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[Rooster]

She Runs Great! Pipes are custom S.S. Stepped 2 into 1 pipes.
There is moderate discoloration the 1st two inches. A lot of S.S.
Pipes turn purple/black about a foot due to excessive heat telling you bike is out of tune. I get 50 MPG on the highway at speeds 70 to 85. Past 85 will the GPM takes a hit to 38 or so.

Old Thunderheader without shields on my 96 WG looks about the same at 54k. The most dependable bike I have owned.

[HILLSIDECYCLE.COM]

Stock Evo cases are questionable IME with big bore cyls., tend to weep, especially the rear. I don't know what the cost is to rebuild your stock motor into a big bore. Might look into the S&S 111" crate motor, square motor=smooth power and a warranty.

Contact Axtell Sales, Des Moines, Iowa, or S&S Cycle in Viola, Wis. in regards to stock case integrity.
Only cases we see here that were problematic, even in OEM trim, were the family of 1992-94 Evo's. Only.
The 90* machined corner behind the rear tappet block sets the stage for a fracture point right out of the gate, and that is where they'll break, stock, or bored.
Scott

[Ridgerunr]

I've seen enough 88' - 93' cases with issues that I'd definitely get aftermarket cases if increasing power. I owned a 1988 and a 1993, both rear cylinder bases leaked, the 1988 bone stock. The 1993 started when I got it to 86 hp, with heads and cams, no overbore. The 1992 FXR I owned with the S&S 80" Hot Set Up made the same horsepower (86)  and didn't leak a bit. Point is it's a crap shoot IME when pumping up an Evo with stock cases. S&S, Delkron, STD, Jims, House of Horsepower made their replacement cases beefier in that area for a reason.

[HILLSIDECYCLE.COM]

Those Evo's always would leak on the primary side, rear cylinder, particularly with the ancient paper gaskets.
No fault of the engine case integrity.
Those cases mentioned really cannot be thicker in that tight area.
They are/were, however, manufactured from 356-T6 aluminum alloy of a much higher tensile yeild than the OE cases.
The years of the cases I mentioned are the ONLY ones we have ever seen any issues, in the 70 hr/6 day a week/30 years of HD enging building enviroment.
Scott

[prodrag1320]

we`ve done too many big bore motors with stock cases to count,never had a problem because of case integrity (pan,shovel or EVO),in our early years of drag racing,we used stock cases.never had any problem there either

[HILLSIDECYCLE.COM]

Had a 97" Shovel hurt the cases once..............client did not have the upper motor mount in place when he installed the engine in the chassis............
Scott

[Classic Beast]

S&S makes a great 126" 4 3/8" bore 4 3/8" stroke 150 Hp with twin cams (has evo or twin cam mounting) I would bet this motor with the shorter stroke would be a good one I run a 127" with 4 1/4 bore and 4 1/2 stroke and it's been good to me. Running the aftermarket cases they are 1/4" wider and stronger so a big bore isn't an issue, stock cases, are ok within limits I ran a 3 5/8" bore 96" shovel for years with stock cases (1975) didn't have any issues with that.