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  #1  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
Senior Chief Master Mechanic
 
Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
Other Motorcycle Model: Honda GB400
Other Motorcycle Year: 1987
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Default Another 90" Hammer build.

So I have not only decided to go for a 90" build for my 2005 rubbermount 48,000 miles, based on SportyTrace's one, I have also decided to provide a bit of a writeup and some half assed photos!
I am not an IT guru so be gentle. But I will take extra shots and answer whatever I am able to.
So I want to do as much as possible myself because that's half the fun....besides the actual parts from Hammer of course.

Axtell XL 3.875 full cast iron cylinders
3.875 30 Degree Reverse Dome Piston, 80 CC Chamber
1.980 Intake 7MM
1.610 Exhaust 7MM
7 MM +.001 Intake Valve Guide
Sledge Head Porting Service 7mm on 883 heads Hammer had in stock
7MM Beehive Spring 600 Lift
7MM Titanium Retainer, 600 Lift
S & S Stud
560 lift Impact Hammer Performance Cam Set
Bronze Oil Pump Gear
Intake Pushrod 10.676 (-.050)
Exhaust Pushrod 10.730 (-.050)
Pinion needle bearings, all 4 sizes.
S&S premium lifters without travel limiters
Mikuni HSR 45 mm Carburetor
Billet Intake Manifold
Screaming Eagle Lefty Bearing
Twin Tec TC88A w/cable
BDL Competitor Ball-Bearing lock-up clutch
Air Hammer CRUSH Air Cleaner
XR Crank assembly

Last edited by splineman; 27th July 2016 at 01:41.. Reason: clarity
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  #2  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
Senior Chief Master Mechanic
 
Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
Other Motorcycle Model: Honda GB400
Other Motorcycle Year: 1987
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Default


The box was well packed, no problems there. Weighed 81lbs!


Into it.

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  #3  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
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Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
Other Motorcycle Model: Honda GB400
Other Motorcycle Year: 1987
Reputation: 487112
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Default





The lefty bearing was kinda loose...
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  #4  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
Senior Chief Master Mechanic
 
Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
Other Motorcycle Model: Honda GB400
Other Motorcycle Year: 1987
Reputation: 487112
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Default



This bearing was really loose and worn out. The seal was not leaking.
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  #5  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
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Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
Other Motorcycle Model: Honda GB400
Other Motorcycle Year: 1987
Reputation: 487112
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Default



My neat little press I got on special from "Supercheap Auto". It's pretty good but I also have access to an adult version if I need one. So far the bearings have been pretty easy to remove. The 5th gear mainshaft bearing pictured above just about fell out after I had the case in the oven! at 50 c for half an hr.

Last edited by splineman; 27th July 2016 at 01:26..
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  #6  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
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Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
Other Motorcycle Model: Honda GB400
Other Motorcycle Year: 1987
Reputation: 487112
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Default





Ready to go and ask a mate to use his mill to set up and case bore.
All the parts came away easily enough. The most trouble are those damn snap rings on the trans shafts. What a pain!
I disassembled the shafts a bit and then pressed out the mainshaft and countershaft alternately until the mainshaft came loose...then finished the countershaft. Harley have a stepped tool to press both at once but i'm cheap and this worked fine. None of the fits were really tight.

Last edited by splineman; 27th July 2016 at 01:31.. Reason: spelling
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  #7  
Old 27th July 2016
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rocketmangb rocketmangb is offline
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Join Date: Jan 2008
Location: So Cal
Posts: 20,750
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2006
Sportster/Buell Model #2: XL1200C
Sportster/Buell Year #2: 2006
Other Motorcycle Model: 48 "Totalled" By a Douche
Other Motorcycle Year: 2012
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Default

Horsepower Whores !
__________________
Thy Sportster Come
It Shall Be Done
On Earth as it is on Salt
2006 Sportster XL1250C
Hammer Sledge Heads 1.98X1.61 Valves
Hammer 600 Cams
Big Ass CP/Hammer Pistons
Mikuni HSR 45 /Hammer Billet Manifold (Now HSR 48)
Jetted 27.5 slow,182.5 Main
97 Needle,Clip posistion 3
Hurricane Flow 3" offset AC,Rocketman Mod
Daytona Twin Tec TC88A,Rico Scarecrow Map
Sumax Thundervolt plug wires,NGK DCPR8EIX spark plugs. Gapped .040 and Indexed
Cycle Electric Stator and Regulator
Alto Carbonite Clutch
Royal Purple 20W50 MC Primary oil
Patriot Defender Pipe
Royal Purple 20W50 MC Engine Oil
Napa 7148 oil filter
Max Power, 111.47
Max Torque, 84.39
Best 1/4 Mile ET to date 11.85
Best 1/4 Speed to date 115.14
Build by Jester Motorwerkz West
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  #8  
Old 27th July 2016
splineman's Avatar
splineman splineman is offline
Senior Chief Master Mechanic
 
Join Date: Apr 2011
Location: New Zealand
Posts: 917
Sportster/Buell Model: XL1200C
Sportster/Buell Year: 2005
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Other Motorcycle Year: 1987
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Default

HaHa the prostitutes of power!
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  #9  
Old 27th July 2016
rubine rubine is offline
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Default

Haha sounds good mate!
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  #10  
Old 27th July 2016
TX Dreamer TX Dreamer is offline
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Default

Goodie!!! Another 90" build!!! Can't wait to see the dyno numbers!

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