Forgot to mention Dragos Bikeworks, another excellent choice.

 

contact info for Keven Baxter http://protwin.com/index.aspx

 

Good luck with the least dollars part.

If you want to performance the engine some more you are looking at P&P on the heads, new pistons, cams and all components chosen to get you to the right corrected compression as a system. You are also looking at a new, larger throttle body, roller rockers, higher performance tappets, adjustable pushrods, etc., then a re-tune.

Your bike is an '04, so it has not been stroked. You may think about taking the bottom end apart, installing the stroker crankshaft then you can achieve 103" or 107". While you have the bottom end apart do the timken LH main bearing mod.

So, all of that should add up to about $6K - $7K. Now you are in the neighborhood of a crate motor. How about a S&S 124"? That is why I asked how much do you want to spend.

Since you have all of that torn apart, let's go ahead and install the 6 speed tranny. Do you see what I mean - there is no end to what you can do. Oh yeah, we are going to need to address the clutch, too. While we are at, we should probably install an oil cooler.

 

The budget question is fair and one you have to think about. You cannot increase displacement of the 88" engined beyond 98" without removing the lower unit to bore the cases for larger pistons and/or install a 4.375" crank. Do both and you could go as larges as 117", but, as previously posted, the cost for all that is going to put you close to the cost of a 120R crate motor; a step change.

So basically, you have three routes you can go; bore your cylinder to fit new pistons for 95" or 98" displacement, work the heads, new cams, valve train and re-tune. A combination of components that play well together and about $2500 later, you should be happy.

The second route is spending more money to go bigger, i.e., lower unit work; Lefty main bearing; new crank, trued, balanced and welded; new cylinders/pistons, headwork, cams, valve train, etc. and about $5-$6K later, you're done.

The third route is the crate motor route. H-D 120R is the best crate motor deal going now; some discount dealers are selling them for under $5000.

So, how much do you want to spend? IMHO, you can achieve your goal following through Door #1.

 

By the time folks get their arms around a 120R, with t/body, by rights roller rockers, GOOD pipe, clutch enhancement, labor, f/f/plugs, your well over 7 large.
Scott

 

A couple years ago you did some work and your already looking for more. Of course budget will dictate how far you can go, with this said, build the biggest baddest motor you can, whether it's a build or a crate because the bug will hit you again.

 

About 3 hours up the road in Americus, GA is Star Racing. Give them a call as well. NO ONE will know more how to make power/speed than they will, if thats what you are after. A G2 126" will give even the fast guys on the road fits.

 

Is it running a canned map or did you get it dyno tuned.
If it's a canned map I will bet some tuning will turn out a few extra hp and torque.
Remote tuning isn't perfect because each bike is different. My mustang ran a canned map from sct which equalled 266rwhp and 302ft/lbs torque.
I got it dynotuned and got 280 and 325 ft/lbs torque.
That is power you can feel. And cost me 3 hours dyno time.
Try a dyno tune unless you really want to throw money at it. The S&S 124 is a bad boy for sure

 

absolutely the G square -126 is no joke, neither is the price; but for $5400 you can get a S&S 111 with a three year warranty for Star racing as well

 

Star does have that T111 yes. I just gave him a shop's info that is kinda close to his house, as he was asking for. If he is considering an engine swap and wants REAL power, not just playing around, the the 126 is the only real answer in my mind. But as you stated his budget and his desire for power(and his ability to handle it) should be his guide.