Differences between pre and post 2006 engines? And cranks?

I bought another 2007 Uly with a bad motor (based on the description I'm assuming a bottom end issue). It's super clean so I'd like to bring it back to life if possible. Which means I'll likely be searching for a replacement engine.

I've found a couple of 2005 bikes that could be suitable donors but I'm unsure of the differences between the 2005 and 2006-2007 motors (aside form the bronze oil pump gear). From what I've read they have different transmission gears and clutches as well. Is this correct? I'm curious what I should expect by putting a pre-06 engine in the bike.

Along those lines, what is involved in replacing the crank in one of these engines? This will likely be the 2nd '07 Uly I have which has a crank/rod issue. Both of them are clean bikes other than the bad engines. I'd like to bring them back to life but I've been quoted $1000 to rebuild / refurbish a bad crank, which is a non-starter for me. I've considered buying a used crank from eBay, but I feel like that's playing Russian Roulette as well.

I've torn down / rebuild Japanese bike engines in the past, but never a roller bearing / Harley engine. I'm curious what obstacles they may present that I'm not aware of.

The engine/primary/transmission differences from 2003-2007 model years inclusive are fairly minimal and subtle. Things such as different pump drive gear material starting a few months into 2006 model year run....switch from DDFI to DDFI2...slightly different pump alignment for 2007....subtle difference in clutch pack component part numbers following 2004.

Every XB model I've ever personally seen or documented with a known crankshaft failure was a 2007 MODEL YEAR and cause was an oiling starvation problem. NO idea why that specific year.

I'm a huge fan of rebuilding what you already have. Tons of info and vids on the case-splitting process. $1000 to rebuild a 2007 crank is a tad high.

Do you have any recommendations regarding a shop to refurb this crank, and / or what you would consider to be a reasonable charge for the refurb? So far I've largely been referred to DarkHorse. It seems they're a bit more high-performance oriented (and priced) than what I'm looking for. I'd be content with OEM power / performance, as long as I get durability / longevity.

I too would like to rebuild what I have but only if it's cost effective. I've considered buying a used crank off eBay but I'm concerned that's too much of a crapshoot given my limited knowledge. Not only the crank itself but also installation/rebuild on the Harley platform. I've been watching videos about setting sideplay (term?) with the crank bearings, etc. That's new stuff to me.

For the current '07 Uly I'm swapping in an engine from an '06 Lightning Long. It's somewhat disappointing as the LL is a running, riding bike. It's just ugly due to being a theft recovery (and the ever present "spray paint everything black"). But the bones are good. I hate to have to kill a "good" bike to save the Uly, but without cost effective options to rebuild the '07 engine I don't know that I have another viable route.

The other '07 Uly I'm picking up on Tuesday. I've already started looking for replacement engines for it, hence this post.

It does look like I might have a spare '09 engine. I'm waiting to hear back from the machine shop. If that's the case I may look for an 08/09 Uly wiring harness and transplant the '09 engine into the '07 bike. I've already got a spare DDIF3 ECM.

Barrett said:

Every XB model I've ever personally seen or documented with a known crankshaft failure was a 2007 MODEL YEAR and cause was an oiling starvation problem. NO idea why that specific year.

Click to expand...

This is a bit concerning regarding rebuilding the '07 as well. I've understood the '07 failures to be a heat treating / alloy / "in some way metallurgy related to the crank" failures. Linked specifically to the crank. Being an oil related failure could move the failure away from the crank as a component and to other components of the engine. The concern being possible destruction of a rebuilt crank due to the same oil starvation issue caused by other "bad" components I'm not aware of.

I am NOT an XB-XL-XR crankshaft expert in any regard but every XB and XR crankshaft I've seen first-hand or friends/customers with failed crankshafts via the dreaded "rod knock" of a failed crank....in every instance was the result of either a completely worn out pump drive gear from owner abuse or oil starvation at high RPM's from being ridden extremely hard an/or abused.

Used engines or used crankshafts always have been and always will be a crap-shoot. Consider rebuilding what you have and seek out a local Sportster engine expert familiar with the process of disassembly...reassembly...measuring and fitting correct crankshaft run-out and side-play.

The below are experts in this crankshaft arena. All perform brilliant work at reasonable prices for a stock crank OEM style rebuild. Google each and all.

Hammer Performance
Millenium Technologies
Crankworks.Com
Motorcycle Machine Shop Services. com
JET Crankshaft Services

That's just what I needed. Thanks!

Again, forgive my ignorance. If the 07 crank issues were a heat treatment / metallurgy issue, are these cranks forever doomed to failure? Or since they're pressed together (at the crank pin), does this mean a new / properly treated pin can be used and the crank is now GTG?

Looking up some of the folks you listed above, and their charges (as I understand them) make me think rebuilding these '07 motors is a possibility after all.