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  #1  
Old 4th December 2019
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Default Pre-rubber stock exhaust to '08 heads and cylinders

I have 2008 OEM 1200 heads, cylinders and pistons I would like to adapt to my 2002 XL883C. It's obvious that my original exhaust mounting hardware will work on my bike. My question is ..... will my stock header pipes fit onto the 1200 heads and clear the larger fins on the late model cylinders and heads? I know I will need the wider carb manifold, flanges etc. Just wondering if there will be a clearance problem with the header pipes? Forward controls of course.
Any input will be greatly appreciated.

olrider
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  #2  
Old 5th December 2019
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Exhaust should fit just fine !
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  #3  
Old 5th December 2019
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Default Pre-rubber stock exhaust to '08 heads and cylinders

Thank you rocketmangb.
I have a starting point now for a winter build. Much appreciated.

olrider
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  #4  
Old 5th December 2019
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You probably will need the wider manifold but I have of success with the short manifold
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Old 5th December 2019
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Default Pre-rubber stock exhaust to '08 heads and cylinders

I've heard that it's been done successfully with the stock carb manifold. When I get started on this, I'll mock the top end up and check clearances. BTW, the listed specs on that 2006 Sportster XL1250C of yours sound awesome. I don't need that much (wouldn't know what to do with it) but it's great to see folks are still building hot sportsters. I have always loved my slightly modded 883 and I'm sure the 1200 conversion will be really nice. I didn't mention before but the '08 heads I acquired have been refurbed and ported. The porting was obviously machined (very clean and minimal) and looking up the ports the valve seats are blended in really nice.

Thanks, olrider

Last edited by olrider; 5th December 2019 at 01:53.. Reason: additional information
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Old 5th December 2019
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Sounds good !!
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Old 5th December 2019
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You'll also need the bracket that bolts the front head to the steering neck area. Your stock one won't fit. The one you need is part number 16689-05. You can get it from your dealer, and we also have them in stock.

One more thing, use the pushrods from the 1200 as well. They're a little shorter (.020) than your stock ones because the heads are a little shorter. This is especially important if you're also using .030 head gaskets, which helps tighten the squish clearance.
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Old 6th December 2019
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Default Pre-rubber stock exhaust to '08 heads and cylinders

Thanks Aaron,
I'll make sure to get those components. Your input is much appreciated.

olrider
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  #9  
Old 8th December 2019
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Default Pre-rubber stock exhaust to '08 heads and cylinders

Can I use my stock '02 pushrod tubes or will the length interfere with torqueing down the shorter '08 heads?

Thanks,
olrider

I hope NRHS doesn't mind me quoting their website on the writeup about XB/04XL (up) heads ..... "Stock XL rocker boxes bolt right up and the stock XL pushrod tubes work fine." Thanks.

Last edited by olrider; 16th December 2019 at 23:44.. Reason: Found answer.
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