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

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  #1  
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Default Boring 883 Cylinders to 1200

Does anyone know what the minimum length of 883 cylinder skirt (spigot) can be?

I am boring out 883 cylinders to 1200 and because of the rather heavy chamfer on the skirt or (spigot) of the 883 cylinder, then the length of the skirt (spigot) becomes a lot shorter as the cylinder bore ID is increased, just wondering if anyone knows how short of a cylinder skirt is still acceptable.
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What year cylinders? You can't bore out the 2008+ cylinders to 1200cc. I'm also not familiar with stock Sportster cylinders that have spigot clearance cuts, which begs to question what you're boring?

http://sportsterpedia.com/lib/exe/fe...in:tsb1267.pdf

Before that it's no problem. The spigot really shouldn't even be an issue as you just bore it to size and run it.
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When I did my 883>1200 conversion (about 2001), I bought brand new 883 cylinders. The original cylinders had fin damage from the wreck by the PO.

I did this so I could have the cylinders bored to EXACTLY match my new Wiseco pistons. It was common knowledge that the factory 1200 pistons had imprecise boring and I wanted a best-fit for the Wiseco pistions.

As Scuba mentions, as long as they are 2007-earlier 883 version cylinders and you are using any kind of standard 1200 pistions, you should be able to bore them to your needed specs without issues. Be sure torque plates are used during boring.


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I have a pair of 2002, 883 take off's. About 8000 miles on them. Contact me if interested.
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Quote:
Originally Posted by IXL2Relax View Post
When I did my 883>1200 conversion (about 2001), I bought brand new 883 cylinders. The original cylinders had fin damage from the wreck by the PO.
if i were in this position needing new cylinders i would be inclined to buy 1200 cylinders and eliminate the costly boring expense?i have an 883 myself and i'm still waying my options.3'' bore to 3-1/2'' is a lot of material to remove.no one has mentioned the heads yet.i'm fairly certain i won't be reusing 883 heads.one look at the comparison picture with Aaron on the 883/1200 bathtub chamber heads on the youtube thread convinced me.
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Quote:
Originally Posted by brucstoudt View Post
if i were in this position needing new cylinders i would be inclined to buy 1200 cylinders and eliminate the costly boring expense?
It was that important to me to have a precise piston fit, that if _I_ went with 1200 cylinders, I would have gone to a .010 over piston, just so I could have the cylinders bored to exactly the clearance I wanted...

I never intended to hotrod/race my ride, so I wasn't interested in the expense of custom performance heads. I bought a set of Lightning heads off someone on the Sportster.org List (and quite a number of other parts from various members).

My 75-80hp with 80tq has been very satisfying. With so many options now available (like Hammer stuff), it becomes harder to pick what you want. Of course, finding a great buy on some better (than std 1200) heads, gives you a head start (financially) toward a reasonable solution.


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Quote:
Originally Posted by IXL2Relax View Post
It was that important to me to have a precise piston fit, that if _I_ went with 1200 cylinders, I would have gone to a .010 over piston, just so I could have the cylinders bored to exactly the clearance I wanted...

I never intended to hotrod/race my ride, so I wasn't interested in the expense of custom performance heads. I bought a set of Lightning heads off someone on the Sportster.org List (and quite a number of other parts from various members).

My 75-80hp with 80tq has been very satisfying. With so many options now available (like Hammer stuff), it becomes harder to pick what you want. Of course, finding a great buy on some better (than std 1200) heads, gives you a head start (financially) toward a reasonable solution.
Just as an option you might look at the Zippers Torkster kit. Yes they rework the 883 heads but still give 75hp and loads of torque thru the full range.
Bructstoudt something to consider for you considering you have the CV. Save a few bucks and send in yours.

Last edited by Folkie; 3 Days Ago at 15:09.. Reason: Fixed quote
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i like the advantages of the '04>bath tub chamber heads. https://www.youtube.com/watch?v=F9d-AJ3R6Js
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Quote:
Originally Posted by brucstoudt View Post
i like the advantages of the '04>bath tub chamber heads. https://www.youtube.com/watch?v=F9d-AJ3R6Js
Of course it's your decision just pointing out another option for lot's less expense.
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As far as I know a 1200 boring does not change the length of the shirt, only the thickness.
I've done a bunch of those conversions on my bikes and customers.
I prefer boring seasoned cylinders that came on the bike rather than buying new ones.
Boring ($100) is a lot cheaper than new cylinders.
My machinist has the torque plates and does a great job.
Also this allows the machinist to fit your new pistons to the cylinders.

As said before this is for 2007 and older.
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