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25th February 2021
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Biker
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Join Date: Feb 2019
Location: Bradley Park
Posts: 93 Sportster/Buell Model: 883c Sportster/Buell Year: 2004 Other Motorcycle Model: Triumph Other Motorcycle Year: 1993
Reputation: 10

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Cant find (2001 Jugs/Pistons On 2005 Engine?)
Hi all can any of you boffins educate me. I have a 2005 883 sportster engine and been offered 2001 1200cc set of jugs and pistons. besides that bit of machining you do on the bottom fin will they fit ok. Can little fin fit on big fin rubber mount engines. Any info or direction to head down would be greatly appreciated.
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25th February 2021
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XL FORUM TEAM MEMBER
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Join Date: Feb 2013
Location: Let Freedom Ring in PA
Posts: 8,403 Sportster/Buell Model: Sportster 883►1200 Sportster/Buell Year: 1994
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http://hammerperf.com/tthoppingup1200.shtml
" As you can see, there's a pretty dramatic difference in the fin sizes between an 86-03 and an 04+ cylinder. This affects both appearance and cooling performance. While small fin cylinders can be made to fit onto 04+ bikes, we really don't recommend it as it compromises cooling and won't look right under the big fin heads that all 04+ bikes came with. On the other hand, putting the big fin cylinders onto an 86-03 bike will enhance cooling. Make your own judgment about whether or not that's a worthwhile trade-off for the appearance issue of putting large fin cylinders under small fin heads. On the other hand, if you're updating your small fin heads to big fin versions, going with big fin cylinders to match and improve cooling at the same time is a no-brainer."
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25th February 2021
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XL FORUM TEAM MEMBER
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Join Date: Jan 2008
Location: So Cal
Posts: 22,289 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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Be very careful with this
04 and newer have piston cooling jets and shorter pistons than 03 and earlier
Long early pistons will break the cooling jets
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27th February 2021
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A Million Facts & Figures
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Join Date: Jan 2005
Location: Famous Potatoes
Posts: 10,288 Sportster/Buell Model: XL883 Sportster/Buell Year: 2007 Sportster/Buell Model #2: Buell Cyclone Sportster/Buell Year #2: 1999
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Rocketman's comment is right on the money, the pistons will break off the oil squirters and then it's a full tear-down to fix it.
But also, flat top pistons under your stock 883 heads would result in a compression ratio of about 11.8:1.
So bottom line, the pistons really aren't compatible, and the cylinders are a giant step backwards. I'd pass.
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27th February 2021
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XL FORUM TEAM MEMBER
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Join Date: Jun 2011
Location: On a farm
Posts: 6,503 Sportster/Buell Model: XL77.2R Sportster/Buell Year: 2006
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I have small fin on my 2006 from Hammer, being in the firsts customers, I like the look of my engine. Anyways, heat go up and most of it is concentrated at the heads. Pistons are easy to cut; done numerous time on stroked engines.
Give me an angle grinders and here I go.
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3 Days Ago
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Biker
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Join Date: Feb 2019
Location: Bradley Park
Posts: 93 Sportster/Buell Model: 883c Sportster/Buell Year: 2004 Other Motorcycle Model: Triumph Other Motorcycle Year: 1993
Reputation: 10

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Thanks all for input. Sorted now
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2 Days Ago
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XL FORUM TEAM MEMBER
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Join Date: Jun 2011
Location: On a farm
Posts: 6,503 Sportster/Buell Model: XL77.2R Sportster/Buell Year: 2006
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Quote:
Originally Posted by 93trident
Thanks all for input. Sorted now
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What happen, how sorted it was.
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2 Days Ago
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Biker
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Join Date: Feb 2019
Location: Bradley Park
Posts: 93 Sportster/Buell Model: 883c Sportster/Buell Year: 2004 Other Motorcycle Model: Triumph Other Motorcycle Year: 1993
Reputation: 10

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Quote:
Originally Posted by rejeanprimeau
What happen, how sorted it was.
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My brother had a pair of tracker pistons that he was going to use on a project and my father had a pair of 2005 883 jugs in garage so gone down that route 
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