Documenting the rebuild of my Pro Sport 107 - motor, exhaust, etc and some WTFs

LA_Dog

LA_Dog

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Yep- usually you have to do some sort of monkeying around. I had to make custom length banjo bolts and spacers to work with the LA Choppers backing plate (because the banjos are all pretty thick). That's why they call it a "custom bike" - 'cuz nothing is standard. :D :up:

I mostly wanted to post that up as a visual example- e.g. front breather line going into rear breather banjo, then down to bottom of bike in a single line.
 
FrankBDPS

FrankBDPS

Well-Known Member
Did you put a thicker spacer between the carb and intake or a spacer between the carb and air filter housing?
 
LA_Dog

LA_Dog

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I have a 1/4" heat spacer between intake and carb
I have a typical "S&S carb adapter" plate between the front of carb and air filter backing plate- it is about 1/4" thick.

I have the banjos sitting behind the air filter backing plate. the hollow head bolt goes through the ear of backing plate, through a 1/2" spacer, through banjo, and into head.

My mech made the longer head bolts by hand on a machine drill press- drilled right down through center of bolt and then out one side, in-line with the position of the banjo fitting. I guess it helps to have a very solid, accurate drill press. lol - He also made the custom spacers on a lathe and drill press.

but I have seen some longer head breather bolts listed on ebay - and the local HD parts counter has a number of polished spacers of varying lengths and bolt hole sizes.
 
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FrankBDPS

FrankBDPS

Well-Known Member
Mine is missing the the plate between the front of the carb and the air filter adapter plate. That quarter inch would make the whole thing work. Thanks
 
LA_Dog

LA_Dog

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Happy Friday guys- Hope some of you are gearing up for a good long weekend ride.

Quick update- Got the new Daytec oil tank today and took it over to shop. I want to send a BIG shout out THANK YOU to BigDogPartsKing for getting me the tank quickly and making sure it was a good one. Totally brand new in box. Awesome. Tank will get sand blasted and re-wrapped with carbon fiber this week. My wife wants the old one to use as a planter. that's totally funny lol.

Guys at shop have been totally cool. Bruce my mech took *everything* apart on the motor- spent 2 solid days cleaning every single thing, bearings, disassembled lifters, etc, put them all in an ultrasonic cleaner, etc. He split the case and had the crank disassembled, bearings checked, re-assembled, way over and above what I'd expect any shop to do. and all at no extra dime on my part.

Brian the "fabrication specialist" is re-doing the carbon fiber work on the new tank at no cost. you know he does all this stuff by hand, uses a pin to pop any tiny air bubbles in the clear epoxy overlay on the carbon fiber so it comes out like glass when clear coat is applied- and they use a UV-inhibitor so it will not yellow- it is a pain staking process. I never knew it was that tough.

New pistons are in the cryo tank and will go through the cryo / heat annealing process over the next 2-3 days.

So maybe, we'll have some engine revvs by end of next week. That would be cool.
 
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LA_Dog

LA_Dog

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ok so here is the latest, drama-filled update. I was expecting to pick up bike tomorrow.. but... no dice. The brand new S&S HVHP oil pump I bought was machined incorrectly and was not supplying oil to the lower end of motor. New pump, same issue. Motor had to come back out, all apart, hoping that the minute of start up running did not cause any damage. Oh and did I mention the brand new S&S replacement pistons I bought arrived with the wrong size wrist pins (pins were for a shovel, not an evo).

Total WTF. Is S&S stuff going to shit? I'm plain outta words at this point.
 
Brew

Brew

Troop Supporter
LA_Dog said:
ok so here is the latest, drama-filled update. I was expecting to pick up bike tomorrow.. but... no dice. The brand new S&S HVHP oil pump I bought was machined incorrectly and was not supplying oil to the lower end of motor. New pump, same issue. Motor had to come back out, all apart, hoping that the minute of start up running did not cause any damage. Oh and did I mention the brand new S&S replacement pistons I bought arrived with the wrong size wrist pins (pins were for a shovel, not an evo).

Total WTF. Is S&S stuff going to shit? I'm plain outta words at this point.
Click to expand...
Man brother, when it rains it pours...:(
 
LA_Dog

LA_Dog

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So it turns out the S&S oil pump *WAS* defective, the oil feed slot was not machined the full length required to meet the oil intake port on case. we had a machine shop fix the slot and the motor will be fire up this afternoon. Piss poor quality control over at S&S. That is over $800 worth of parts (oil pump and piston set) and both came with issues out of the box.

If this does not fix things the motor is getting tossed and I will put a new motor in it. but I'm going to cry like a baby shelling out the additional cash. Although after seeing these S&S quality issues I don't think I'd feel totally confident in one of their new crate motors. I don't want an Ultima or rev tech because there is no one to call if there are tech questions. I don't like buying anything from companies that do not have a tech support department with knowledgeable staff.

I can't even imaging how much a KJ 124 motor would cost.
 
LA_Dog

LA_Dog

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I just checked out KJ's site- they don't offer anything in large bore for Evo and all of the TC motors are for 07-up HDs. Typical though, just about all the well known shops have dropped everything Evo and solely focused on the TC / HD aftermarket segment. You got better luck getting parts for a Knuck or Pan now than an Evo, unless you stick with S&S. lol.
 
john sachs

john sachs

Well-Known Member
Ultima HAS a good warranty, and a good tech dept............... :argue:
Just finished a 117" epa S&S Big Dog motor for E. Trotta's shop. Went 137 hp, and 134 Torque, with a poor exhaust system. I'll post the sheet as soon as I get it.
John
 
LA_Dog

LA_Dog

Go Fast, Go Faster
john sachs said:
Ultima HAS a good warranty, and a good tech dept............... :argue:
Just finished a 117" epa S&S Big Dog motor for E. Trotta's shop. Went 137 hp, and 134 Torque, with a poor exhaust system. I'll post the sheet as soon as I get it.
John
Click to expand...
Hi John- This is just my opinion based on my experience. Sure I'll bet they help you.. since you are you.. and a dealer :D.

But.. there is no tech support number to call. Ultima Products -

I wanted to talk to them about their FXR open primary, and motor, but all I could get after searching was a Midwest rep who did not know anything tech and said they "do not answer tech questions for the general public" and "there is no direct support", "contact your dealer" blah. And they couldn't even tell me a local dealer in my area. :job:

Sorry I just can't go there. If I lived by you John, sure no prob! I'm sure they are good motors, and they are really good for you since you know them inside and out, have a direct line for assistance etc, but for joe motorcycle owner there is no love.

At least SS has tech support and is good about answering questions- they've given me all sorts of info through this rebuild process. Still don't know what's up with the bum parts, that was really disappointing.
 
LA_Dog

LA_Dog

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John that S&S build sounds awesome! I bet Eddie's real happy.

On the upside- bike started up successfully, oil is flowing. initial startup run-in completed. tomorrow will be test rides / initial break in. stay tuned. I have a line on a brand new SS 124 motor locally, if things don't look right I'm calling it quits and swapping the motor. It's amazing the folks involved with this motor build - from my mech to the machinist at R&D - have all said "in all my years I've never seen anything like this". Yeh it's been like that. For example, two bad oil pumps.. both defective in a different way but with the EXACT same failure to feed oil to the lower end?? what are the odds?
 
Brew

Brew

Troop Supporter
SOunds like things are coming around now. Test her out tomorrow, break it in right and dont over do it... :2thumbs:
 
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