1995 Heritage Softail engine build

[Adam76]

Picked up a 1995 evo heritage earlier this year as a second bike to rebuild when I'm not riding. It's an addiction. 

Last evo I had was a 1996 heritage softail. That was a pretty standard build. 9.5 comp, ev27 cam, upgraded dyna ignition slip on mufflers and rejetting the CV carb.

It was pretty decent but this time I want to go for a bigger build with more performance.

What do you suggest for the build?

Piston choice?
Wiseco, KB,

Minimal headwork necessary?
Valve job?
Bigger intake valve??

Camshaft?
Woods 6 / Woods 7
Tman 590 / Tman 625

compression
10-1 / 10.5-1 / 11-1

Best programmable ignition?

Exhaust?
Slip on mufflers
2-1 pipe

Looking for Max power 2000rpm- 5000rpm.

Thanks for any build suggestions.

[JSD]

Bath tub the heads . 4/58 stroke for starters. Reed valve or steel breather

[turboprop]

An 80" Evo at 10:1 with an EV-46 cam is a proven combination for the target RPM range.

[Hossamania]

I really liked the 46 in my Evo, it turned on hard in the mid and upper rpm. Pulled away from all those 27s that everybody was hot on. That was on a stock motor. A little compression and good exhaust (had Longshots), maybe some headwork, would have really woken it up.

[93evorider]

I did something similar about 10 years ago, so here is my opinion for what its worth.

 I have a 93 heritage-the first thing you need to realize is its solid mounted- so your not gonna rev it to red line very often if at all. You need good torque off the line up to about 4500 RPM
  Here is what i did --  I went with a 4 5/8 S&S crank with S&S cases 3 13/16 bore for a --106" evo.
I worked over heads and 10.8 to 1 compression with a woods-8 cam- Mikuni 42 carb- This dynoed at 120 Ftlb/115 HP.
  My advice to you is I would go at least 96" ( I think in 1995 the evos had the better cases so you may be able to bore your stock cases ) with at least 10.5 to 1 compression- forged pistons-- some head work and a cam to match what you set compression to-- -- any way that's my advise and good luck on your build.

   I know when I pull the " OLD DOG " out and ride with my twincam friends they are all surprised when I can not only keep up with them but run away if I feel like it, Keep us informed as to what you decide to do.

[98s1lightning]

Cool to see someone else running 3 13/16", that's the old school stuff now!!!

[JSD]

We ran aftermarket cases 4 5/8 " Sputhe 3 13/16 " Branch Heads G carb . Bandit clutch. In the 1990s . Big miles and power. 

[98s1lightning]

The older I get the more I want to build a 89" evo, and see if its the "just right" to be able to ring it out in the powerband and also get decent fuel mileage. I know a mild 80ci runs pretty decent so an 89 must be a blast. If I wasn't buying cylinders and planned for lower end work I'd go 4 5/8" wheels on stock bore and maybe bathtub heads.

I'd spend the money on the stroker crank and run stock heads if limited on budget, to get the torque, then add some gear and lower the rpm for cruising in 5th. I'd really enjoy testing a 61t belt on a late model Evo softail, with some more torque than stock 80 is needed.

[jsachs1]

I built 8 evo stock case engines back in the day. GREAT stock looking SLEEPERS. 92 cu. in. 
Along with the stock cases, I used:
3/4 " stroke S&S flywheels, knifed edged. I had to weld/extend scrapers.
Stock Evo 80" cylinders, bored .020" over.
1200 Sportster pistons, .020" 0ver.
Stock Evo base gaskets, .060" head gaskets. The gasket combo results in an .030" quench.
My ported Evo heads, 1.900" in. X stock Evo exhaust valves.
HQ 23 cam or Mid-USA Viper cam.
42mm Mikuni carb.
The engines all made good numbers. Worst was 104 hp. best was 109 hp.
I still have one in my 95' FLHR.
John

[HogMike]

We did a similar build on my 1995 FLH
Used a S&S sidewinder kit 93"
Doug D. did my heads
Mikuni 42
True duals with Fullsac cvo cans (back in the day) LOL
Andrews EV-72 is what we ended up with
 
I still have that motor sitting on the shelf here!
Runs pretty good but, of course, I just HAD to go bigger!

I'll be looking for a basket   FLH one of these days to slip the motor and trans into.
 
Wife says I need another project.

 

[98s1lightning]

Great info tho, thanks

[98s1lightning]

I built 8 evo stock case engines back in the day. GREAT stock looking SLEEPERS. 92 cu. in. 
Along with the stock cases, I used:
3/4 " stroke S&S flywheels, knifed edged. I had to weld/extend scrapers.
Stock Evo 80" cylinders, bored .020" over.
1200 Sportster pistons, .020" 0ver.
Stock Evo base gaskets, .060" head gaskets. The gasket combo results in an .030" quench.
My ported Evo heads, 1.900" in. X stock Evo exhaust valves.
HQ 23 cam or Mid-USA Viper cam.
42mm Mikuni carb.
The engines all made good numbers. Worst was 104 hp. best was 109 hp.
I still have one in my 95' FLHR.
John

Did you have to mill wrist pin boss wider on XL pistons for use on BT connecting rods?

Small end of rod wider on BT than sportster

8 1/2" flywheels or 8 1/4"?

[jsachs1]

I built 8 evo stock case engines back in the day. GREAT stock looking SLEEPERS. 92 cu. in. 
Along with the stock cases, I used:
3/4 " stroke S&S flywheels, knifed edged. I had to weld/extend scrapers.
Stock Evo 80" cylinders, bored .020" over.
1200 Sportster pistons, .020" 0ver.
Stock Evo base gaskets, .060" head gaskets. The gasket combo results in an .030" quench.
My ported Evo heads, 1.900" in. X stock Evo exhaust valves.
HQ 23 cam or Mid-USA Viper cam.
42mm Mikuni carb.
The engines all made good numbers. Worst was 104 hp. best was 109 hp.
I still have one in my 95' FLHR.
John

Did you have to mill wrist pin boss wider on XL pistons for use on BT connecting rods?

Small end of rod wider on BT than sportster

8 1/2" flywheels or 8 1/4"?

Pistons are Wiseco K1660 series, .020" over. Stock-No mod to wrist pin internal area.
S&S 32-2030-2234 4-3/4" stroker flywheels.
Knife edge outer flywheel rims.
I extend/weld the flywheel scraper area.
John
 

[JSD]

John are the Evo 4 3/4 s&s wheels 8 1/4". I have shovel at same stroke and i was surprised  to see 8 1/2 wheels  S&S 

[98s1lightning]

When I run that number 8 1/2"

[JSD]

When I run that number 8 1/2"

I wonder why the master John built up scraper ?
Because of knife edging the wheels ?

[Deye76]

Bath tub the heads . 4/58 stroke for starters. Reed valve or steel breather

The S&S 89" Hot Set Up with their .561 cam was fun, made pretty good power. 

[98s1lightning]

Can you post a video of that 92ci running?

Idk if this forum does videos 

[kd]

When I run that number 8 1/2"

I wonder why the master John built up scraper ?
Because of knife edging the wheels ?

The outer circumference of the flywheels just barely clear the case just before the approach to the cylinder base.  Oil on the flywheel halves built up from passing through the residual oil in the bottom of the crankcase would otherwise fling off up into the cylinders and flood them causing excessive oil consumption.  The surface is called a scraper even though it doesn't contact the flywheels.  A knife edge cut perimeter doesn't match the profile so John would add material and reshape to a suitable profile and clearance.