883 vs 1200? Crank shaft or any other lower end differences?

[FiftySixer]

Seems like every time I talk to a local independent HD mechanic, I get an opening statement along the lines of “ I’ve been at this for x many years and I know what I’m talking about and it’s X Y & Z. PERIOD”

Like a biblical quote of scripture that is TRUTH ABSOLUTE!

So the last guy I talked to about installing the hammer 1250 kit says that the crankshafts are different on the 2001 xl883 vs xl1200. He’s been at it 30 years and it’s just an inarguable fact.

I didn’t argue or contest his affirmations. Just politely said I’d get back to him.

As far as I was aware the only mechanical differences between the 883 bs 1200 are obviously the top end ( in this case all being replaced) and the gear drive from 27 to 29 tooth.

Internally in the case they are the exact same, Are they or are they not?

Veteran’s and experts please chime in.

Best regards, 56R

[FiftySixer]

An addendum to the above: My build list has changed only slightly:

I like the stock headers with the baloney slash cuts that I’m keeping those on the bike instead of installing the white brothers 2into 1’s I scoured the globe to find. I know I’ll be giving up 5-10 ponies but as others here have told me based on my parts list I should be getting 105-110 at the wheel with the 2 into 1 and giving up a few ponies by keeping the stock exhaust to be around 100 or close to it is ok by me. I love they way they look and I love the way they sound.

MY BUILD PARTS LIST: Hammer Performance 2004+ Big Fin 1250 kit with Flat top pistons, 2004+ XL 1200 Heads NEW built by Hammer,
Hammer 570 Cams, 42mm Mikuni HRS Easy kit, Twin Tech Single fire coil, Twin Tech Ignition, Hammer billet manifold,
S&S Roller Rockers, New Push Rods, Telescopic push rod tubes, Hammer 3" Air Cleaner & Filter,
Pingle High Flow petcock, 04+ oil pump & bronze gear/Chrome White Brothers 2 into 1.

[Hippysmack]

Here is the case/crankshaft page in the Sportsterpedia.
http://www.sportsterpedia.com/doku.p...:evo:engmech01

It seems wheel assemblies from 86-94 did change from 883/1100/1200.
Same assemblies/rod part numbers from 95 - 02

(edit, the rod changes for 2000-2003 are in the SP)

Cases were the same respectively for 883/1100 883/1200

[shanneba]

The 2001 part number for the Crank/flywheels , connecting rods, bearings is the same for the 883 and 1200-

23905-00A SET OF FLYWHEELS AND SHAFTS, w/ thrust washer, plug, crankpin, connecting rods, bearings & flywheels ALL

Here is a link to the 2001 XLH parts catalog:

2001 XLH MODELS PARTS CATALOG

[IXL2Relax]

One must be careful to make a distinction (sometimes) between what parts came from the factory as stock that year and what was eventually made to retro-fit later (and previous) models. Sometimes, there were differences in various parts.

My 1994 parts catalog shows the 883 flywheel/rod set as 23905-89.
It also shows that the 1200 flywheel/rod set was 23900-90. Supposedly, the 1200 versions were balanced differently than the 883 versions to account for differences in the piston weight.

My 2002 parts catalog shows P/N 23905-00 as applicable to both 883 & 1200.

In the sportster.org days, it was considered better to upgrade the 883 with Wiseco 1200 pistons (which were closer to the weight of the 883 pistons) than to start with a 1200 engine - less mass in motion.

Correction - From the SP - The 1995 year model was the conversion point that began using the 883 flywheel/rod set in both 883 & 1200 engines.

So - It is important to be year specific as to what WAS INSTALLED and what CAN BE INSTALLED.


One other point. The HD online parts catalogs are mostly late-year catalog versions for earlier model bikes. I found many of these online parts catalogs are 2018 versions even when intended for models from 20-years earlier. They generally are for identifying the currently available parts and may not reflect what was installed at the factory when the bike was built.


IXL _______ >>>> My Motorcycle Chronicles Are Here <<<<
For Sportster Tech Info:
Ride The Sportsterpedia - A Toll-Free XLForum Information Highway!

[FiftySixer]

Ive come to the decision that I’m pulling the engine crating it and sending it to hammer so the job is done perfect without question.

I’ll be eating the shipping to and from but from my point of view a god investment.

W

[John Harper]

I don't see anything in your build parts list that you can't do yourself. You can do it! Save your money for some cocktails to celebrate your build!

John

[Scuba10jdl]

Originally Posted by IXL2Relax

Supposedly, the 1200 versions were balanced differently than the 883 versions to account for differences in the piston weight.

This is the reason. They commonized the cranks by using a common balance factor. Previous to that they used different balance factors between the 883 and 1100/1200 models.

[FiftySixer]

John Harper: thank you brother but I’m not equipped with the right tools, don’t have a decent work space and with little to no mechanical experience I’d rather spend the money than morn screwing up the motor. I love the bike too much to risk it. The bike is almost dead mint with 9k miles on it.

Also thanks scuba10jdl and Shannon’s for the clarification.

Best regards, FiftySixer

[Turbo Sporty 48]

Originally Posted by FiftySixer

Ive come to the decision that I’m pulling the engine crating it and sending it to hammer so the job is done perfect without question.

I’ll be eating the shipping to and from but from my point of view a god investment.

W

Have you checked with Hammer?
Sometimes they are so busy, tax time is huge for them.