I'm getting ready to pull the cylinders on a 99 Sportster 1200S to replace a leaking base gasket, not to mention a broken exhaust port stud on one of the heads (with tip of an ez out conveniently broken off flush with the stud - yahoo). The engine has about 50K miles on and runs well with no noticable oil usage, but I'm thinking a set of rings might be in order just because I have it apart. My question is do I need to replace the pistons too if I have the cylinders honed for .005 over, or can I use the rings on the existing pistons (assuming they are in good shape)?

Who knows, maybe I'll get lucky and the cylinders will still be in spec, but just in case . . . . .

 

If you go .005 over you'll need new pistons & rings.

 

Yup, Larry's right. Match the rings to pistons and bore size. With 50k, might not be a bad idea to get the cyls measured for roudness and overall condition.