Why did you go with a new motor, rather than rebuild your old one? Are there differences to the case (stronger?) with the 120 cui?

 

You cant build that kind of HP for what the 120R costs, considering that you can sell the old engine and get back some coin.

 

Is anything breaking or is the clutch just slipping? What clutch is failing and what clutch are you gonna use?

 

Sronger cases and different bottom end. 107 is the max the standard cases can cope with.

I have a 100HP 103 motor with 3,000 miles on if anybody wants to buy it.

 

.
.
.
the stock cases will go way beyond 107.

my 006 88" motor, for example, is now at 121".
.
.
.

 

Well we got stuck into it today, me and my son in law.

Tank and seat off first



I set the boy to work on the clutch and inner primary





Starter motor on 06 omwards is way easier to remove



Primary was off in minutes!



Rotor was hard to remove against the magnetic pull but the boy is some form of human tractor :-)



Next we dropped the regulator to reach the front mounting bolts



And undid the 4 gearbox bolts



After first jacking up the gearbox, you need to increase the jack height as you go to keep the gap between box and motor even



And before we knew it the old motor was out and standing on the floor!



We got so carried away by how easy it was that I forgot to take pic of the empty frame:-( and just dropped the new motor in...4 mins from grunt and heave to joy!



Now we are bolting it all up and I will take pics of the parts we have to swap over from the old motor plus the new shiny ones :-)



I'll be back.....

 

Mmmmm, the heads say it all...



Old inlet port



New inlet port..



Inner primary is back on and I have to get back to the workshop

 

Thanks for taking pics of this process. Very cool to "watch" the whole thing.

 

subscribed....

 

aside from selling the old engine, I looked at the 120R and what it would take to get it operating efficiently and found it to be about $8+K (me doing all the work) and for $5K I can get similar results with Star Racing doing the work on my current engine. So am opting for that route myself.