Upgrade high mileage Ultra
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2nd Gear
Joined: Sep 2011
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From: Minnesota
Upgrade high mileage Ultra
My 07 (96)now has a little over 80,000 miles. I'm ready to pull the cord and do an upgrade to the 103. I'm going to have my local HD do the work, have a lot of trust in them. I currently have SE255 cams and happy with them. I was considering SE204's but I don't think the dealer has done many of them and from reading the forum, the 204's can be a touchy tune. They will also do a mild port with larger valves to add more air. I have some quesions. I want to keep this bike forever - I'm 66 and put 15-20K miles on a year, so want reliability and longevity.
1. The dealer has recommended welding the crank. Since I want the bike to run a long time, should I have them rebuild/balance at the same time? The dealer will also check things like cluch and starter at the same time to determine if they need replaced.
2. I have about 45K on my cams. Should I get a new or slightly used set of SE 255's and replace now?
3. Anything else I should be looking at so that I have a good 100K miles of non issues ahead of me? (They replaced a transmission bearing last year)
Thanks!
1. The dealer has recommended welding the crank. Since I want the bike to run a long time, should I have them rebuild/balance at the same time? The dealer will also check things like cluch and starter at the same time to determine if they need replaced.
2. I have about 45K on my cams. Should I get a new or slightly used set of SE 255's and replace now?
3. Anything else I should be looking at so that I have a good 100K miles of non issues ahead of me? (They replaced a transmission bearing last year)
Thanks!
Extreme HDF Member
Joined: Sep 2010
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From: Phoenix '53, '88, '09 Big Twins
welding the crank drastically raises the costs, requiring tearing the motor completely down.
BUT if you are drastically raising the power output of the motor, this may be required.
i do not have the experience to speak to this.
( I keep my bikes at stage 1 for reliability).
2.) I would NEVER reuse "used" motor internals- the cost is in the labor, not the cams.
3.) maybe chassis services such as swingarm bearings ( best done when the belt is replaced, so maybe wait on that)
forks rebuilt
steering bearings ?
Mike
BUT if you are drastically raising the power output of the motor, this may be required.
i do not have the experience to speak to this.
( I keep my bikes at stage 1 for reliability).
2.) I would NEVER reuse "used" motor internals- the cost is in the labor, not the cams.
3.) maybe chassis services such as swingarm bearings ( best done when the belt is replaced, so maybe wait on that)
forks rebuilt
steering bearings ?
Mike
Seasoned HDF Member
Joined: Nov 2010
Posts: 17,548
Likes: 7,201
From: Oxford, Nc
Susceptible as the 07's were to crank issues, I'd weld it. Check the crank run out and if it's above .001" I get it trued prior to welding.
I replaced my cams at 81,000 and the hard chrome finish was just starting to show signs of wear.
I replaced my cams at 81,000 and the hard chrome finish was just starting to show signs of wear.
Last edited by Stiggy; Sep 9, 2012 at 02:07 PM.
Road Warrior
Joined: Mar 2009
Posts: 1,317
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From: Idaho
Hmmm... well as a guy with a 97K on my 2000 ultra I can tell you a welded crank does give some peace of mind.
I would look at the clutch make sure they upgrade with the SE upgrade.
I would also sit down with the dealer & look at the price of just putting a 103 motor in vs building a 103. Labor is going to be a pain.
I would look at the clutch make sure they upgrade with the SE upgrade.
I would also sit down with the dealer & look at the price of just putting a 103 motor in vs building a 103. Labor is going to be a pain.
Thread Starter
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2nd Gear
Joined: Sep 2011
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From: Minnesota
Thanks so far. Yes, I am going to do the complete kit rather than bore my old cylinders... not that much difference in cost and with the high mileage, may as well go all new.
Any thoughts on the SE204 vs staying with SE 255s? Same cost unless I can get a pair off a CVO. I think I like the SE 204 but from all the comments, it wants a lower compression and is sensitive to heat, which means it would always need high octane. I do a lot of touring and normally get high test, but there have been times I've had to put 89 in depending on where I'm at.
Any thoughts on the SE204 vs staying with SE 255s? Same cost unless I can get a pair off a CVO. I think I like the SE 204 but from all the comments, it wants a lower compression and is sensitive to heat, which means it would always need high octane. I do a lot of touring and normally get high test, but there have been times I've had to put 89 in depending on where I'm at.
Seasoned HDF Member
Joined: Nov 2010
Posts: 17,548
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From: Oxford, Nc
I would consider re-using your old cylinders because they are used, or 'seasoned' therefor better than new.
Like you, I run 20,000 miles a year and constantly "tour" in those rpm ranges. The 103 is the same as my older 95. Same cylinders and pistons. The difference is in your longer stroke, So I recommend the Andrews 26's. Low intake duration and the bike pulls from 2000 strong all the way past 5,000. I suspect like me you never get past 4,000 most of the time. I'm thrilled with my choice.
Because it's a Dealer job, they may insist on HD cams. 255 cam is similar to my 26's with an even lower intake duration. 254's are almost the same.
204 is more mid range. Think about where you ride most on the time.
Like you, I run 20,000 miles a year and constantly "tour" in those rpm ranges. The 103 is the same as my older 95. Same cylinders and pistons. The difference is in your longer stroke, So I recommend the Andrews 26's. Low intake duration and the bike pulls from 2000 strong all the way past 5,000. I suspect like me you never get past 4,000 most of the time. I'm thrilled with my choice.
Because it's a Dealer job, they may insist on HD cams. 255 cam is similar to my 26's with an even lower intake duration. 254's are almost the same.
204 is more mid range. Think about where you ride most on the time.
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Seasoned HDF Member
Joined: Jan 2011
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From: Michigan 15 Minutes East Of Hell
As "Stiggy" says ... I would consider re-using your old cylinders because they are used, or 'seasoned' therefor better than new. Absolutely nothing wrong with using the old cylinders ... they are/will be more stable ... and you'll save a couple of bucks ... just find a good machine shop and use torque plates ... Good Luck with your build Brother!
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Thread Starter
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2nd Gear
Joined: Sep 2011
Posts: 6
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From: Minnesota
Thanks on the suggestion to reuse my cylinders. I'll talk to HD and get an estimate. That way they could wait until they get the pistons in and measure for a better fit before boring the old cylinders.
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2nd Gear
Joined: Sep 2011
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From: Minnesota
Got the bike back a couple of weeks ago. Wow, does it ride nice. They dynoed right away and I got great results! I attribute this to the 204 cams, 103 upgrade, 1.725 rockers, the Kromeworks Power Tune header and of course my tuner. TQ curve kicks in strong about 2500 and is flat to 5000 rpms: 115 TQ and 101 HP.
So, in addition to the above changes, they replaced the drive belt and sprokets, compensator with the SE compensator, hydraulic lifters, diaphram spring with SE, manual CRs and some minor parts. When they sent the flywheels out to get balanced and welded, the flywheels were to far out of tolerance so they replaced with new (still within budget). Finally, when they had it apart, they found I had again blown the main transmission bearing (this went out last year and they replaced, so the new one only had 15K miles on it!).
So with the problems they found, I'm glad I didn't wait another 20K to do this work and besides, now I can enjoy a "new" bike.
So, in addition to the above changes, they replaced the drive belt and sprokets, compensator with the SE compensator, hydraulic lifters, diaphram spring with SE, manual CRs and some minor parts. When they sent the flywheels out to get balanced and welded, the flywheels were to far out of tolerance so they replaced with new (still within budget). Finally, when they had it apart, they found I had again blown the main transmission bearing (this went out last year and they replaced, so the new one only had 15K miles on it!).
So with the problems they found, I'm glad I didn't wait another 20K to do this work and besides, now I can enjoy a "new" bike.