams. Some of those parts would be credited back to me as warranty picks up all gaskets fluids and labor. also ncludes a stage 1 air cleaner kit which I already have. That credit would pay for the Compression releases. Or I could get the kit without cams at $700.00.
I am not interested in replacing heads or throttlebody.
I am thinking if I use the 10.5:1 compression pistons my buddy gave me I would most likely have to replace heads. Someone correct me if I am wrong. Therefore I would probably need to add new pistons to the equasion even if the Jugs are usable

 

There are no base gaskets in your engine.

 

When my brand new '08 Road Glide was found to have a porous crankcase, I paid for the HD 103" Big Bore kit since the labor was free. It made a nice improvement in performance. The kit did not include compression releases, and my dealer told me that they were not necessary. In hindsight, I think they were, as my starter started grinding after about 10k miles.

But overall, the kit was well worth the money, especially since the labor was already covered by warranty. I'm not sure about the mixing of aftermarket parts like you are considering, but the difference in the 96inch motor vs 103inch motor was quite noticeable.

 

I just had work done on my 96" 2008 Wide Glide. At 120K the compression was a little low and the leak down test didn't pass either.

Extended warranty covered new jugs and pistons, plus reconditioning the heads. I wanted the same as you, I put a lot of miles on my bike and wanted to keep it dependable.

I upgraded to stock 103" jugs and pistons, reground valve seats with new guides and heavier springs (no compression releases as the compression ratio barely increased). Warranty also replaced the worn SE compensator, leaking clutch cable, leaking stator, oil pump, cam plate and bearing.

I added the 259E cams and the dyno tune produced 100 hp and 105 tq.

You would probably want a different cam for more low end power with the bagger.

 

Jugs are Harley 103 jugs. Will not use the pistons I got with them. So the only savings would be the cost of Jugs. They will at least have to be micd and Honed so not sure where I will save on cost over just buying kit. I would like to use the Diamond cut jugs. But not sure how that would look when my heads are not diamond cut.

 

I think you will be happy with the 103. I went with the stage 3 kit and Its a decent powerhouse for what I have into it. If something goes wrong I will definetly go a different route as far a motor build. A stage 2 build which you are refering to will be cheaper for sure. If you are looking to save money just put a set of cams in there and a get it properly tuned or get an auto tuner. I would not even consider doing an engine build without doing cams with it. A 96" with cams would be suffice and fairly inexpensive. A 103 with stock cams would be pointless in my opinion.

 

Although pointless may be a strong word, there would not be enough gain vs. money in my opinion to only upgrade the jugs/pistons without a cam.

A cammed '96 will outrun a stock 103" all day long.

I put the 103 Stage II on over the winter and am loving it right now. The dealer said that ACR's were not needed, That may be the case but I sure with I had them. I'm sure my starter will go sooner than it would have.

mikebaby

 

I did the 96" to SE 103" Pro Upgrade Kit, used the 255E Cams and also had them install MCR's. I am more than satisfied with the performance gains relative to torque. I would suggest at 35K to stick with SE upgrade kits and see if your dealer will warranty them.