So, in June I bought an 04' King Custom. 46k miles with a 95 kit, hydraulic cam, stage 2 kit, free flow exhaust, polished and bored. It now has 48k on it. On our way to Bob's Biker Blast on Saturday night, we were doing about 70mph in 5th gear, heard what sounded like a lifter ticking but there was a crotch rocket passing me so didn't think anything about it. As the other bike made distance, the noise got louder and became a distinct knocking and then banging withing a mile of traveling. I found the next gore point on the freeway, sucked in the clutch and she died!!!! Tried to restart but to no avail. During the attempt, heard loud knocking followed by what sounded like and exhaust gasket missing, and white smoke coming from the rear jug, and oil running out of the air cleaner. Never found any loose connections, cracks in any cases, or anything externally out of place. I bought the 3yr Extended Service Plan when I got the bike, so the dealer plucked it out of my garage this afternoon and said they will probably have some answers for me by Thursday. So, what is the general consensus? What went wrong and if I need a new motor, what are the chances of the warranty covering the 95 kit and hydraulic cam since THAT is what I bought 3 months ago? Also, what is the typical turn around for something like this. I won't say where I bought the bike, but it was in the greater Phoenix area, East Valley. Thanks for your input.

 

I'm not sure what happened, but I'm pretty sure it's bad. Your bike should be repaired to the state it was when you bought it. Good luck...

 

Welcome to HDF from the UK. I won't try to diagnose what has happened, but there is a major internal failure that will involve a rebuild, probably from crankshaft up. The dealer will remove your engine and dismantle it, so he can let you know what exactly has happened and needs to be done to put you back on the road.

It is likely the engine can be repaired, although the costs of doing so will probably be balanced against replacing it. The MoCo has a remanufacturing programme, which you can see details of by going to their website. Select 'Owners' tab, then 'Engines'.

If your dealer goes down that route your 'new' engine will come with the hydraulic tensioner kit installed, however will be bone stock in all other regards. It can also be upgraded to 95". You don't actually get back your knackered engine, the factory sends a fresh one off the shelf, but with your VIN, so turnaround is quite quick.

 

That is a good question.It may depend on what the service writer tells the ESP person.

So you bought the from the dealer with the engine work already done?
Did they say the ESP will cover the upgrades?

 

Have the cam tensioners ever been replaced or upgraded?

 

mine did very similar thing..... it dropped a valve and trashed the piston,head ,cylinder and crank... an indy shop did mine(total cost was around 3500. bucks

 

If you bought the bike with 95 kit already installed and you bought the Svc plan it shouldn't make a difference. When I bought my tc96 I asked the dealer if my ESP would cover problems after a 103 upgrade, he said "if it's installed when you purchase the ESP, then no problems."

 

I am betting they were. I think that is what he meant by hydraulic cam in the original post. Just forgot to add the word "tensioners"