I think I found my problem.

[Upallnight]

Been having problem with the engine in my 1995 Sportster. Rebuilt the carbs still no change, brought another set of carbs and rebuilt them and still the same. So last Thursday my brother and I removed the engine from the boat.

When I went to open the front cover plate for the magneto, about a half pint of oil came out. I guess I need new crankshaft seals. Went to remove the flywheel and when I used the puller to pull the flywheel off I heard a metallic plink on the metal pan that I placed the engine on. Look and saw half of the key for the flywheel. I guess the key must have sheared off at some point, and I'm hoping that is the problem with no power from the engine.

None of the cylinders look scored. The top of the pistons looked fine. I might replace the rings since I have it torn down this far. The pistons had a mark on the top .001. So does this mean the piston are oversize? What size rings should I buy?

Should I just buy a rebuilt engine?

 

[Waterluvr]

At the very least you need to determine if your cylinder bores are still concentric after all this time, odds are they aren't and just a honing and new piston rings won't get you far for long. Look for any shiny spots on the cylinder walls and take some careful measurements as the only cure for out of round cylinders is boring with the proper finish hone and oversize pistons.