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Sportster Motorcycle Motor - Top End Discuss Sportster Motorcycle Top End issues. Rockerboxes, Valves, Cylinders, Pistons, Rings, Lift Rods, etc...

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cylinder, honing, top end

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  #1  
Old 4 Weeks Ago
T_worth T_worth is offline
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Join Date: Jun 2018
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Sportster/Buell Model: Xlh 1200
Sportster/Buell Year: 96
Reputation: 10
T_worth is an unknown quantity at this point
Default To hone, or not to hone

I'm doing a Top End Rebuild on my 96 1200 sporty. I pulled the cylinders and noticed verticle lines in my front cylinder. It's not necessarily scored as I don't feel any grooves on the cylinder wall. Smooth as a baby's butt. I can still see light honing marks, so I thought I'd do a few quick passes with a honing tool to freshen it up. I ordered standard size piston rings, I'm hoping I won't need any oversized rings if I do a quick honing job. Check out the photo https://imgur.com/a/KE8nPLZ

It's my first attempt at doing a rebuild and possibly honing. So any guidance and tips would be helpeful.
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  #2  
Old 3 Weeks Ago
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bustert bustert is offline
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Sportster/Buell Model: 1200s
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appears to be grit that went through the air cleaner.
a deglaze would be in order
however, you need to check taper, if excessive, new rings will not last long.
will she run, well yep. i have seen way worst.
using a sunen hone or ball scratcher?
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  #3  
Old 3 Weeks Ago
T_worth T_worth is offline
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Sportster/Buell Model: Xlh 1200
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When you say check taper, do you mean I should measure bore service wear at ring path; from 1/2in from top of cylinder front to rear and side to side, to center and bottom of ring path?

I think the honing tool at the garage is a surren. It’s very similar to this one (https://www.google.com/search?rlz=1C...21M05TpLWHLNM:)
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  #4  
Old 3 Weeks Ago
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bustert bustert is offline
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Sportster/Buell Model: 1200s
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yep
what turned up is a brake hone thingy
on larger or ill fit bores, it will bell mouth the bore due to the way the springs work
the sunen is straight and used a micro adjuster to expand.
if the taper is good or within spec, just use a ball scratcher do not have to get rambunctious.
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  #5  
Old 3 Weeks Ago
T_worth T_worth is offline
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Sportster/Buell Model: Xlh 1200
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Default

My FSM doesn't list any taper specs. However, using a telescoping gauge, micrometer, and multiple measurements of my best ability. I have noted the following median measurements for my front cylinder. These measurements are BEFORE deglazing/honing.

Top Front to rear: 3.4983
Top Side to side: 3.5009

Middle Front to rear: 3.4995
Middle side to side: 3.4986

Bottom Front to rear: 3.4990
Bottom Side to side: 3.4996

I don't know the specs for the cylinder to taper. What are the service limits on a tapering cylinder?
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  #6  
Old 3 Weeks Ago
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on the aluminum jugs, it is recommended that all measurements be made using torque plates. if not, there could be .001 diff in measurements.
the spec is
taper .002
out of round .003

also of interest is upper gasket surface warpage .006 and bottom gasket surface .008.
remember, the evo jug is in compression unlike the jug of the ironhead.
all measurement ref'd to factory new spec's.

does all of this matter, well yep and nope>
depends upon what you want, she'll probably run anywho but doing it right will make it last longer. that is what i like about the ironhead, was more forgiving than the chinese jugs.
1200 jugs are 3.4978 and service limit is 3.5008
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  #7  
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Turbo Sporty 48 Turbo Sporty 48 is offline
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Default

How many miles on the bike?
What are your goals and limits? Money, time, desired horsepower, skills...
Well, you can use a mic, good.
Torque plates, see it depends. Are you gonna break the glaze, put on new gaskets, assemble it clean and proper and ride, then do it. Are you going to put new rings, pistons, port the heads, cams, ignition kit,...then get the torque plates and do it proper.
Racers and old bikes have something in common, loose tolerances, one by design the other by wear.
Your ride, your time, your dime, enjoy.
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