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[tennisman]

I'm looking at adding an EVO to the stable and am wondering what the main weak points of the EVO engine/drive train are.  Can you EVO experienced riders enlighten me?  Thanks!
T-man

[Gettinold]

Compared to TC....... None. 

[09fltrse3]

200k plus miles on a 98 Roadking and other than a top end at around 80k the bike has been very reliable. I still have it for local transportation, the 09 SERG is now my travel ride, but if someone wants to challenge the King, it's up for the ride. Andy.

[spydglide]

Compared to TC....... None. 

Yeah, all that and they don't run so hot !    har.  spyder

[lucille]

I'm looking at adding an EVO to the stable and am wondering what the main weak points of the EVO engine/drive train are.  
T-man

A FXR 1-2-3-4 perhaps?

Really aren't weak points with an EVO
There are dozens of good, proven cam grinds....take your pick.
Change out the original INA cam bearing for a Torrington, and while you're in there, a steel breather gear.
Don't be shy with the oil changes....
These are the only things that come to mind on the weakness of an EVO.
There were porosity issues with some of the cases.....

There are numerous mild hop-up combinations that don't affect reliability with an EVO...

[Chains]

Don't know of a lot of weak points, but I have built them with cams, head work and ignitions and they scream.  Only problem I ever had was ignition switch on my 96 went bad in Key west and when it went there was no way to start the bike.

[dartman]

I'm looking at adding an EVO to the stable and am wondering what the main weak points of the EVO engine/drive train are.  Can you EVO experienced riders enlighten me?  Thanks!
T-man

I had a bunch of them up till 99 the only problem I had with a few of them were headgaskets and that was primarily my fault, the head bolts on the EVO,s were so long that they require a decent warm up to reach proper torque, not a good idea to rev a cold one.

[HOGMIKE]

I had a bunch of them up till 99 the only problem I had with a few of them were headgaskets and that was primarily my fault, the head bolts on the EVO,s were so long that they require a decent warm up to reach proper torque, not a good idea to rev a cold one.

Yes, proper warm up. Had some minor problems with oil leaks at the base gaskets once.

Had to replace a starter relay at 100k miles, though. I think it should be covered under warranty! 
           
No real weak points that we saw here.

 

[grandpadoc]

I had problems with the e.i. on my 84 FXR, but made the easy switch to points and never had a problem after that. The 87 FLHS was faultless, and the 98 FLT had e.i. problems again, but it still is running strong today 100,000 + with no tear down in site. 
If there were good ol days with Harley it would be in the era of the E motor...the best Harley engine ever made.

Doc

[tennisman]

Thanks to ALL for the replies - that gives me confidence to go after a low mileage EVO as a good 2nd bike to my CUSE3.  Thanks!!

[grandpadoc]

Thanks to ALL for the replies - that gives me confidence to go after a low mileage EVO as a good 2nd bike to my CUSE3.  Thanks!!

If you can find one, the FXR would be my choice for a second bike. They called them "rubber glides" because of the rubber mounted engine, tranny,  pegs, handlebars and who knows what else, but what a sweet riding bike.  Doc

[sadunbar]

If you can find one, the FXR would be my choice for a second bike. They called them "rubber glides" because of the rubber mounted engine, tranny,  pegs, handlebars and who knows what else, but what a sweet riding bike.  Doc

Since I bought my wife an FXR4 for her birthday last fall....(not counting trips....just daily riding)....I have put far more miles on her FXR than my SEUC.  What a blast to ride!  If I find another FXR in the right condition and at the right price, I'll have one of my own for a daily rider!   

[tennisman]

Well, I found a bike, but not an FXR, it's a Softail custom, no rubber-mount.  I guess the engines are not counter-balanced in 1996 either?  Anyone know?

[SBB]

Well, I found a bike, but not an FXR, it's a Softail custom, no rubber-mount.  I guess the engines are not counter-balanced in 1996 either?   Anyone know?

No

SBB

[110tHunDer]

Since I bought my wife an FXR4 for her birthday last fall....(not counting trips....just daily riding)....I have put far more miles on her FXR than my SEUC.  What a blast to ride!  If I find another FXR in the right condition and at the right price, I'll have one of my own for a daily rider!   

That's funny, Scott.  I find myself heading to the FXR more than the 2 touring bikes, too.  They're neat rides, for sure.

[johnsachs]

My experience............A ton of it.
Cases are weak,in terms of pulling studs.
Base gaskets WILL eventually leak.
If using factory torque specs on the heads,you will eventually have head gasket issues.
I would stay away from engines 90' and earlier,altogether.
All these COMMON problems can be fixed with better quality parts(most have to be aftermarket).
John

[spydglide]

Had to replace a starter relay at 100k miles, though. I think it should be covered under warranty! 
           

 

I've currently starting having the starter relay problem at 109K miles on my '94.  Guess it's not going to fix itself either......since it's becoming more and more of a pain in the butt.    aaarrgh.  spyder

[grandpadoc]

...had the coil wire break or come loose a couple of times which resulted in hours of     Doc

[Black Diamond]

1984 Evos can be hard to find some parts for. They changed many parts after 1 year for the 1985 models.

JW

[grandpadoc]

1984 Evos can be hard to find some parts for. They changed many parts after 1 year for the 1985 models.

JW

...went from chain to belt and different mounting for shocks for starters.

[grb]

Bought my 1990 FLHS new. The things that have gone wrong with it are alternator stator failed, cylinder base gaskets leaked, gearlever return spring broke, gearbox oil seal leaked, starter clutch failed, ignition sender failed. None of the replacement parts have given trouble and all in the list happened early on, so will probably have been put right in any bike you might buy today. Evos are not as strong as TCs, but most of us don't tune them until they squeak anyway! I fancy an FXR with a giant motor in it....

[micheso]

 I've had my 92 EVO Low Rider six seasons,a little abusive at times and a few longer rides her & there.Besides 50,000 mile maintance,I have only had two little problems,stator replaced and put in nylon bushings to replace wore out rubber for handle bar stability!!!She has great torque,handle bars changed for kicking back and cruising 78 mphs at 3800 RPM.Easily switches to touring and back to sport look in 20 minutes!!LOVE HER DEPENDABILITY!!!!MICHESO

[brassspike]

My mild 98 evo v2 does not seem to have problems with tc88s!  Has only been on a trailer once and that was when I brought it home. The cvo Road King has spent a LOT of miles on a trailer, out of service, and headed back to the dealer!! Its a god thing that I kept her!

[grandpadoc]

My mild 98 evo v2 does not seem to have problems with tc88s!  Has only been on a trailer once and that was when I brought it home. The cvo Road King has spent a LOT of miles on a trailer, out of service, and headed back to the dealer!! Its a god thing that I kept her!

We rode the 98 RG again last weekend when my CVOs down and I am still amazed how great that bike is. Lots of power, quick shifting, smooth riding and free of rattles and noises unlike my CVO twin cam. I feel lucky we kept it in the family with my son who uses it as a daily rider. 100K+ almost worry free miles and a go anywhere and get home kind of bike.    Doc

[Rooster]

My 96 Wide Glide with 54k on has never let me down and still runs strong. Going to give it a new battery as this is the seventh year on this one, always on the tender.

[Gecko]

My '98 Fat Boy was dead reliable, it wouldn't stop until you shut it off.  Never touched the carb, no leaks, no noise compared to my 110.  When I sold it to my brother he asked what tools he should bring for the thousand mile ride back to NM.  I told him none.  The later ones were the best engine they've made.

[brassspike]

Just took the WG out for about 25 miles. Oil temp 165 heat index here is 118 according to my weather station. Wish my SERK could do that!!

[spydglide]

Just took the WG out for about 25 miles. Oil temp 165 heat index here is 118 according to my weather station. Wish my SERK could do that!!

That's reason enough to keep the WG, right there.  har.  spyder

[tennisman]

Well, I finally settled on one!  Got a 1996 Heritage Softail with 11,900 miles on it.  Was a mess but it has cleaned up good - you can see some pics here when I was taking it home:

http://www.facebook.com/album.php?aid=2072950&id=1192315342&comments=&po=1#!/album.php?aid=2072950&id=1192315342

[Finster101]

Pre 95 cases would pull cylinder studs if you built them much.  The base gasket leak could be taken care of with a fix that screwed a tube into the jug and then went into the case.  Other than that they are great.  These are easy fixes.  They sound better than a twin cam too!

[tennisman]

Amen on the sound...that was the main point of picking up an Evo....I like the Softail looks, too.  Tranny shifts a bit hard though, even after putting in Mobil 1 synthetic 75/140 gear oil.

[Finster101]

Run that Mobil for a while then dump it and put in Red Line Shock Proof oil.  After a few miles it looks like strawberry quick,  but it has sure worked well for me.

[HILLSIDECYCLE.COM]

I'm jumping in on the tail of this, but I agree with John Sachs, and will add that the rear cylinder base WILL eventually leak/weep. Certainly not the end of the world at all.
In certain instances, the cases were known to fracture behind the rear lifter block in the 90* machined corner in even in OE trim, but all in all, those 80" Evo's were a damn good engine.
Same bore/stroke combination(3.500" hole, with a 4.250" arm) that S&S was contracted by the Moco, to develop for Shovel application, in the mid/late 70's.
Scott

[kansaskim47]

 
98 Roadking with 124k with no issues. Changed carb, cam and cam followers at 36k, still runs great. Has always had some mechanical noise in the top end, but magnetic plug and filters have not shown any metal.

Has always run Castrol GTX 20-50 changed at 3k miles with a black NAPA 1215 filter.

Only problems have been 2 starter clutches, a pinched gasket in the front rocker box, and a cracked coil.

Still running the original clutch, primary, drive belt, and clevblock bushings.

Evo's main weakness is in the cylinder base gaskets. Make sure you have some heat in the cylinders before you put much load on the engine. Idling for 30-45 seconds or until you can feel definite heat in the lower cylinder works well.

Would take off anytime for a cross-country trip.

[spydglide]

Still running the original clutch, primary, drive belt, and clevblock bushings.

Evo's main weakness is in the cylinder base gaskets. Make sure you have some heat in the cylinders before you put much load on the engine. Idling for 30-45 seconds or until you can feel definite heat in the lower cylinder works well.

Would take off anytime for a cross-country trip.

Good to hear & good advice on the warm-up.  Gotta luv those eV0's  har.  spyder

[tennisman]

Well, I did finally buy one, a 96 Heritage Softail Classic - luv that motor sound....is a bit rougher ride than my Ultra SE, but to be expected.  Sure like how cool it runs.  Is a fun ride.

[Rooster]

Always warmed up before taking off so never had a base gasket let go. I was warned about that years ago and I paid attention. Tried to beat the 110 leaks but still they still got me. I always wait til the rear rocker box feels warm.

[tennisman]

Besides my 06 Softie, I have an 08 Ultra with a 110" motor - no leaks on the 110 after 40,000 miles.  Had one leak early on that was just a oil filter adapter gasket (it has an oil cooler).
T

[FXR2evo99]

Well this has been an interesting "THREAD" to catch up on..........for sure.
 
It's great to see the positive feed back about "probably" what is considered one of HD's greatest engineering and marketing conflicts at the time and utimately given up for something less "difficult" to manufacture, to today becoming more and more a very sought after ride, ie: The FXR, for those of you interested you might like to get some popcorn and your favorite and take a "peek" at a historical perspective of what and why the FXR may be ultimately known as one of HD's finest models ever produced.

Simply, CLICK HERE

Also here is a pretty good "THREAD" discussing some of the reflections above that were dealing with the "weaknesses" regarding various cylinder base gasket leaks, head gasket leaks, and even some of the issues surrounding the rocker area leaks.  You will perhaps discover what some suggested "fixes" might entail and basically how simple they were to implement for the most part.

If you wish to take a "peek", simply CLICK HERE.


Regards,

Tim

[Free]

here is my 1991 FXR.  the only major problem I had was the inevitable base gasket leak at 20k or so.
After 15 years of riding, I replaced her with a S&S 124 and smile every time I take her out.  I use the 2006 CUSE for my long trips, but find myself riding this bike a lot more. She has been through a lot of changes and I think the only thing that remains stock is the frame

best

Free

[bknerr]

from what i`ve seen, they don`t take kindly to increased cylinder diameter. studs way too close to cylinder wall. the edelbrock heads really woke mine up though.

[Free]

My first real performance upgrade was Edelbrock heads. must have been around 1994 or so. I really liked them. had them until I got the bigger engine.

Free

[TomL]

In 86/87? there was a weak spot in the crank cases due to thin castings, it could crack and become an oil leaker. Next thing is the starter prior to 89, it works but just does not have the umph of the new gear reduction type. Cylinder base gaskets were another headache thru the 80's but that has been rectified with a new type. Cylinder studs on the very early EVO's were junk but the factory changed them about 87 I beleive. Also the replacement of the Torrington inner cam bearing didn't work for long if you went to high seat pressure valve spings. Otherwise the motor is near bomb proof tho some will say the push rod angles hinderd performance some, hence the TC and its XL type angles were an improvement, except too dam many moving/wear parts on the TC. TL

[tennisman]

The Evo was a fine motor in its time, great sound, and very reliable. On the hand they were very gutless, and back then the brakes on every HD were just plain dangerous. Ahh, those good old days.

I presently own a 2008 CVO Ultra, and so far it has been very reliable. Hope you enjoy your Evo.      

Dangerous brakes, indeed, which led me to replace the single piston front caliper with a HHI 4-piston squeezer....now I can stop and make lemonade at every stoplight!

[Gecko]

We often complain about HD quality, and rightfully so. They have basically been making the same bike over and over again for decades, so it should be near perfect by now. However, when we look back at what HD put out the door just 10 to 15 years ago, what a difference. Better electrical systems, great stereos, better brakes, batteries that actually last several years rather than half a riding season, no shaking at any speed above 5 mph, better power, better seats. Hmmm, maybe these are the good old days, but we just don't know it yet.  

Better electrics: except the ACRs that fry their wiring, heated grips that last a month, electronic dip sticks that last a month...  Great stereos: Maybe it would help drown out the "normal" knocking mine makes and the MoCo refuses to even admit to (and they don't make the stereos).  Better brakes: my second set of rotors warped and will be replaced with Lyndols for a mere thousand bucks or so.  Batteries: They don't make them (fortunately).  No shaking: Mine does when you roll off the throttle ("normal"), and scissored cranks aren't exactly smooth.  Yes, these may be the good old days, but only because they will care even less as the number of bikes sold dwindles.  I've riden them for a lot of years, but this will be my last Harley.

[tennisman]

Better electrics: except the ACRs that fry their wiring, heated grips that last a month, electronic dip sticks that last a month...  Great stereos: Maybe it would help drown out the "normal" knocking mine makes and the MoCo refuses to even admit to (and they don't make the stereos).  Better brakes: my second set of rotors warped and will be replaced with Lyndols for a mere thousand bucks or so.  Batteries: They don't make them (fortunately).  No shaking: Mine does when you roll off the throttle ("normal"), and scissored cranks aren't exactly smooth.  Yes, these may be the good old days, but only because they will care even less as the number of bikes sold dwindles.  I've riden them for a lot of years, but this will be my last Harley.

And let's not forget starters, compensators, and the ever present lifter replacements! 

[tennisman]

Since I started this thread before buying an EVO, I'll give it an update - the EVO I bought (a 96 Heritage Softail Classic) is a jewel and I love riding it.  Oil temps almost never exceed 200 deg F, it always starts easily, and idles with a whole lot less shake and a WHOLE lot quieter motor than my 110" CUSE3.  I did put a 4 piston Hawg Halter brake on the front to replace that anemic OEM single piston brake.  So, since October 2010, I've put on 9000 miles on it.  Very happy with this bike, even though the tranny is a bit stiff to shift.
T

[Hank Hankerson]

here is my 1991 FXR.  the only major problem I had was the inevitable base gasket leak at 20k or so.
After 15 years of riding, I replaced her with a S&S 124 and smile every time I take her out.  I use the 2006 CUSE for my long trips, but find myself riding this bike a lot more. She has been through a lot of changes and I think the only thing that remains stock is the frame
<a href="http://" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">http://</a>

Wow, what a great FXR!  What kind of front fork is that that's on there?  Inverted...but how does it ride?  Adjustable compression and rebound damping?  The 39mm on my pop's rides like crap and with the crap 11.5" P&A shocks on the back it rides more like a flying sofa than something I'd feel comfortable cornering in.  Anything above 50 mph in a tight corner and it feels like the rear end is going a different direction than the front.

I will say, hovering the motor between 2500 and 3000 when taking the corners gives me all the control and power I'd ever need in a bike.  The more I ride it, the more I like the rumble.  I just wish the price paid for an H-D equated to a superior handling bike with an low end juice of an air cooled V-Twin.

[Rooster]

Since I started this thread before buying an EVO, I'll give it an update - the EVO I bought (a 96 Heritage Softail Classic) is a jewel and I love riding it.  Oil temps almost never exceed 200 deg F, it always starts easily, and idles with a whole lot less shake and a WHOLE lot quieter motor than my 110" CUSE3.  I did put a 4 piston Hawg Halter brake on the front to replace that anemic OEM single piston brake.  So, since October 2010, I've put on 9000 miles on it.  Very happy with this bike, even though the tranny is a bit stiff to shift.
T

I still have my 96 fxdwg. And at 54k I can still get on it and go anytime without worry. Need to upgrade brakes as you say as it was a little challenging towing my tent trailer. Heavier bike much better for that. I remeber being warned in the early days to warm up real good to avoid base gasket leaks which I have always done and never blown one yet. Unlike the three times on my 07fltcuse when the 110 was still in it. Sure wish HD still had that kind of Quality these days. I also remember my older riding buddys saying Hear no Evo See no Evo. And now they all say the Evo is the best motor. HA HA.

[Shovelhead]

Compared to TC....... None. 

Yep, what he said, exactly ! 

[ltank]

I am a FXR EVO man. I had a new 89 FXRS but sold it after a few years. Missed it badly. A few years ago I got a used 2000 FXR4. Evo are great motor with a few small issues but wat better than the newer TC motors. I just got a great deal on a S&S V111 for $4,550. Getting it installed now. My old EVO motor runs fine 26k miles but wanted to take on my son's 95" TC Softail.

[JoeSDE]

Had some issues with my '99 FXSTC. Lost crank bearing @ 30,000. Lifters went @ 45,000 and took the EV 27 cam with it. Sometimes like a bad woman, but I just won't let it go. SE heads, single fire ign. Runs great, fits perfect. Little bad luck with the motor, but I still love this bike.

[cahdbiker]

Tennisman, there is an inexpensive tool you can get to adjust the rear shocks. Part no. HD-94455-89 "softail shock absorber spanner". Just undo the locknuts and adjust out to increase preload for heavier load or  adjust in for a lighter load. For local riding I usually ride my softail. With one person on it it is more comfortable than my 09SEUC, but not for a along trip,although I have ridden it from Simi Valley Ca. to Steamboat Springs Co. and back with passenger and too much luggage and had a great time.

Well, I did finally buy one, a 96 Heritage Softail Classic - luv that motor sound....is a bit rougher ride than my Ultra SE, but to be expected.  Sure like how cool it runs.  Is a fun ride.

[tennisman]

THANKS!  Great tip! 
BTW, that's a great looking Heritage!  We have the same pipes, I notice.
You can see my Ultra in this month's AI mag letter section with my camera-toting wife on the back takin' the pic.
Terry (aka T-man)

[cahdbiker]

Free, Beautiful bike, I put a S&S 107 in my 95 Heritage. I did have some problems with it after 2000 miles (loose pistons).At the time I thought I was still going to be using it for longer rides or I would have gotten at least a 113" Happy Holidays.CAHDBIKER

here is my 1991 FXR.  the only major problem I had was the inevitable base gasket leak at 20k or so.
After 15 years of riding, I replaced her with a S&S 124 and smile every time I take her out.  I use the 2006 CUSE for my long trips, but find myself riding this bike a lot more. She has been through a lot of changes and I think the only thing that remains stock is the frame

best

Free

[timo482]

i went from shovel to twin cam, never had a evo [kids] the twin cam with all its trouble is way way wayyyyyy better than the shovel.

i also remember guys with problems with case porosity and transmission shafts and clutches - but i had all those problems on the shovel too.

both twin cams have been so much less work and so much faster than the shovel that i keep wondering what the complaining is all about? 40k on a top end 80k per crank - MAX. real often guys i knew had to do the entire engine at less than 30k. as soon as i had to leave the choke on a bit to run decent it was time for a valve job pronto - every year the heads were off - i have all the special home made bent wrenches to get shovel heads off - every other year the crank, rod ends mainly. and a trans main shaft seal and main gear bushing while you were at it - oh and a chain every thousand miles or so. and oh i forgot the heads could only take guides to a certain size over - so new castings every 4 years or so - and the left side of the crank case would get to where the bearings would not press in. i have heard that there are now ways around this and ways to salvage those old cases and heads - but in 1980 it was "throw it away and get new cases and heads"

from all the complaining - id think my twin cams should need a total overhaul every 10k? ill check the cam bearings and lifters - those seem genuinely a issue. but were evo's that much better than twin cams are? if so would it pay to put a evo and evo trans in a twin cam bike [should fit phisically] ?

[tennisman]

So far, my bought-used EVO has been rock solid - I only have 21K on the clock but my twin cam was already in the shop by then.  We'll see as time goes on.
True what is said on the power end, but one can't compare an 80-incher to a 110.  I like the 110 power for sure, but the EVO is adequate for day rides, and I love the quietness of the EVO engine compared to the 110.
T

[ltank]

My 2000 FXR4 EVO had two problems. A alternator wire shorted to chasis that caused some weird problems before finding it. The other was the leaky rear cylinder base gasket.
Other than that it is flawless. But i wanted more power to take on my son's TC FXST so I just installed a New S&S V111 EVO.  My custom SS 2-1 pipes are being made so i put my old Python 3 pipes on. Still need to put a Barnett Scorpian clutch and a new S&S high strength rear belt.

[ltank]

Other side of bike. Don't know know how to post more than one pic

[spydglide]

My 2000 FXR4 EVO had two problems. A alternator wire shorted to chasis that caused some weird problems before finding it. The other was the leaky rear cylinder base gasket.
Other than that it is flawless. But i wanted more power to take on my son's TC FXST so I just installed a New S&S V111 EVO.  My custom SS 2-1 pipes are being made so i put my old Python 3 pipes on. Still need to put a Barnett Scorpian clutch and a new S&S high strength rear belt.

Sweet hot rod.  How are those spoke wheels gonna hold up to that power?  spyder

[ltank]

Spokes only on front wheel. Rear wheel has a Harley cast aluminum solid rear rim. standard 16" rim

[spydglide]

Spokes only on front wheel. Rear wheel has a Harley cast aluminum solid rear rim. standard 16" rim

My bad... ........old eyes  har.  spyder

[HUBBARD]

Back in the day, my Cylinder-Base gasket problems were the result of not letting the Engine warm up before mountin' up and throwing the fuel to it.  May not be your situation, but sure was mine.  Lot of work to replace those bitc*es, too.  Always gave me an excuse to spend more money, too.  Like in, "I hate to have this Motor down this far, and just replace these gaskets!"  Later--HUBBARD

[Shovelhead]

i went from shovel to twin cam, never had a evo [kids] the twin cam with all its trouble is way way wayyyyyy better than the shovel.

i also remember guys with problems with case porosity and transmission shafts and clutches - but i had all those problems on the shovel too.

both twin cams have been so much less work and so much faster than the shovel that i keep wondering what the complaining is all about? 40k on a top end 80k per crank - MAX. real often guys i knew had to do the entire engine at less than 30k. as soon as i had to leave the choke on a bit to run decent it was time for a valve job pronto - every year the heads were off - i have all the special home made bent wrenches to get shovel heads off - every other year the crank, rod ends mainly. and a trans main shaft seal and main gear bushing while you were at it - oh and a chain every thousand miles or so. and oh i forgot the heads could only take guides to a certain size over - so new castings every 4 years or so - and the left side of the crank case would get to where the bearings would not press in. i have heard that there are now ways around this and ways to salvage those old cases and heads - but in 1980 it was "throw it away and get new cases and heads"

from all the complaining - id think my twin cams should need a total overhaul every 10k? ill check the cam bearings and lifters - those seem genuinely a issue. but were evo's that much better than twin cams are? if so would it pay to put a evo and evo trans in a twin cam bike [should fit phisically] ?

Well , actually the later Evos were a rock solid 100k mile engine, even with performance upgrades. My S&S Shovel is more dependable than my 110" twin cam has been and and my Shovel would smoke the TC 110 off the line until a lot of $$$ was spent on it.

[Thermodyne]

Early EVO's had case issues.  Cracks from stress risers mostly.  Around the lifter blocks, rear motor mount, primary oring boss.  Later cases suffered from thin castings. 

Late 80's early 90's had INA cam bearings.  Wallowed out bearing holes and chewed up breather bores are often found after a failure.

And there were more than a few silent recalls for loose bearing races and such. 

By the late 90's they were mostly sound.

As a rule 89-94 are cases are scrap.  The rest are fine if crack free.  Mid 90's cases must be carefully checked before boring for oversize jugs.  95 on are the cases to look for. 

If your cases are good then that leaves just a few issues, like base gaskets and worn oil pumps causing sumping.

The MoCo replaces EVO cases on the rebuilt engines they install.  They don't fool with trying to sift out the usable ones.  New matched numbered cases are <$800, and Delcron's can be had for just a little more.     

[tennisman]

Well, since I started this thread prior to buying an EVO, I have since bought a 96 Heritage Softail Classic and love it as a day rider.  I bought it with 10K on the clock and have added 15K more with only one small failure, I managed to break the plastic "Enrichener".  I do notice a slight seepage at the base gasket on the left side of the motor, but it's so minor, I can live with it.  It's been a great addition to my "stable".