Hello All,

I am a expat Canadian in China, here for a few more yrs. Normally my bike purchase or project was going to be upon returning back, but that would only be in several yrs. What a coincidence that my neighbour from Germany used to build custom H-D bikes in Germany, so we have recently decided to build 1 bike each over here. I think it is not very commom here, it will be a very interesting project to say the least.

I'd like to post some prilimnary specs on my bike project, and post a few questions here and there. I would also invite, and be very happy to recieve any kind of comments reagrding my post. Thanks alot in advance ::

Spec ::
-Engine: 80 CID Big Evolution 1984-1991. Engine will be set-up for sure as phase 1, possibly phase 2 with cam/head hopefully reaching 75-80hp.
-Carb: S&S Super E or G
-Frame: Softtail style, rake approx 40 deg
-Wheels: Rear Aluminum approx 220mm, Front maybe spokes or aluminum.
-Forks: Dia41 polished maybe wide-glide style
-Tank:3,5 gal 1 pcs TBD
-Transmission: Stock H-D 5 speed or Baker 5 speed. (Would like some comments about this)

The bike(s) will be done in phases so we need to define the priliminary things, meanwhile I need to make sure everyything is compatible with the entire project. Any comments on any of the above would surely be appreciated.

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I'd like to start with a couple of questions.

1) Engine: If I choose an older used 80 CID evolution (approx 1985), my friend a mechanic says that we would disassemble and refurbish / clean (lightly or not so likely bore out) the cyclinders, refit / replace pistons etc. With the expectation of having a A class motor, pushing approx 70-80 horses minimum what are the typical steps or risks we could take ?

2) Frame: For choosing the appropriate frame, could someone mention some possible custom frames approx 38-40 deg rake, softail style? What I would like to know is what are all the precautions i should take ? For example what mating parts (such as transmission, forks,) should i exactly have defined before selecting the frame ? Which frames (there are a ton out there) are the ones I should consider ? Is it possible to obtain / purchase the design and drawings of such frames ?

Thanks alot in advance,

wow...sounds like a fun build...but will the PRC allow the parts to be shipped in...?
The HD big book has an evo $2995.95 5 spd $1695.95
JIMS valve train w/.510 lift and .235 I .242 E duration cam, wiseco forged pistons "e" carb w/thunderjet and a thunderheader will give you the HP your looking for... might want to smooth out those exhaust ports also....I've seen kits from Ultima complete drive line w/6 spd for under 3K

My buddy has a little rigid with a 80" Evo HD powertrain from their book. He recently had the heads done and put in a little better cam and that thing is like a new bike! Granted it's pretty light, but you've got to really hang on now! FUN!

Out of boredom one day I built a virtual bike useing that setup for under 10K

I've thought about doing that, but I keep coming back to '85 or '86 FXWG. First of the evos, last of the solid WG. Buy one used and clean it up. No title or insurance woes. That's just me.

Those WG's are real hard to find, your right about the solid mounts but they also didn't have the 5 spd, it was still a 4 spd frame...I thought about that too...
when you buy one of those evo's out of the catalog it comes with a Harley title...you have to sign a waiver saying it will be used with all EPA mandated emmission controls...Yeah Right...

I'm pretty sure it comes with an MSO. Unless you put it into a previously titled bike, anything you built would still be a 'custom built vehicle'. And I don't mind the 4 speed if I'm not burning the freeway.

you might be right with that MSO stuff, I had ass-u-me-d it came with an HD title...

Yeah we have considered this issue. At first, we thought we would label the engine as a compressor or pump, something that would not trigger the customs agent (My friend has a good relationship with the customs officer in another city). It usually has to do with which HS code the parts are classified by for entry and duty %. But one company in Hong Kong (subsiduary of USA company which I won't name) says they can get the parts through.

You can find all the catalogs here. You can also pick up a copy from any dealer for free.

MSO is likke a VIN right? I had not thought about that .. What would be the complications of a "custom built vehicle" ? Tax, insurance, etc ??

This is what my old school friend is choosing, but i get the feeling that at some "some" highway or freeway miles will be had ..

MSO is the Manufacturers certificate of origin. It's documentation of where that unit/parts came from. You need this to register what ever the MSO goes with. "Custom built" sometimes causes additional steps to register and insure the vehicle and in some areas, it has to be inspected by the state too. You must have all documents for all parts purchased with part numbers/prices etc on them.

All I can pass on is what my friend had to do in IA to register the bike he had with HD engine and tranny out of the HD catalog and a custom frame, kinda like what you're talking about.

He had to have the MSO for the frame, tranny, and engine taken to the DOT and they checked the numbers on the pieces to the numbers on the MSO. The record these in the database, but I don't know those details. The DOT also stamped a VIN into the frame using their number stamps. This is what the bike is titled under. He also couldn't get anything but liablity insurance for it because it was a custom build. I have no idea what excitement you might be in for here.

Excellent project! The only thing I might suggest is that you consider the Baker DD6 gearset for a 5-spd. case, or just the complete tranny. You will probably want to do some travelling around on the bike when you are done, and the 6-spd might make that more comfortable.

Thanks alot for all your replies, it's been really helpful so far.