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Discussion Starter #1
Been waiting for Laconia Bike Week to start and just after getting up there this past Sunday the engine developed a NEW noise, figures. Loud rapping from front cylinder when cold. To loud to continue using it so I took it on in to Harley with 4days left on the warranty. New cylinder kit front and back being installed all under warranty. Claim is carbon buildup and front cylinder out of spec. I have my doubts about it being the problem. Anybody run into this before?
 

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Wow, I'd like to know what this is all about. What year bike ya got & how many miles? Stage 1-2-3 or 4? I got about 3 & a half months left on my warranty.
 

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Yowza! :eek: Never heard of this. Good you got it worked on under warranty. Hope it results in future good times. Makes you leery though? :confused:
 

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Discussion Starter #4 (Edited)
2011 RGU ,,22,000 miles. Stock. PM me for further details.

Warranty on the work is 90 days parts only. Contacted Harley to find out price of extended warranty. $1334 for 3 years, same coverage as factory.
 

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I'd have them check the crank runout while they are at it. My crank went out with the same mileage but I had made motor changes. If you still have the same noise when they put it back together it's probably the crank. Installing a new cylinder won't mask piston slap very long if at all if that is what you were hearing. Keep us posted.
 

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I'd make sure that they at least check the front rod bearing and the crank when they tear it down.
'Got the 5yr ESP (around $2k) 'Glad I did, paid for itself in the first 6 months
 

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Discussion Starter #7
I'd make sure that they at least check the front rod bearing and the crank when they tear it down.
'Got the 5yr ESP (around $2k) 'Glad I did, paid for itself in the first 6 months
I will be purchasing the ESP when I pick the bike up. I figure this would have run around 2k for parts and labor so far. I have little faith in their resolution. It would be foolish to let the warranty expire anticipating further issues.
 

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Discussion Starter #8
Update:Engine Rapping Noise

Got my bike back from Harley today.

New Pistons,rings,plugs,gaskets etc. All covered under warranty, cost 0.00.
It is now running better than it has from day one. Even the "Normal" noise has been minimized.

I'm told that it was caused by excess heat in front cylinder. The result was the front cylinder to go out of spec resulting in Piston slap. Also that the excess carbon buildup on the heads made the heat worse. I'm told the carbon buildup was caused by me riding like an old man in the lower rpm range and NH piss poor gas quality. So looks like I will be riding above the 2500rpm range in the future. Another interesting note is no break in period.

I'm a happy camper with a 3yr extended warranty, I had to do it.
 

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FWIW the TC engine is fine at 3k rpm and a little more, if you've been running under 2.5k you've been missing the best part of the motor. Maybe lugging it has contributed to the problems? Anyway glad to see you have it fixed, and the price seems right also.

Sent from Motorcycle.com Free App
 

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Discussion Starter #10
Extended Service Plan

Was going to pass on the ESP when my warranty ran out. I waited for the cards to come in the mail warning me about the warranty running out. So I called the Harley number on the card and they quoted me;
2 yr = $1109
3 yr = $1334 - 10% down, 12 monthly payments to pay it off interest free
4 yr = $1604
5 yr = $1900

While I was picking up my bike after they finished the work I sat down with the finance guys and asked what the dealership charges for the extended warranty.

2 yr = $1600, for every year after the 2yrs $749. So for a 3 yr through the dealership it would be $2349.

That's a $1000 bucks I saved by waiting for the card to arrive.

The dealer said the prices I received from the Harley number I called were what he has as Harley Employee prices. Offered to match but with no financing.
 

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30,000 miles on motor. They said front cylinder was leaking down when they tested it. Told me to bring it back in the winter and they would warranty both pistons.
 

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Discussion Starter #13
I really believe the issue was there from day one just not that noticeable. I've spent the last 2 yrs listening to everyone's 103 and none had this one particular sound. About a month or so back I installed an 09 headpipe and thundermax autotune to help eliminate heat. In 60^ weather my heat management would kick in. Helped significantly but I think it was already to late.

Today I will be putting the Thundermax and 09 catless headpipe back on. Hopefully this will prevent future issues with fuel management and excess heat.

Any advise is welcome please.I don't want to go through this again.
 

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Just a heads up but you can go to any HD dealer about a month before your 2 year factory warranty runs out and negotiate a deal on the extended warranty. I negotiated a deal on a 5 year extended warranty for $1200 and it wasn't from the dealer I bought my bike from. All extended warranties from HD are negotiable! :wink:
 

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Got my bike back from Harley today.

New Pistons,rings,plugs,gaskets etc. All covered under warranty, cost 0.00.
It is now running better than it has from day one. Even the "Normal" noise has been minimized.

I'm told that it was caused by excess heat in front cylinder. The result was the front cylinder to go out of spec resulting in Piston slap. Also that the excess carbon buildup on the heads made the heat worse. I'm told the carbon buildup was caused by me riding like an old man in the lower rpm range and NH piss poor gas quality. So looks like I will be riding above the 2500rpm range in the future. Another interesting note is no break in period.

I'm a happy camper with a 3yr extended warranty, I had to do it.
Intersting, I remember when I bought my 110 / CVO, my mechanic told me to do myself a favor and run it around 3K all the time - that it would make it HAPPY :grin: - I've always run close to that range anyway and still do with my 17, I also do everything I can to drop the heat, V&H duals, tuners, this time I'm using the HD fan, I always shut down in heavy traffic (bike week etc) - I also try to burn 93 from Mobil whenever possible - I do shut down the front cylinder when I have to, the 17 doesn't seem to like that with the cam i'm running - any way there is a lot of merit to what they told you - that 2.5K to 3K range is worth running...
 

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I'd have them check the crank runout while they are at it. My crank went out with the same mileage but I had made motor changes. If you still have the same noise when they put it back together it's probably the crank. Installing a new cylinder won't mask piston slap very long if at all if that is what you were hearing. Keep us posted.
My engine blew because of crank runout at the same mileage. When we opened it up, the crank shaft was literally blue from overheat. My front piston was in many pieces, so make sure they check runout. I think there was a problem with the 2011 103 engines.
 

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Got my bike back from Harley today.

New Pistons,rings,plugs,gaskets etc. All covered under warranty, cost 0.00.
It is now running better than it has from day one. Even the "Normal" noise has been minimized.

I'm told that it was caused by excess heat in front cylinder. The result was the front cylinder to go out of spec resulting in Piston slap. Also that the excess carbon buildup on the heads made the heat worse. I'm told the carbon buildup was caused by me riding like an old man in the lower rpm range and NH piss poor gas quality. So looks like I will be riding above the 2500rpm range in the future. Another interesting note is no break in period.

I'm a happy camper with a 3yr extended warranty, I had to do it.
If you want to stop the carbon build up, you'll need to route the breather lines away from the intake.
 

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Do you have any links on that, or elaborate info? Just curious.


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Links on what? How to do it, or on the oil building up on the pistons?

The how to, yes. I can point you to a how to do it, and a search will find several here on this site.

The building up is just common sense. If they blow enough oil to wet the oil filters down and drip on peoples feet, then how much oil did they manage to suck down. You can bet it was a lot more than leaked out after it was shut down. You find a teaspoon full on the side of the scooter, and it's down half a quart, guess where most of the missing oil went. Fact is, most Harley's burn 90-99% of the oil that carries over. Riders only notice it when it drips out of the air cleaner box.

Some folks like to say the build up is from shlt in the gas. Hey everything burns pretty much the same gas these days, the EPA saw to that. And while it's not at all rare for a Harley to need the carbon scrubbed off the pistons well before 20K miles, other contemporary engines tend to look pristine at comparable mileages. If there was all of this crap in the gas, then no one would be able to get 100,000+ miles out of a set of spark plugs. But almost every manufacturer does. Except Harley, who can barley get 5000 miles out of a set.
 
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