I've pulled several complete motors out of bikes. Your best bet will be a good used motor (Pinwall has done me right several times as well) , get a friend with a good sense of mechanics to help (two sets of eyes never hurts) , and knock that puppy out. You could be up and running in a weekend. To boot , you'd really know your way around your own bike when you finish. BB

Well, the decision has been made. Thanks to everyone for the input.

Weighing all the pros and cons and taking into account my personal situation with work, lack of free time and desire to spend said time riding as much as possible, I decided to take the plunge and go with a big-bore rebuild.

I expect to keep this bike at least another 10 years - and if I and the wife decide to get a more dedicated touring bike down the road, I'll convert this to a solo cruiser.

So...within 4 to 6 weeks I should have the following (to go with the pre-existing V&H longshots, Dyna 3000 and Baron's BAK)

- PR 108 big bore kit - rebored/plated cylinders etc.
- high comp pistons
- adjustable pushrods
- PR cams
- PR spring kit
- new lifters
- 1mm oversize valves (my tech thought 2mm would REALLY kill the MPG)
- complete head porting and valve job
- 42 mm Mikuni carb
- ported intake manifold
- new high speed oil gear (my original failed in two spots - cracked right off - which is why the engine failed)
- brand new engine internals, o-rings, seals, gaskets everything replaced

And I figured, while that's being done I may as well get them to install some additional upgrades:

- Barnett clutch kit
- braided stainless brake lines
- progressive front fork spring
- 1000 lb Eibach rear spring

It's not cheap, but I am extremely excited (and nervous) to get this bike back and get it broken in properly. While most of my riding is on the highway, wife on the back, going for long, enjoyable tours, I think it will be kind of fun to kick H-D owner's asses 10 ways to Sunday if they challenge me at a light

Do you think it would be worthwhile to move to a 32 tooth pulley from the stock 33?

Also, my tech suggested I KEEP the fuel pump rather than removing it - something to do with keeping a constant flow of fuel regardless of the level in the tank - and that he has never seen one fail in 12 years of working on Yamahas. Thoughts?

Definitely do the front pulley replacement, and don't even hesitate to go down to the 31. If you want to kick Harley hiney, that will definitely help alot!!!

You'll probably want to add a Speedo-Healer, too, if you do.

As for the pump. It's you're call. Some pumps definitely have failed, but gravity never did yet!

I only removed mine because I wanted less clutter around the motor, and more jug showing.

If you experience fuel starvation issues, do the Grizzly valve, and cut down the main fuel feed tube of the petcock by 1/2", as a minimum start to resolving any pumpless fuel feed problems.

I only cut down the tube, and nothing else, and have no issue with either of R*S... but then I don't go full-throttle racin' Harleys either!

lose the fuel pump you don't need it with the 42 anyway I think I would go with the 45 though

Tug wrote:
lose the fuel pump you don't need it with the 42 anyway I think I would go with the 45 though

I agree with Tug, HSR45 or go Big Bucks with a Genesis SeriesIV 48mm, read the tech article about the install of one. The 42 is probably not enough for that big 112 kit. Both the 42 and 45 dont require a pump at all from what Ive read so far.

Rod

When I did the 110 PR Big Bore on mine, PR suggested I run the 42. I am still running the S&S G currently, but I may switch to a 45 mikuni. Only might go to the 45 because I have it here. Otherwise I would go to a 42.

I may have created some confusion - the bore is 100mm - the displacement will be 108 CI (or 1775 cc).

If I was going north of 110CI I would probably consider the 45mm carb, but from everything I've read on other threads here, the 42mm carb is more than adequate for the 108 CI upgrade.

I'm finding it hard to sleep at night thinking about what it will be like to sit on this bike in mid-to-late April and take it out for it's first ride. I haven't been on a bike since the tornado incident last August. Can't wait!

Well, here we are - July 11, 2012 - almost 11 months since the tornado mishap - and I *finally* have my bike back.

At various points since February, different things have been backordered...talk about a terrible experience. At one point Patrick Racing had a bad order of pistons come in - then they were backordered on other components. Then the guy who replated the cylinders for my shop did them out of spec so my shop sent them back. Frustrating!

Complete list of changes from stock (some of these were on the bike before I did the Patrick Racing mods, indicated with an asterisk)

- Patrick Racing 108 big bore kit (cams, spring kit, etc.)
- high compression pistons
- adjustable pushrods w/ polished covers
- new lifters
- 2mm oversize valves (PR was backordered on valves so he had 2mm made from an outfit in Quebec)
- complete head porting and valve job
- 42 mm Mikuni carb
- ported intake manifold
- new high speed oil gear
- brand new engine internals, o-rings, seals, gaskets everything replaced
- Barnett clutch kit
- braided stainless brake lines
- progressive front fork spring w/ 15 wt oil
- 1000 lb Eibach rear spring
- Max Air pumpless kit
- removed front wheel hub covers (mine were scratched and looked like crap)
- starter had brushes replaced
- loc-tite starter/stator interface
* Baron's BAK
* Dyna 3000

All I can say is "holy s***" this bike pulls.

However, in a classic example of Murphy's Law, I picked it up last Saturday, drove it about 50 km and brought it back for a quick oil change (I'm doing the MotoMan break-in method).

The next day, took it out at 7 AM with my adoring wife on the back. 19 km out of my house, the motor stopped - while in traffic.

I could start the motor, but as soon as I shifted into gear it died.

I managed to navigate safely to the side of the road. 2 hours and $150 later my bike was back at home, towed courtesy of MotoLimo.

Thanks to the lovely folks in this forum I quickly determined it was either an issue with the kickstand switch or clutch switch, or the master relay.

Sure enough, I did all the diagnostics with my multi-meter - the master relay was faulty.

New one arrives today, along with a new Warrior starter relay.

I built myself some new 4 gauge cables (starter, battery and ground) last night as I found that when I got the bike back from the shop there were times it was hard to start - not all the time, but once in a while I would push the starter, it would turn over then silence - then a couple of seconds later turn over again.

I checked the battery and it needed a charge - I suspect the shop didn't put it on a battery minder over the last couple of months. I'm also hoping the new cables and starter relay will alleviate some of the load so that I don't have any more issues (I have a sneaking suspicion the load put stress on the relay that failed.)

With any luck, in about 8 hours I'll be back on the road. Fingers crossed!

Now to find a good, cheap petroleum based oil with enough ZDDP in it to tide me over until I get to 2000 km so I can get back to putting in Mobil 1 V-Twin Synthetic. Any suggestions? I'm in Toronto, Ontario, Canada.

Thanks!

George

Ive always wondered what the roadstar sounds like with the big bore kit and HC pistons.

Glad you are back on the road again!

Congrats on getting it back together,hope everything runs great for you