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Sportster & Buell Motorcycle Racing Talk about racing your Sportster motorcycle and/or Buell motorcycle.

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89", clearance, engine, frame, s&s

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  #1  
Old 27th July 2012
arizona's Avatar
arizona arizona is offline
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Location: Seville Spain
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Sportster/Buell Model: XLCR
Sportster/Buell Year: 1977
Sportster/Buell Model #2: S&S 89"
Sportster/Buell Year #2: 2001
Reputation: 10
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Default 89ci S&S Sporty engine into 1990 frame

Hello all,

Recently purchased a 1990 four speed Evo Sporty for the sole purpose of replacing its stock 883 engine with a complete 89ci S&S Hot setup kit .Which also includes the S&S Super Stock cases. On paper this S&S engine in .465" taller than stock. The 1990 bike in mind has .650"clearence !!!!!!!!(most bikes are lucky to have .250” clearance ) at the tightest location (aft rocker box/frame tube).Removed 883 stock engine and tried to install the S&S to no avail. Looks as if we need to remove at least .250" off of the top frame rail directly above the aft rocker box .What went wrong?? Is the 4 speed evo frame different than the 5 speed? Is the kickstand area different?? S&S claims their slightly taller engines should fit 1986-2003 Sporty frames.
Thanks in advance, BC
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  #2  
Old 27th July 2012
Dakin Engineering Dakin Engineering is offline
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Sportster/Buell Model: XLH
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5 speed engines have the alternator up front right where the 4 speed kickstand mount is. I saw a Zipper's 100" in a modified frame. He shaved the underside of the backbone and welded in a flat plate above the rear head.

Sam
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  #3  
Old 27th July 2012
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arizona arizona is offline
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Sportster/Buell Model: XLCR
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Sportster/Buell Model #2: S&S 89"
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Reputation: 10
arizona is an unknown quantity at this point
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Good point...noticed a bit of scratching on the underside of clutch cover where the kickstand area is as we manhandled the engine onto the 1990 frame.I would do the same with the welding option on the backbone but first want to ensure engine will drop fit into frame.So far its a no-go.
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  #4  
Old 27th July 2012
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A 4 liter V8 eater A 4 liter V8 eater is offline
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Sportster/Buell Model: 883 Flat Track Racer
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Sportster/Buell Model #2: RIP 1200S
Sportster/Buell Year #2: 1999
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Quote:
Originally Posted by arizona View Post
Hello all,

Recently purchased a 1990 four speed Evo Sporty for the sole purpose of replacing its stock 883 engine with a complete 89ci S&S Hot setup kit .Which also includes the S&S Super Stock cases. On paper this S&S engine in .465" taller than stock. The 1990 bike in mind has .650"clearence !!!!!!!!(most bikes are lucky to have .250” clearance ) at the tightest location (aft rocker box/frame tube).Removed 883 stock engine and tried to install the S&S to no avail. Looks as if we need to remove at least .250" off of the top frame rail directly above the aft rocker box .What went wrong?? Is the 4 speed evo frame different than the 5 speed? Is the kickstand area different?? S&S claims their slightly taller engines should fit 1986-2003 Sporty frames.
Thanks in advance, BC
Please keep us updated on the build
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  #5  
Old 27th July 2012
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Sportster/Buell Model: XLCR
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Sportster/Buell Model #2: S&S 89"
Sportster/Buell Year #2: 2001
Reputation: 10
arizona is an unknown quantity at this point
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...before I start looking for a 1991 and newer solid mount 5 speed Sporty, you can bet I will do all that could be done to stuff that 89" into that 1990 4 speed frame.
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  #6  
Old 27th July 2012
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Sportster/Buell Year: 1986
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It´s a pretty tight fit at the rear cylinder on the four-speeds so you may have to heat that area of the frame and get the big hammer out to fit aything higher.
Just my opinion though.
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  #7  
Old 27th July 2012
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Sportster/Buell Model: XLCR
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Reputation: 10
arizona is an unknown quantity at this point
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If thats all thats needed than I can comply...I have been also told a heavy duty hydro jack can come in handy with the heat to just tweek the frame tubbing.Eventually,think I just might remove the aft rocker box top cover and try and fit S&S motor just to see how all else falls in place.
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  #8  
Old 27th July 2012
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Be shure, what ever you do, measure twice before starting banging to se if flattening will give you anough space.

Thankfully though, HD did not use any fancy steel alloy in those frames ( and the scale will tell) so some heat and force should not do any harm.

By heating just the area you are flattening, the rest of the frame should be OK.
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Old 27th July 2012
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Sportster/Buell Model: XLCR
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Sportster/Buell Year #2: 2001
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arizona is an unknown quantity at this point
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I have a good pulse on where the frame needs to be shaved and yes, will measure 30 times before and metal work begins...some folks even shave off some metal from the aft rocker box cover.BTW,here is Spain, a used Sporty (any year) costs at least 5k USD and I got a "deal" on this '90 for 3k Euros ($4k)
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  #10  
Old 27th July 2012
rontech rontech is offline
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Quote:
89ci S&S Hot setup kit .Which also includes the S&S Super Stock cases.
Is this an S&S sportster engine or a big twin EVO style? I didn't know S&S made a sporty engine. Should be interesting.
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