Well things just got interesting. I spoke with my local HD shop this afternoon about my bike and also spoke directly with HD Corporate Tech Support.
The positives first. HD is standing behind everything and my local dealer has been great to work with as they have been for many years. My 2017 CVO Limited 117 Stage 4 engine was disassembled for inspection. Cylinder x-hatching looked good. The oil pump looked good. The oil pump O-rings looked good but now starts the more difficult news.
The piston oil jet screws were inspected for torque spec per the guidance from HD Tech support. The piston jet screws were definitely loose which I assume means more oil from both the nozzle tip AND around the jet gasket entered the crankcase at a higher rate than the oil pump is designed to remove from the crankcase. Which explains the excess oil measured in my crankcase. As the oil builds up, the crank is sloshing through more and more oil and there’s less and less oil for the oil pump to lift from the pan to the top of the engine.
Unfortunately, at this point the dealer tech described to HD Tech support that not only were the oil jet screws loose, but the crank and rods were “stiffer” to rotate than they should be. I had experienced high engine temps numerous times since the engine was upgraded to a stage 4 in Feb of this year although the oil jet screw issue appears to be unrelated to the Stage 4 kit. While there were no obvious signs of metal in the oil, HD tech support decided on-the-spot to replace the entire engine AND oil pan in the event there’s any bearing material starting to flow in the engine from the overheating. But that raises the next issue.
I have a Stage 4 kit on my current engine. Due to the crank and rod bearing concerns, they want to replace the entire Stage 4 kit once it comes off backorder. Harley agreed to pay all parts and labor costs for reinstalling the new Stage 4 kit. Until then, I’ll be back to riding a completely new stock CVO 114 engine.
Another issue is that I no longer have my stock throttlebody for the 114, since I upgraded to the Stage 4 Throttlebody. HD agreed to ensure the dealer has a stock 114 TB to install on the new long block/oil pan that is scheduled for delivery to my dealer next Wed.
I also spoke directly with HD Corporate Tech support. They were excellent to deal with and followed-up with my dealer regarding the stock TB and Stage 4 questions. They also informed me that the Stage 4 kits are scheduled to come off backorder mid-July. Dealer has already scheduled me for the Stage 4 upgrade on the new engine, fully covered by HD.
Good to see Harley responding promptly and with full accountability to make the bike as good as new. It’ll be just in time for a 7500mile trip to Sturgis at the end of July. Very interesting experience but I have no regrets on purchasing this new bike, even after this engine replacement. It really is a terrific machine. Hopefully these “M8 launch pains” are now in the rearview mirror!