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[JamesButler]

Hello,
Has anyone turned their stock 80" Evo into a 96" big bore stroker (3-5/8" bore and 4-5/8" stroker flywheel)? I've been thinking about doing this to my FXR3.  I've read and been told that this is a very strong and durable build, and that the post-1995 cases were made stronger and will not be compromised by the extra 1/8" bore. Anything more and you'd be sacrificing durability and be better off dropping in a bigger aftermarket motor.  Ofcourse the 96" setup would be used along with other mods, i.e., cam, carb, exhaust, ignition, headwork, pistons, valvetrain, inc. comp ratio, etc.  Any downsides or negatives to this setup or any particular things one should be should be aware of?

[SBB]

Hello,
Has anyone turned their stock 80" Evo into a 96" big bore stroker (3-5/8" bore and 4-5/8" stroker flywheel)? I've been thinking about doing this to my FXR3.  I've read and been told that this is a very strong and durable build, and that the post-1995 cases were made stronger and will not be compromised by the extra 1/8" bore. Anything more and you'd be sacrificing durability and be better off dropping in a bigger aftermarket motor.  Ofcourse the 96" setup would be used along with other mods, i.e., cam, carb, exhaust, ignition, headwork, pistons, valvetrain, inc. comp ratio, etc.  Any downsides or negatives to this setup or any particular things one should be should be aware of?

James

In 1986 I had a 1986 FXRC with a S&S 98" kit in it.
That was 3 5/8" X 4 3/4".
It was a fun and fast machine once I got it cranked.
1986 was before compression releases on street Harleys.
A 4 5/8" stroke on your bike will need those compression releases.
With the right combination of parts you will have a fast and fun machine.
Good luck!

SBB

[sadunbar]

James

In 1986 I had a 1986 FXRC with a S&S 98" kit in it.
That was 3 5/8" X 4 3/4".
It was a fun and fast machine once I got it cranked.
1986 was before compression releases on street Harleys.
A 4 5/8" stroke on your bike will need those compression releases.
With the right combination of parts you will have a fast and fun machine.
Good luck!

SBB

Back in 96 I built a 96" stroker EVO for a softail custom I built...  3 5/8 bore and 4 5/8 crank...  Chip is correct about compression releases, you'll want them for sure.  I lost a starter before I pulled the heads and installed releases.  I was warned at the time about piston/cylinder wear because of the short skirts.  But a friend now owns the bike and it still runs like a champ 40,000 miles later.  Dynoed at 100/100...  Mikuni carb, Headquarters cam, Headquarters cylinder head porting, Thunderheader...   

[91FXR]

I put the S & S 96 stroker in my 95 FXDL. After the cost of the kit, head work, ignition and labor I probably could have bought a complete engine and kept my 80. Haven't had any issues with the starter. I do have to run premium fuel and my MPG dropped to high 20's low 30's. Dont know if its me twisting the wrist or those bigger lungs in it now.
One thing for sure, you'll love the way it lopes at idle and runs when you twist it. Dennis 

[johnsachs]

I put the S & S 96 stroker in my 95 FXDL. After the cost of the kit, head work, ignition and labor I probably could have bought a complete engine and kept my 80. Haven't had any issues with the starter. I do have to run premium fuel and my MPG dropped to high 20's low 30's. Dont know if its me twisting the wrist or those bigger lungs in it now.
One thing for sure, you'll love the way it lopes at idle and runs when you twist it. Dennis 

100% correct,anddddddddd you don't have to deal with the weak cases.EVERY year Evo has the problem.
A 107" Ultima engine is probably the strongest,and most reliable deal out there.
John

[JamesButler]

John-
I do worry about the cases. I've read that Ultima has a strong product- maybe from you on a different site- .  My builder also has great things to say about them.  How much would it cost to drop in the 107 ci Ultima? What does that package include? Labor costs? etc.

[johnsachs]

JB,
Check with your builder on price.The motors can be bought without breaking the bank.Installation is like replacing a stock Evo motor.They fit all stock frames including Softails.
John

[JamesButler]

John-

I recently tracked down Denny Denish, the author of "The Big Twin High-Performance Guide" because I wanted to learn more about the evo builds, and his three volume series on increasing hp and tq. of the evolution motor is one of the best if not the best ever written on the subject.  Anyway, after telling him where I lived, in the western suburbs of Phila, PA, he told me to call a guy named Mike Magaro in Harrisburg, PA., who he said is one of the best in the business when it comes to evolution engine builds.  I called Mike who turns out to be a great guy.  With over 40 years  experience of drag racing racing his FXR, setting record times and working on evo motors, Mike has remained current. He too, had great things to say about The Ultima motors and even runs the Ultima 127 ci in his "street FXR".  Went out to see him at his shop about 90 miles away from me. His shop is immaculate!  Not only did he offer to lend me his copies of Denish's books after talking with me for about an hour, but he told me to come back after I read them, so we could decide how I wanted to proceed with my build. Currently, I'm deciding between the 96" big bore/stroker build or using one of the Ultima motors with over 100 ci.   

[johnsachs]

James,
I've known Mike for many years.I was the one who hooked him up with Ultima.
He's one of the best Harley no bar racers around.Runs with a Super D,and makes it work on the street.
If you don't mention my name,and call him "Mikey",he'll know where it came from.Another good friend,and also helps Mike out,is Jim Libonatti at Mega Flow.
John

[JamesButler]

John-
Small world Ha ha ha!  I met with Mike last week again to further discuss the new build.  When I talk to him next time, I'll tell him some guy I met was asking about "Mikey".    He has mentioned Jim from Mega Flow when we spoke. I believe Jim will be doing the heads for the build.  I am having a harder time now deciding on which build to go with.  Seems the more I learn, the more my mind changes.  Originally, I wanted to go with an 80" EVO hop up, then it was the 96" Big Bore/Stroker build because that seemed to be billed as "the best bang for the buck", and now it could be an Ultima 107 ci build.  Originally, my thought was to keep the FXR3 as stock looking as possible by using and modifying as many stock parts as possible, and to combine them with proven internal aftermarket parts -- to increase performance without sacrificing reliability, tractability, and durability. In other words, build a "sleeper".  But now if I go with the Ultima 107 build, it would seem to throw the whole stock philosophy out the window.  I don't race the bike, I don't redline it either, so i know I don't need huge horsepower, and I do want a build that responds well from the 2,000-5,500 rpm range. But for those monthly long trips, I would like the added h.p.  Ultimately, it comes down to trading dollars for torque.  

[HILLSIDECYCLE.COM]

Hello,
Has anyone turned their stock 80" Evo into a 96" big bore stroker (3-5/8" bore and 4-5/8" stroker flywheel)? I've been thinking about doing this to my FXR3.  I've read and been told that this is a very strong and durable build, and that the post-1995 cases were made stronger and will not be compromised by the extra 1/8" bore. Anything more and you'd be sacrificing durability and be better off dropping in a bigger aftermarket motor.  Ofcourse the 96" setup would be used along with other mods, i.e., cam, carb, exhaust, ignition, headwork, pistons, valvetrain, inc. comp ratio, etc.  Any downsides or negatives to this setup or any particular things one should be should be aware of?

96" Evo's are strong powerplants, and are very versitale as well.
Can be used in touring bikes with proper cam/compression, or with increased cylinder head mods/different cam/compression, can be scorchers as well.
With a OE CV carb, a Dyna 2000i, and either a Andrews EV-3, or a Wood 6, with even slip-on Cycle Shacks, or S/E mufflers, and a head that rolls off 140-145 cfm, you'll see just about 100 hp, and 110 plus ft/lbs set at 10.0 cr.
VERY strong touring combo, that rips the torque right off the bottom, and pulls hard to redline.
Fuel economy will be very good as well.
Scott

[Pajoe]

I may want to talk with Mike about working on my Ultima 113",
I thought the only trustworthy guys that worked on Ultima engines
were located in New York and Florida. Wow, Harrisburg is ideal for me.

I found the name on a shovelhead forum, is this the Mike Magaro
you are talking about?


MAGARO'S RACING ENGINES
R2912 PAXTON ST.
HARRISBURG, PA 17111
717-561-4255

I looked and the phone number matched:

Magaro's Cycle Service
2912 Paxton St
Harrisburg PA 17111
717-561-4255

Company Profile:

Magaro's Cycle Service is located in the county of Dauphin. It is associated with following industry(s): Sporting Goods And Bicycle Shops - Bicycle And Bicycle Parts, Repair Services - Bicycle Repair Shop.


Google maps "street view"  shows the shop across from McDonalds, near Advance Auto etc


http://maps.google.com/maps?hl=en&um=1&ie=UTF-8&q=2912+Paxton+St+Harrisburg+PA+17111&fb=1&gl=us&hnear=Highspire,+PA&cid=0,0,16997647502198695725&ei=2dplTKCDOIGC8gbOr6GjDQ&sa=X&oi=local_result&ct=image&resnum=1&ved=0CBMQnwIwAA



Thanks in advance


joe

[johnsachs]

That would be him .........Mikeeeee 
John

[JamesButler]

Yep-
That's him, address and phone.  He's usually in the shop by 11am and stays past 9pm.  Check out his shop. It's immaculate. You'll also see his '92 FXR with the 127 ci Ultima.  Mike's a great listener, so tell him your thoughts on the build and he'll tell you what works best.  good luck

[JamesButler]

Finally decided to go with the 80" evo hop-up build. One factor was  cost.  It would be more cost effective to go with an aftermarket engine such as Ultima El Bruto 107" or more if I wanted to go with more displacement.  Plus, the evo now has barely 5K miles on it and it seems wrong to not get more out of it.

[Pajoe]

I think you will be happy with the improvements....

[TomL]

My advice would be leave the stock cases out of the equation! Since you will have to have the spigot holes for the cylinders bored out to accomodate the larger bore cyls. Go with STD/S&S cases already to accept the 3 5/8 bore. Post 88 bikes have the new gear reduction starter so comp release most like would be a waste unless you are well above 10.5:1 which isn't too practical for a street bike on the junk gas these days. Do the proper tweaks to the heads, performance carb and exhaust first. If you have the need to tinker with a tunable ignition go for it. The rubber mounted set ups had a tendency to crack the inner primary also so consider the support that is made to mount between the trans end cover and the cam cover. Also be sure you torque the inner primary to the motor/trans before torqing any other motor/trans screws. Break in properly and then yeee haaa, hold on tight when you twist the wick!  TL

[HILLSIDECYCLE.COM]

Finally decided to go with the 80" evo hop-up build. One factor was  cost.  It would be more cost effective to go with an aftermarket engine such as Ultima El Bruto 107" or more if I wanted to go with more displacement.  Plus, the evo now has barely 5K miles on it and it seems wrong to not get more out of it.

An 80" Evo, with a Wood 6, @ 10:1 cr WILL show 80 hp and 90 ft/lbs MINIMUM.
Normal riding will have your fuel economy way up as well.
Scott

[FXR2evo99]

IF YOU ARE GOING TO STROKE IT, STROKE THE DAMN THING

 



Regards,

Tim

[lucille]

IF YOU ARE GOING TO STROKE IT, STROKE THE DAMN THING.......  


Regards,Tim

That 'big' baby may be on a 1" throw crank........ ........stroke?....

[HILLSIDECYCLE.COM]

Finally decided to go with the 80" evo hop-up build. One factor was  cost.  It would be more cost effective to go with an aftermarket engine such as Ultima El Bruto 107" or more if I wanted to go with more displacement.  Plus, the evo now has barely 5K miles on it and it seems wrong to not get more out of it.

It's been awhile now.
How did you make out??
Scott

[JamesButler]

Scott,
Thanks for asking.  I decided to hop up the 80" Evo rather than bore and stroke it to 96".  I went with a mechanic named Mike Magaro out of Harrisburg, PA (about 90 miles away from me).  He did the work over the winter.  Mike was recommended to me by a few people, and I was very pleased with his work.  He sent the heads out to Jim Libonati at MegaFlow. Since the build, I've only put a little over 2K miles on the it, but there have been no issues.  I have not yet dynoed the bike, so I can't give any hp/tq numbers,  but there is a noticeably great feeling of increased power, pull and FUN shifting thru the gears from idle to 90-95 mph. Messing around on the local interstate, I've gotten it up to 105 mph, but from 97 to 105 takes some distance/time.  Suppose though, if it accelerated from 90 to 115 mph as quickly as it does from 70 to 95mph, then I would enjoy that as well.  It had some left at 105, I'm guessing to @ 110-115 mph max, but I caught up to traffic and had to back off.  I see the Ultima 127" in one of Magaro's FXR's, and I do wonder what the ride would be like on it. Anyway, here are most of the specs on the 80" hop-up build Magaro did,

KB 9.5:1 Pistons
Adjustable Pushrods
V-Thunder 3000 Cam (my choice not his) 
S&S Super E Carb, switched petcock/new throttle cable
K&N Air Filter
Heads by MegaFlow
SuperTrapp SuperMeg 2 into 1 Exhaust

 

[Pajoe]

James,

I was at the Autozone store  near Magaro's the other day and thought about you. I am glad everything worked out well, and I bet you have a more reliable engine then if you had bought an Ultima big inch crate engine.   I might contact Mike to do some work on our Ultima engine, but it won't be until it's too cold too ride. A few years ago I had different indy shop do the top end; along with some performance upgrades to our 80" and the  work was OK. However, even though we planned on it not taking more than 3 weeks, it took about 5 weeks and this was during our favorite riding weather in the fall.

[ltank]

I bought A S&S V111. It has a 4.125" bore and stroke with 585 can . Runs/starts great!  Put in my 2000 FXR4
CVO, Rivera-Primo 6 speed and a Barnett Scorpion Clutch. Custom S.S. 2 into 1 collector with stepped headers.Love it! Over10k miles so far in 8 months of riding.
Ltank

[Shovelhead]

Go all bore / no stroke on your Evo