Catostrophic Engine Failure - Help on Next Steps

[IronMike08]

Hi Guys

I am looking for some advice on the next steps for my motor and also interested in hearing your thoughts on what exactly could have happened to it.

The Background: 2000 Fat Boy. 45,000 miles. At 18,000 miles it was bored out to 95" and the complete HeadQuarters 1550 Hi Compression Kit (with head work, new valves, etc.) was installed. Runs with a re-jetted stock carb, K&N hi flow air cleaner, V&H Straight Shots.

Cam Chains were polished during this rebuild at 18K miles and new cam chain tensioners installed.

Last weekend, on way to Laconia I heard a high pitched whine for about 10 seconds at highway speed before motor died. Thankfully I was prepared for a stall, pulled in clutch and headed to the side of the road.

Had bike flat-bedded to dealer to see if we could get it back on the road.  They confirmed primary side was ok and also pulled cam chest. The first cam chain tensioner was shot to pieces – nothing left on the pad, just the metal. So, no dice on getting back on road – bent pushrod could be seen and rear cylinder could not pass leak-down test. Trucked the bike back home and started tear down yesterday.

It was like nothing I've ever seen before – massively bent rear exhaust pushrod, slightly bent rear intake pushrod (fronts looked ok) and engine would not turn over trying to bump rear wheel. Removed rear cylinder head to find the piston in pieces! Valve bent to all hell in the head and the connecting rod also massively bent.

This is obviously a total engine removal and I'd love to hear your advice on next steps. Specifically if anyone knows of a good place to take the motor in the northern NJ area and also if the engine refurbish program with HD would be worthwhile. Seems that for a "new" 95" Stage 1 motor I'd be looking at $3,650.

I can also post additional pictures if there are specifics anyone would like to see.

Thanks in advance for any feedback.


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[Ohio HD]

Sure, more pictures might better understand what went wrong, in the order it happened.

Relatively close to you is Hillside Cycle in Munnsville NY. Not exactly down the street, but close enough to use them if you chose to. Scott Palmer is a regular on the board here, and may see this and chime in. He's more than competent and equipped to build you a motor.

http://www.hillsidecycle.com/

[wholehog]

something in the cam chest hung up the exhaust valve and the piston hit it...probably is not a lot salvageable on your core beyond maybe the case itself and a rebuilable crank....

an H-D reman engine might be the most cost effective way to go if you keep the dealer out of the install (there was a thread about this not long ago)......be sure the oil tank and lines are flushed....good luck

[surf]

Check out Blackhills Ken in Rockaway, NJ. He'll steer you in the right direction.
http://www.blackhillscustomparts.com/

[joe_lyons]

More pics please.  Head, cam chest, and check the lifters(take them apart and see how much plastic is in them) and how the lifter bore is.

[mrmike]

Yup Blackhills Ken would be the guy in Jersey to talk to, he's a stand up guy and he knows his stuff, also a member on this site.

Mike

[irishrover]

how about ebay you might get a whole motor that's a drop in at a reasonable price. don't hurt to look best of luck hope you get up and riding soon

[VDeuce]

A 120R crate motor might be tempting if you can get it to fit. I know they make a B motor, but say it is for '07 and up. Would need compensator and an intake setup, plus a clutch upgrade. There's probably not much if anything salvageable in that motor...

[prodrag1320]

what brand pistons were they?

[joe_lyons]

what brand pistons were they?

Prob. Whomever head quarters has make their pistons.

[greg02flhri]

Have you pulled the lifters and looked at the lifter bores?  When my tensioners went back in '08 I couldn't believe the amount of tensioner pieces in the lifters when I took them apart.  Also scored my front lifter bores a bit but I'm still running it with no apparent problems.  Based on what I saw though, I can imagine enough crud going through there to seize up the lifters, holding the valves open, etc. etc.

My tensioners were running on polished cam chains as well.  The inner chain was toast - wasn't very flexible.  I wondered if it was from not getting all the polishing compound out of the chain caused it and then caused the tensioner to wear quicker (20K miles),  or if the blown tensioner wrecked it.  Won't ever know....gears in there now.

[autoworker]

I would investigate these three options.

Blackhills Ken
HD Reman and build from there
SE 120R

[dakota224]

Take it up to Hillsidecycle in NY and leave it there for 2 weeks. its going to need a complete rebuild .  I hear strong engines come out of that shop..

[Ultrashovel]

I would use the HD remanufacturing program if I were faced with the same situation but that's only because I like stock motors. There may be damage to the crankcases that would entail having them replaced anyway. The cost would be about the same as an independent rebuild but perhaps a longer warranty. (Not sure on that).

Sorry to see this. I know how you feel, too. BTDT.

[CndUltra88]

OUCH, hope the repair is less painfull.
Rob

[wheelie1239]

  That sucks. Pretty sure that I read on this site somewhere that the reman option requires motor to be removed and installed at HD dealer. I would do a search on motors, have seen some good deals in past few months. Ebay, craigs list, HTT, even do a google search. Might find a internet shop having a sale. I have friends that have used Hillside and have been very happy! Good luck...

[aceman2101]

I know where there is a stock 103, they are asking 2500.00. I believe it has about 10k miles on it. been sitting there for a long time, may be able to get it cheaper than that

[qtrracer]

I know where there is a stock 103, they are asking 2500.00. I believe it has about 10k miles on it. been sitting there for a long time, may be able to get it cheaper than that

I hope so. Usually those can be had for under 2k, thats why it is still sitting.

[biggzed]

My Head Quarters high compression 103 came with CP Forged pistons

Zach

what brand pistons were they?

[koko3052]

 
depending on how much gold that you want to part with... with everyone going to bigger motors ,there are a lot of 88's kicking around that can be had for a song! JMO

[Ultrashovel]

On thing to think about is the need to register any different engine against the title of the bike with the local DMV. That can be a hassle.

If you were to have a remanufactured motor installed, you get all new crankcases and cylinders with the same VIN number.

[prodrag1320]

My Head Quarters high compression 103 came with CP Forged pistons

Zach

what brand pistons were they?

it looked in the pic of the "peice" of piston left that it could have been a KB

[Sonny S.]

My Head Quarters high compression 103 came with CP Forged pistons

Zach

what brand pistons were they?

it looked in the pic of the "peice" of piston left that it could have been a KB

yeah they don't like to be kissed

[pauly]

G'day,

How was the camchain and gears?

Pauly

[wholehog]

That sucks. Pretty sure that I read on this site somewhere that the reman option requires motor to be removed and installed at HD dealer.

I think where it ended up is that a dealer install will get a longer warranty but self install gets a shorter warranty.....

as far as the VIN stamp on the engine...big deal.....just keep a copy of the bill of sale for the engine