1990 FXR Rebuild: Engine


The Engine is what I wish I had the most documentation on, but unfortunately, it's what I have the least amount of documentation on. When I first started - one of the main issues with the bike was that the carb seal was blown - and the engine ran really hot. So much so that stuff was literally melting off the bike and the exaust pipes were cracked right at the headers so badly that when the heat shield got removed, I found I was going to have to replace the exhaust.

Mickey took the engine out and put it on a stand during the rebuild. He asked me one day what I wanted to do about it. I could tell he wanted to send it out, and I agree'd with him. The engine was a big unknown. I had no idea how long those seals were blown and I also knew that there was a problem with the primary drain plug and I wasn;t sure how much gunk was getting drained out of the system when changing the oil.

So I decided to send it out to the Harley engine re-manufacture program. It was simple too, I didn;t have to fill out anything, Mickey just packed and shipped it for me and it came back about 3 or 4 weeks later.

Unfortunatley with no paperwork. I could see they swapped a ton of parts out when rebuilding the engine, but there was no paperwork. Bummer.

EVOLUTION® ENGINE
1340 V² EVOLUTION
Fits '84-'98 Big Twin, '99 Softail® and '99-'00 CVO Dyna® models.
16108-99A Silver and Polished 1340 V2 $1,995
16007-99A All Black 1340 V2  NEW $2,195
16107-99A Black and Chrome 1340 V2 $2,295
19115-99A Silver and Chrome 1340 V2 $2,295

I wish I had documentation on the engine remanufacture. The oil pump looks brand new, at the minimum, all the fittings sure are new. One of the things Mickey notices was some scraping wear on the outside of one of the oil lines. I thought about using friction tape, but instead Mickey changes the configuration of the lead line from the oil tank under the seat. It used to reside above the clutchbox along the top of the tranny, then up the frame to the oil tank. Not he ran it underneath the tranny with the other oil lines, which they changed on the FXR in the next model year, 1991. Mickey also custom fabricated a support bracket for the 3 oil lines from the oil tank, keeping them more secure up against the frame, as well as keeping them from laying right on the tranny. The oil line that was re-routed is also shielded in heat mesh to keep it from rubbing the hose where it does touch the transmission as it curves underneath from it's fitting on the oil pump.

 

Engine (Before) Engine (After) Motormount (Before) Motormount (After)

Mickey pulled the engine and put it on a stand before it got sent out for remanufacture.

The engine came back a few weeks later - they replaced a lot of parts...

The front motormount was one of the 1st items on Mickey's list when he first got the bike, you can see here how the rubber was literally falling off the thing.

The front motormount replaced with a newer style.

Cam Timer Cover Intake Manifole (Before) Intake Manifole (After)

The Timer Cover on the right side of the bike next to the brake pedal..

The carb seals were blown and I was afraid that as the exhaust was cracked right at the engine, this piece would fare less fortunate too - but it was fine.

The same carb intake manifold painted by Mickey and ready to accept a 40MM Klein CV carb.
Timing hole cover Oil Lines Before Oil Lines after engine rebuild Oil Lines After

Mickey was working on the timing and had this out - got a chance to see some of the solvents and lubes he uses for different pieces.


The oil pump before the engine rebuild. Note the old hose fittings.


I can't be certain because I have no paperwork from the rebuild - but I'd say this is a new oil pump.

The top hose has been rerouted underneath the assembly. Harley changed that 1 year later in 1991, so Mickey rerouted the hose now for me, plus he used a nylon mesh to prtect the hose form rubbing.
Oil Line Bracket:      

This is a piece of an old air cleaner cut out to fit onto the frame and hold all 3 of the oil lines coming out of the oil tank under the seat. It holds them in place against the frame and not rubbing up against the back of the drivetrain.
     

 

<Back>

 

1990 FXR Rebuild: Chassis
Swingarm | Frame | Wheels & Tires | Handlebars | TripleTree

Swingarm

The swingarm was not in too bad of a shape. It was repainted and most of the bolts swapped out. It was lubed up on reassembly.

Swingarm Before

The rear tire was one of the first things replaced. Mickey had a tough time getting the rear axle out - a lot of the swingarm hardware got replaced.
     

 


Frame

http://www.flickr.com/photos/bignurd/4914907694/


Wheels & Tires

rebuilt back wheel

speedo cable thing in front


Handlebars

bushings, chrome light cover-led indicators, new wiring

http://www.flickr.com/photos/bignurd/4914908536/


TripleTree

http://www.flickr.com/photos/bignurd/4914907868/

http://www.flickr.com/photos/bignurd/4914908366/

http://www.flickr.com/photos/bignurd/4914304569/


 

<Back>

 

1990 FXR Rebuild: Drivetrain
Primary (Roller Chain) | Transmission | Clutch | Secondary (Belt Drive)

Primary (Roller Chain)

cover painted to match engine, hole plugged

Transmission

Clutch

thrower

Secondary (Belt Drive)

 

<Back>

 

1990 FXR Rebuild: Suspension
Front Sliders | Shocks | Seat

Front Sliders

Shocks

Seat

 

<Back>

 

1990 FXR Rebuild: Brakes

As Mickey tore down the bike, one of the first things he wanted to change design wise was to switch to a 4 piston front brake. The brand new assembly is from a 2001 Sportster. This required new front sliders which I'll talk about in the chassis section and a new brake cable with a boot and pushrod assembly. In the controls section the hand controls got swapped out for a newer style. The rotor was still good.

When replacing the rear tire, Mickey pulled the rear brake and disassembled it and painted it, then reassembled the brake, keeping the original calipers and rotor.

The brake switch for the footpedal was completely melted off the bike from the engine running so hot with blown carb seals. The Footpedal and brake arm were replaced in the rebuild with higher quality parts. The brake linkage was redesigned and much simpler. One of the pins was actually missing from the original linkage.

The rear brake pushrod and boot assembly is under the rear brake reservoir very close to the exhaust pipes. The FXR originally had longshot straight pipes which were installed such that the brake linkage was actually hitting against the side of the exhaust pipe. Another problem was that the brakerod was installed such that It was making contact with the Master Cylinder boot at an angle, causing the master cylinder instead of compressing straight back it compressed at an arc, limiting pressure to close the caliper. A pretty serious safety issue. The rear brake resivoir is the OEM part - the front brake resevoir is new - a part of the hand control upgrade I performed.

The pipes were cracked and I knew they'd have to come off but mickey actually custom fabricated a new rear brakerod. It has threads at both ends with custom connectors to allow for adjustment in both play at the master cylinder end to control how far down I have to push the footbrake before closing the rear caliper but also at the front end of the pushrod allowing play in the footbrake linkage to set how high or low to position the footbrake to fit my foot on the pedals properly. In the exhaust section I talk about the shortpipes I put on the decision making process there. But they are fitted to the bike properly and not causing issues like the last ones.

Rear Brake Before: Rear Caliper : Rear Caliper Reconditioned: Front Caliper Before:
New Front Caliper Footbrake Linkage Front Master Cylinder: Rear Master Cylinder:

 

 

<Back>

 

1990 FXR Rebuild: Electrical
Turn Signals | HeadLight | Hand Controls | Panel | Starter | Coil | Voltage Regulator | Battery | Wiring Harness | Horn

Turn Signals

HeadLight

Hand Controls

Panel

Starter

Coil

Voltage Regulator

Battery

Wiring Harness

Horn

 

<Back>

 

1990 FXR Rebuild: Air

Fuel-Air-Spark. Basic requirements to run an engine. Air was a big problem on this bike. The Carb seals were blown to extra air was getting into the engine making it run very lean. Running lean = running hot. So stuff was LITERALLY melting off the bike. The brake switch mounted right underneath the blovk was literally melted away. The exhaust when the heat shield came off was cracked right at the mount onto the exhaust manifold. You could literally see inside the pipe.

Mickey put a new OEM# 27421-99C Klein CV carb in.

 

Keihin CV Carb OEM# 27421-99C Carb Before (seal leak) Carb Before

This is a Kehin CV Carb. It's not a new part - but it's low mileage and new to this bike.

This is a Kehin CV Carb. It's not a new part - but it's low mileage and new to this bike.
This was the carb on the bike when I first brought it in. The main problem with the whole project was that the Carb Seals were blown and the engine was running hot.
This was the carb - you can see how fuel was leaking from blown carb seals and from the looks of it there were small fires on the carb.
EVO Big Twin breather Kit New air filter Original Foam OEM element  
This is the new breather assembly. As it's not OEM for this carb - a custom milled extender had to be milled for mounting this off the engine - so fitment of this piece was weight bearing and snug to fit on the carb.

New air filter. This looks to me like one of those Arlen Ness filter kits - maybe a "Stage 1 - Big Sucker" (20% more horsepower).

Old air filter. OEM: 29259-89
 

 

 

<Back>

 

1990 FXR Rebuild: Exhaust

a

b

c

d

e

f

 

<Back>

 

1990 FXR Rebuild: Controls
Hand Controls | Foot Controls | Linkage

Hand Controls

Foot Controls

Linkage

 

<Back>