Thanks for the replies. Those are not the answers I wanted to hear! I thought I could just bolt on the new cylinders and pistons and have 96 inches of new engine. Oh well, I guess I'll have to have the new cylinders bored to match my existing pistons which are in 95 inch cylinders from the big bore kit in 2002. There just must be alot of wear on my cylinders after 68k miles cause of the piston slap. It's quite loud. I will also have my heads rebuilt and I would like to have them ported if money allows. We'll see. I'll keep you all apprised of my situation as time goes on. I don't plan on tearing into the engine till July when I'll be retired and have all the time in the world to work on this. Then it will be 110 degrees every day and too hot to ride anyway.
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Evo bikes were 4.25 stroke, TC were 4." stroke, and newer 07 TC and UP were 4.375"
I'd do this;
Bore your SEASONED cylinders out to 95" and put in New HD SE 10/1 pistons and have the pistons Bought and send them WITH the cylinders to the boring shop to make sure they
Fit Them and bore/hone properly... GENERIC boring the cylinders is Not the way to go.....
Measuring to the Pistons to the cylinders is a MUST........so there is NO piston slap as You all ready had That problem and don't need that again.....
If you want a good Head Man, I have used Bob Gage over in Yuma now .... Good Head Man Flowed and ported/manly valves and springs/set up my heads for G SS570's...... did all my heads while he was UP in Snohomish Wa..
I'd call Bob Gage and ask him if he does the boring there also??
Probably save as a package deal???
If so, let him do the whole job... You gotta Know IF you want to go with Lower torque cams OR ?????
signed....BUBBIE