Build Profile — 1991 FXR

Sam's FXR 2.0

Owner Sam Smith
Engine S&S V111
Power 110 BHP
Gearbox Baker DD6
111 CU IN Displacement
110 BHP Est. Power
DD6 BAKER 6-Speed
1991 FXR Platform
V2 REBUILD The Upgrade

Dad's Influence

Sometimes it just needs a second build to get it all the way you really want.

Heritage, tradition, and history are all words chucked around whenever the topic of Harley's FXR series comes up. Especially amongst those old enough to have owned and ridden one when they were a current model between 1982 and 1994. Claims are made about the Erik Buell-designed chassis being the best-handling Big Twin ever rolled out of a crate branded Harley-Davidson.

"This FXR build goes way back for me," explained Sam. "I grew up messing around with BMX bikes in my dad's garage, just taking things apart to see how they worked. That turned into working on cars, and eventually I found my way to motorcycles — motorcycles have always been a big thing in my family, my dad and both uncles are all motorcyclists and have all been customisers."

His old man built some pretty cool Triumphs and metric cruisers back when Harleys weren't affordable in the UK. That first FXR was his dad's first Harley — sold because he was too busy raising Sam. The original paint on Sam's FXR 1.0 was a direct nod to that machine.

Sam's FXR engine bay and tank detail
Sam's FXR 2.0 street shot
Rider's POV — down the open road
Sam's FXR 2.0 rear three-quarter
The story behind 2.0 is as simple as I knew I could do better. I'm a bit of a perfectionist.
— Sam Smith
Sam's FXR 2.0 low rear angle

Built Better

Sam has built two very nice FXRs. FXR 1.0 ran the V111 engine with a stock swingarm and a black and silver paintjob. Then a mate started building an FXR. After looking and thinking, Sam bought the roller and parked it in the shed alongside 1.0.

He added all the good bits to 2.0 — the Metmachex alloy swingarm, Öhlins Blackline shocks, upgraded brakes front and rear. When it was ready, he pulled the V111 from 1.0 and dropped it into 2.0 before selling the roller on to his mate, who had plans for a Twin Cam conversion.

"I wanted the classic Harley black with ketchup and mustard '91-plus FXR paint, but with a bunch of flake added to the black to make it pop." The entire bike was built by Sam in his own garage — wiring harness included, made from scratch. "I actually enjoy wiring. It's the part people usually hate, but it comes easy to me."

An S&S V111 paired with a Mikuni HSR45 carb and Baker DD6 gearbox forms the heart of it all. "The FXR has always felt like a tightly wound spring. It's powerful now, but smooth. Way more fun than my Dyna."

In The Shed

Baker DD6 transmission going in
Drivetrain
Baker DD6 six-speed installed. S&S V111 long block and Mikuni HSR45 do the heavy lifting.
TwinTec ignition and wiring bay
Electrics
Daytona Twin-Tec ignition on a scratch-built harness. The part Sam actually looks forward to.
Full bike on the lift mid-build
Assembly
Metmachex alloy swingarm fitted. Racetech forks with gold valve emulators and Burly preload adjusters.
Sam's FXR 2.0 on an outback road
You're not sitting on it; you're sitting in it. It's raw, it's alive.
— Sam Smith

What Makes It

Engine
S&S V111
S&S 585 cam. Taylor leads, Powerplant coil cage. Thunderheader exhaust. Tuned by Brandon at Thunder Tech.
⚙️
Gearbox
Baker DD6
Six-speed overdrive. Barnett clutch hiding behind a stock-looking primary cover.
🔧
Suspension
Öhlins Blackline
Racetech springs and gold valve emulators up front. Metmachex full alloy swingarm — subtle and British.
🎨
Paint
House of Kolor
Custom black with heavy flake. Genuine 1991 FXRS Harley decals — took months to source the real thing.

Guts & Bolts

Engine
Type S&S V111
Cam S&S 585
Est. Power 110 BHP
Max Revs 6,200 RPM
Carb Mikuni HSR45
Air Cleaner San Diego Customs × HPI Hi Flow
Tuner Brandon — Thunder Tech
Ignition Daytona Twin-Tec
Leads Taylor Leads
Coil Powerplant Coil Cage
Exhaust Thunderheader
Transmission Baker DD6
Primary Stock Cover — Barnett Clutch
Frame & Suspension
Platform 1991 FXR
Front-End 2" Over Tubes
Lower Legs Harley 2000+
Fork Springs Racetech
Fork Mods Gold Valve Emulators, Burly Pre-load Adjusters
Rear Shocks Öhlins Blackline
Swingarm Metmachex — Full Alloy (UK)
Wheels & Brakes
Front Rim 19" HD Thunderstar
Rear Rim 16" HD Thunderstar
Tyres Michelin Scorchers
Front Calipers Harley 2000+ — BRAKING Rotors
Rear Caliper R1 Sumitomo — Metmachex Bracket, BRAKING Rotors
Controls
Bars Powerplant U Bends — 8" Risers
Gauge Mount Krispi Bits Custom
Gauges Motogadget Motoscope Mini
Grips ODI Vans
Seat Le Pera Daytona Tuck and Roll
Levers / MC Stock Harley — 11/16 Master Cylinder
Pegs Powerplant Footpegs
Controls Stock FXR Mid-Mounts
Kickstand Extended — FXR Division
Headlight Daymaker
Indicators Underperch LEDs
Tail Light Integrated Moons MC
Guards & Finish
Front Guard Cutrate Sport Fender
Rear Guard Stock Harley
Fuel Tank Stock Harley
Painter Simon — Motorcycle Panel & Paint
Artwork Genuine 1991 FXRS Harley Decals
Paint House of Kolor — Custom Black with Heavy Flake
Hardware Stainless, ARP & Titanium Throughout
Sam's FXR 2.0 — outback road profile
Sam's FXR build in progress on the lift
Sam's FXR 2.0 — rear street shot
I've met friends all over the world through the FXR community. That's what really sticks.
— Sam Smith

Keep Exploring

Sam's FXR 2.0 is one of several builds documented on TCFXR. Browse the collection or dig into our technical references for your own Twin Cam conversion project.