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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  
Old 24th April 2012
Screw Loose Dan's Avatar
Screw Loose Dan Screw Loose Dan is offline
I think I like Sportsters
 
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Sportster/Buell Model: 883L (sorta) & a 1200R
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Default Screw Loose's 90" Street Build - aka 2012 Refresh

Well, I've had the bike since August 2006 and put somewhere around 48,000 miles on her. In December of 2006 I had the now infamous "screw loose" moment in the hills of West Virginia and by February 2007 she had been converted to a 1212 with 883 stage 2 heads and 497 cams.

Those of you that have been here long enough will remember (have nightmares about??) the oil consumption threads back in 2007/2008. I was one of the "participants". The top end has been off my bike more times then a stripper spreads her legs in an evening, looking for insight and solutions to stop using oil since the conversion. (Somewhere in there I swapped the 497's for 536 cams.) I've been told the oil consumption issue has been addressed with proper rings, which I had put in. I still use more oil then I care to talk about. But, admittedly my bikes been abused. Also, the Harley shop that originally did my conversion did me no favors (gap rings??). So, there's always been question marks as to what and where the problem was. Ultimately, after obsessing for the first year or so I've continued to put oil in and just ride.

Long beginning to this story...

Now, the bike's been making a bit of a racket. First thought it was just an exhaust leak. Fixed an intake leak. Thought maybe a floating valve or something. Again, I haven't really babied it for those miles. Decided it was time to freshen things up. Had enough miles on her to warrant doing some work. Always wanted 1200 heads. Always longed for a true BIG bore (I chuckle when I see guys refer to 1250 as big bores).

But, I still want this thing to handle an occasional road trip. I have the 1200R now as a second bike and will likely use it for most of my trips. But, ya never know when a hot woman from Australia wants to come over and go on a road trip. So, the bike will need to be "streetable" and reliable. Everyone's definition of these things varies (remember, I've putting a quart or two of oil in at least every 1000 miles ).

The Plan: At this point most decisions are made, but I'm sure there will be some game day decisions.
  • 90" cast iron cylinders.
  • 1200 Heads with either Crush or Sledge head work (I'm currently leaning towards Sledge). 15° squish band and all the normal goodies from Hammer Performance.
  • RS585 Cams
  • Balanced and Carrillo rods for the crankshaft
  • Jims Lifters
  • S&S Roller Rockers
  • Assembled by Hammer Performance

There's a few compromises here. The cast iron even though it weighs a bit more, I want the added strength. The RS585 cams...that's been a tough decision but Hammer Dan and I discussed it at length and I think that's the best compromise. They are also proven performers in this configuration and I didn't want to go over .600 lift. The assembly - as much as I love tooling on my bike, a man must know his limits. You add these parts up and it becomes expensive. Remember - there's a reason for the Screw Loose moniker. So, I decided to have Hammer make sure everything fits together like it should. (I think it was Lenster's build where I saw the grinding on the cam chest that pushed me over the limit! )

A fair warning! This build will likely be the slowest moving on earth. I'm not in any sort of rush at this point. And most of the "juicy" stuff is being done by Hammer Performance.

But, I'd be banned if I didn't include some pictures. Here's removing stuff.

"Before"


Progress:




Took days to get the transmission sprocket off and buying more and more tools until I got it, so I have to include this picture...












Crated and ready to go:
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Screw Loose Dan
Current fleet:
2007 - 1200R (Orange bike)
2012 - XR1200X (XR)
2016 - 1200CX Roadster (new one)
2007 - 883L/90" -current project - (Black bike)
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  #2  
Old 24th April 2012
Rico 05R's Avatar
Rico 05R Rico 05R is offline
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Oh yeah a 90 inch thumper!!!
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  #3  
Old 24th April 2012
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ReddTigger ReddTigger is offline
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Default

Dam Dan.. Way to go..

So Now I'm like officially Jealous..
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  #4  
Old 24th April 2012
AustinXL's Avatar
AustinXL AustinXL is offline
Senior Chief Harley Engineer 2nd Class
 
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Figured something like this was coming when I saw the thread about engine shipping . Will be keeping an eye on this one, congrats Dan!

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  #5  
Old 24th April 2012
OmegaRunner's Avatar
OmegaRunner OmegaRunner is offline
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Default

Right-on Dan! I look forward to reading your write up as the project progresses. I dream of doing the same and sending my motor off to a professional. Someday...
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  #6  
Old 24th April 2012
td67mustang's Avatar
td67mustang td67mustang is offline
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Well now I'm subscribed! This is gonna be a fun one to watch.
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  #7  
Old 24th April 2012
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Gcram399 Gcram399 is offline
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Very nice selection of parts and having someone else doing the machine work and wrenching is a cool way to get what you want without having to worry about missing something. The only engine work I ever had done outside was the 454 in my 70SS. Too much $$$ involved to risk messing it up.
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Hammer Performance 1250 kit w/ 30* Reverse Dome Pistons, Smash Level 883 Heads w/ 1.770 Intake/ 1.615 Exhaust & PAC Alloy Beehive Spring Pack, Impact 560 Lift Cams, Hammer Billet Aluminum Intake Manifold, Air Hammer Naked Billet Air Cleaner w/ 3" K&N Element, Mikuni HSR 42, Dynatek 2000P Ignition, Energy One Clutch w/ 15% Diaphram, Muller Power Clutch, Basanni Road Rage 2-1 Exhaust w/ 4" Performance Machine Billet Tip. Drag Specialties 8-Bolt Encapsulated Rotor, Cycle Electric Regulator and Stator.
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  #8  
Old 24th April 2012
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Default

Congrats. You're going to love the TQ these big bores make. IMO, all sporties should have at least an 88"

Carillo rods??? Holy smokes, those are pricey!!! are you sure you need them? Are you going to be racing?

Check out EGNBLU 90". He had a crazy good dyno chart. Something like 100 ft lbs at 2000 RPM and stayed there I think until 6000.

He had your exhaust (D&D fatcat) and S&S 600 cams I believe.
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  #9  
Old 24th April 2012
Screw Loose Dan's Avatar
Screw Loose Dan Screw Loose Dan is offline
I think I like Sportsters
 
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Sportster/Buell Model: 883L (sorta) & a 1200R
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Default

Thanks everyone for the words of encouragement. I'm not quite at the point of uber excitement yet as it's still a long road ahead before I'm popping wheelies at will.

Quote:
Originally Posted by xlint89 View Post
Congrats. You're going to love the TQ these big bores make. IMO, all sporties should have at least an 88"

Carillo rods??? Holy smokes, those are pricey!!! are you sure you need them? Are you going to be racing?

Check out EGNBLU 90". He had a crazy good dyno chart. Something like 100 ft lbs at 2000 RPM and stayed there I think until 6000.

He had your exhaust (D&D fatcat) and S&S 600 cams I believe.
No racing, but I want reliability. And they aren't as expensive as I thought they might be (but it's all relative at this point).

I'm VERY familiar with EGNBLU's build. There's no doubt it was the seed that started all this.

You mention dyno numbers. And, I'm sue I'll be asked a bazillion times, so I'll mention...I'm not crazy about comparing dyno sheets. I think they serve a purpose and are a tool. But, it's not something I obsess over. Will I get it dyno'd? I'm sure. Will I share, probably. Numbers I'm shooting for? Conservative 100+/100+. It's more about the miles of smiles!

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  #10  
Old 24th April 2012
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Rico 05R Rico 05R is offline
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With Hammer Dan doing that 90 for you, it will be an ass kicker for sure.
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