The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Motor / Engine > Sportster Motorcycle Engine Conversions
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Sportster Motorcycle Engine Conversions Advice, questions, and tips for 1200, 1250, 1340, 1450 etc... for Sportster and Buell motorcycle engine conversions

Active Threads
0 Hi From NJ
Last Post: Calcustom
Posted On: 8 Minutes Ago
Replies: 15
Views: 238
0 Cost of ejikation
Last Post: owlsplace
Posted On: 11 Minutes Ago
Replies: 1
Views: 134
0 What did you do for your sporty Today?
Last Post: Skuzeee
Posted On: 13 Minutes Ago
Replies: 6,140
Views: 780,404
0 Pushrod cover seals
Last Post: owlsplace
Posted On: 26 Minutes Ago
Replies: 4
Views: 45
0 Best way to 883->1200cc ?
Last Post: aswracing
Posted On: 45 Minutes Ago
Replies: 13
Views: 415
0 Clutch issues
Last Post: rocketmangb
Posted On: 53 Minutes Ago
Replies: 10
Views: 261
0 Primary will not seal
Last Post: Toejam503
Posted On: 1 Hour Ago
Replies: 2
Views: 22
2 Memory Highway
Last Post: Toejam503
Posted On: 1 Hour Ago
Replies: 0
Views: 8
0 Tillotson Welch Plugs
Last Post: Coz
Posted On: 1 Hour Ago
Replies: 0
Views: 17
0 Hardtail frame conversion with 3" stretch and avoiding a chain conversion kit
Last Post: rokytnji
Posted On: 2 Hours Ago
Replies: 6
Views: 192
0 28 years later..
Last Post: USAFpj
Posted On: 2 Hours Ago
Replies: 29
Views: 1,071
0 2010 xl 1200 low solo seat fit
Last Post: jharback
Posted On: 2 Hours Ago
Replies: 5
Views: 140
14 HD ad for Dirt?
Last Post: gusm2
Posted On: 3 Hours Ago
Replies: 2
Views: 153
0 Bearing questions
Last Post: bustert
Posted On: 3 Hours Ago
Replies: 12
Views: 445
0 Turn signals and switch required 1972 xlch
Last Post: bustert
Posted On: 3 Hours Ago
Replies: 4
Views: 148
0 ....1
Last Post: Graywolf
Posted On: 3 Hours Ago
Replies: 4,918
Views: 288,988
0 What's your opinion on windshields?
Last Post: jharback
Posted On: 4 Hours Ago
Replies: 1,181
Views: 198,484
10 Show your bike next to a Cow
Last Post: mick42
Posted On: 4 Hours Ago
Replies: 18
Views: 623
0 Hello from oklahoma
Last Post: Veeflys
Posted On: 5 Hours Ago
Replies: 16
Views: 271
0 Triumph or Harley!
Last Post: Veeflys
Posted On: 5 Hours Ago
Replies: 10
Views: 471
0 New Member
Last Post: Veeflys
Posted On: 5 Hours Ago
Replies: 21
Views: 482
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Stairman
Posted On: 6 Hours Ago
Replies: 44,376
Views: 6,968,394
0 Hottie of the day, no nudity.
Last Post: Stairman
Posted On: 6 Hours Ago
Replies: 12,288
Views: 1,120,597
0 What engine oil do you use?
Last Post: Tomcatt
Posted On: 6 Hours Ago
Replies: 466
Views: 92,425
0 Cold Start. Then stall
Last Post: Tucsonmax1
Posted On: 7 Hours Ago
Replies: 10
Views: 311
0 Greetings from Queens
Last Post: shanneba
Posted On: 7 Hours Ago
Replies: 14
Views: 177
0 From Illinois with my first sporty
Last Post: Highly-Dangerous
Posted On: 7 Hours Ago
Replies: 22
Views: 1,041
0 Front end swap
Last Post: stalkie
Posted On: 8 Hours Ago
Replies: 11
Views: 572
0 once a cheater always a cheater?
Last Post: Glamazon
Posted On: 8 Hours Ago
Replies: 38
Views: 4,089
0 Removing oil pump
Last Post: Highly-Dangerous
Posted On: 9 Hours Ago
Replies: 32
Views: 816
More...
Members Birthdays
oakies, Gunhappy2 (61), SamIam (55), biggdann (49), boyer911 (49), danii (42), PVD24 (40)
Sponsored Links
Reply
 
Share Thread Tools Display Modes
  #11  
Old 13th May 2011
Arnie's Avatar
Arnie Arnie is offline
Biker
 
Join Date: Mar 2011
Posts: 24
Sportster/Buell Model: 883 Sportster
Sportster/Buell Year: 2003
Reputation: 10
Arnie is an unknown quantity at this point
Default

Great pics!
Reply With Quote
  #12  
Old 13th May 2011
921200hd 921200hd is offline
Master Mechanic
 
Join Date: Apr 2010
Posts: 275
Sportster/Buell Model: 92 sportster 1200
Sportster/Buell Year: 92
Sportster/Buell Model #2: my other ride has tits
Reputation: 1227
921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about
Default

sweet instructions with color pics looks good so far i hope to see more pics
Reply With Quote
  #13  
Old 13th May 2011
Phillober's Avatar
Phillober Phillober is offline
Master Custom Bike Builder
 
Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,398
Sportster/Buell Model: XL1250
Sportster/Buell Year: '02
Reputation: 329678
Phillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond repute
Default

Now to get the wrist pins out, wasn't easy, they didn't just slide out. I searched the forum and found some great advice, some use a C clamp, some a threaded rod to help push the pin through... however all I had laying around was this giant bolt... which I guess is the same as a threaded rod


I stuck one end into the pin (wasn't worried about damage since the 1250 kit comes with new pins). I tried pushing, but what worked best was to actually start threading it into the pin while applying pressure


then I pulled it, and it came out a bit before the threads gave


no worries, I then took the bolt to the other side and pushed the pin out the rest of the way


pin comes out, piston comes off like butter, and now you can see the connecting rod, pin and piston all seperate


now you have the connecting rod left, we'll hook up the new pistons to that, also the book says the be careful around the studs (the 4 big long bolts sticking out of the engine cases, 4 for each cylinder), not to bend or hit them or they might fail... suggests putting some tubing over them but I don't have any tubing so I just played it safe.

next the book says to take out the tappets, I started to remove the base plate


but these were sumsofbeaches to get moving too, then I ran into this


out of a fear of stripping a bolt I stopped, however this was just on the rear cylinder, the front cylinder came out fine. I didn't actually remove the tappets until I got the cam cover off


placed a bowl underneath to catch oil, didn't have to drain the oil before doing this but a bit did fall out when the cover came off


and then it just swings out, there's still an oil line coming from the oil tank and the ignition module is still connected to the cam cover so I couldn/t take it completely off, notice the cams stuck to the cover
__________________
2 time XLForum Fantasy Football Champion!!
Reply With Quote
  #14  
Old 13th May 2011
921200hd 921200hd is offline
Master Mechanic
 
Join Date: Apr 2010
Posts: 275
Sportster/Buell Model: 92 sportster 1200
Sportster/Buell Year: 92
Sportster/Buell Model #2: my other ride has tits
Reputation: 1227
921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about921200hd has a spectacular aura about
Default

what size of bolt did you use for the wrist pins ?
Reply With Quote
  #15  
Old 13th May 2011
Phillober's Avatar
Phillober Phillober is offline
Master Custom Bike Builder
 
Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,398
Sportster/Buell Model: XL1250
Sportster/Buell Year: '02
Reputation: 329678
Phillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond repute
Default

The other side of the cam cover, notice i haven't drilled off the timer cover yet


ok, I'm not actually pointing to the hole there but notice what's directly above my finger, that's the bottom of the tappet peaking his little head out, they rest on the cams and as the cams spin the tappet's move up and down, since the tappets sit below the push rods they push those up and down as they move, if you go back to the rocker box pics, you see the top of the push rod sits under the rocker arm, which is connected to the valve springs which open and close the valves as they move


and if I push the tappet up, they come out of the top, (you must remove the push rod tube bases and loosen the bolts at the base of them - the horizontal ones in this pic, you can see one sticking out farther than the other one by the tappet I'm pointing to)


and here is Mr. Tappet, soak them in oil while doing the rest of the work



Back to the cam case, cams just slide right out. Well all except big #2, I have to get the timer cover off first to get that one off


Here's the tappet holes without the tappets, you can compare this to the pic above when they are still in there


And this is as far as I've gotten on the 1250 conversion. I mailed Dan the heads today and I don't have a drill to get the rivets off the timer cover to finish the cams. so far this has been about 7 hours of work over 2 days

I still have some more pics though

here is a comparison of the 883 and 1250 cylinders


upon closer examination you can see my old 883's are roughly 3 inches in diameter


and the 1250's are 3.5 inches...oooohhhh yea!!
Reply With Quote
  #16  
Old 13th May 2011
Phillober's Avatar
Phillober Phillober is offline
Master Custom Bike Builder
 
Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,398
Sportster/Buell Model: XL1250
Sportster/Buell Year: '02
Reputation: 329678
Phillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond repute
Default

Quote:
Originally Posted by 921200hd View Post
what size of bolt did you use for the wrist pins ?
Looks about a 1/2 inch

Reply With Quote
  #17  
Old 13th May 2011
~Grind~ ~Grind~ is offline
XL FORUM LIFE MEMBER
 
Join Date: Oct 2009
Posts: 3,291
Sportster/Buell Model: 1200C
Sportster/Buell Year: 04
Reputation: 2164565
~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute~Grind~ has a reputation beyond repute
Default

Great thread! That bolt looks to be a 1/2-13. Please keep those pics and comentary coming. You're doing a great job!
Reply With Quote
  #18  
Old 13th May 2011
Phillober's Avatar
Phillober Phillober is offline
Master Custom Bike Builder
 
Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,398
Sportster/Buell Model: XL1250
Sportster/Buell Year: '02
Reputation: 329678
Phillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond repute
Default

I decided to see what was inside my carb, seeing as I'll probably have to re-jet, here's the bottom of the carb, if I'm not mistaken (correct me if I am) the flat head screw at the bottom of the page is the mixture screw. these normally have a plug over them from the factory which require being drilled out in order to properly tune the carb. looks like mine has been drilled


Time to check the jets, there's 4 screws on the bottom of the carb that need to come off


those come off easy, then the bottom of the carb just slides off, notice the half rusted looking metal rod at the top of the pic, this slides through the rubber hosing at the bottom of the pic (you can see the hole it goes into), the half rusted rod isn't bolted to anything and can easily fall out, no worries, just don't lose it


in the above pic, the thing I pulled off is called the float bowl, it has gas in it, mine was actually pretty dirty with debries and junk floating around

Here is the bottom of the carb with the float bowl removed


in the above pic you'll notice 2 round brown things in the center next to a round hole, the bigger bottom round brown thing is the main jet, it takes a flat head screw driver and comes out easy


and here is the emulsion tube with the main jet stuck into it from the bottom


then a much smaller screw driver goes in the deep hole in between the two round brown things, this is the pilot jet. it only takes a handfull of turns to loosen completely, don't sit there for 8 min waiting for it to come out, it's small, after a handful of turns of the screwdriver just turn the carb over and it'll fall out



here's where it says "170"


and the "42"
Reply With Quote
Sponsored Links
  #19  
Old 13th May 2011
SuicideCharley's Avatar
SuicideCharley SuicideCharley is offline
Bike Builder
 
Join Date: May 2010
Location: Fresno, Ca
Posts: 1,878
Sportster/Buell Model: 1200S
Sportster/Buell Year: 1996
Reputation: 31791
SuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to allSuicideCharley is a name known to all
Default

Hell yeah! You're finally doing it, and showing much more patience than I did. I missed a lot pics because I was rolling, looking good man. I'm stoked for you!
Reply With Quote
  #20  
Old 13th May 2011
Phillober's Avatar
Phillober Phillober is offline
Master Custom Bike Builder
 
Join Date: Aug 2009
Location: Dallas, TX
Posts: 3,398
Sportster/Buell Model: XL1250
Sportster/Buell Year: '02
Reputation: 329678
Phillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond reputePhillober has a reputation beyond repute
Default

Alright, that's all I have so far, going to round up a drill and finish the cam install as soon as I can, then I just have to wait for Dan to do the heads

I'll continue to be overly thorough with pics
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



Sponsored Links
All times are GMT +1. The time now is 17:56.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC