Ok, so I was kinda right, haha! Looking at the dyno run it doesn`t build as fast as the 06 and at 4500 it stops pulling hp and drops as fast as it raised at the beginning of the run. Will check it tomorrow, thanks for the info.

VBP

 

If I recall, right around 06-07 is where they went to the 6 speeds. That changed the primary ratio, which would skew the dyno results. ??

 

That wouldn't account for a 20% variation.


VegasBigPapa,
Sometimes even the proper o-ring doesn't fit tight and completely seal the connection between the oil pump "neck" and the scavenge port. After my last sumping adventure, I started using the o-ring from the oil drain plug for a softail behind the scavenge port o-ring to force the scavenge port o-ring to form a tight seal. The drain plug o-ring is small OD and has to be stretched over the oil pump neck. Probably not necessary but I don't worry about sumping after putting one together any more.

 

Just a question could you tell the difference in riding both bikes or just from the dyno sheet you new something was wrong?

 

Well, no sumping. Pulled the plug and got maybe an oz or two so, back to the drawing board. We can tell a difference in the bike riding them, the 04 needs a fair amount of throttle to get off the line and just doesn't feel as fast.

 

Did you take the bike for a ride before pulling the plug?

 

It hasn't been ridden for a couple days since I have had to torn apart. Will the oil drain out of the crankcase on its own? Less oil drained from the plug than what was in the cam box when I pulled the cams.

VBP

 

Desn't sound like sumping is the problem.

I went back and read the OP and noted that cam timing was checked. Was that a visual check of the timing mark alignment on the rear cam and pinion (outer) gears? Did you pull the cam plate and check the alignment of the inner cam gears as well?

 

I pulled the cams and checked the marks inside as well. The odd thing is, we compared them to a set of S&S cams and gears that my dyno guy had and my cams didn`t have the witness marks on what would be the outside (in the cam plate) and the gears were a bit different. They were lazer etched with S&S and the serial number but the timing marks were etched on mine as well. The set my dyno guy had, the marks were cast into the gear like a small dimple. He has been in business for 15 years and he has never seen a set of gears that were lazer etched and didn`t have the dimple. He said Andrews has made S&S gears forever but S&S just started making some of there own. However after all that, the marks that were there did line up. Talked to a Harley cert. tech and he doesn`t think it is a fuel or spark issue as the computer would throw a code and my dyno guy is skeptical that the Powercomander is bad since it has been on the dyno 4 times and hasn`t given any trouble. Dunno....

VBP

 

Strange indeed. I am very curious now and consider this a teaching moment. You guys have checked everything I can think of but I am not a pro, so could be missing something. I know S&S has a rep for quality but if they have recently started making inner cam gears and all other options have been run to ground, I would be tempted to get a set of Andrews gears (like the ones your dyno guy has) and compare the cam positions between the two sets of gears.

It sounds very much like cam timing is retarded a tooth. I don't know what one tooth off on the inner gears relates to degress of cam rotation; would have to do the math. Put a degree wheel on the pinion and check actual cam timing events against spec.

Please keep posting, I am very curious on what is causing the variance in output.