I plan on begining my 03' 883r / Buell conversion within the next two months. my conversion will consist of HD 1200 cylindars, Buell Thunderstorm heads and pistons, HD SE 1200 ignition module, and HD SE cams. Ive been doing quite a bit of research on this and I think Im ready to begin the conversion. My question is for anyone who has done this type of conversion, is their anything I should know that is left out of internet articles or any problems you faced during the conversion I should know about?

Thanks for your help

Evan

The Thunderstorm heads use a 7/16" bolt and stud for the front engine mount. Also, it is spaced further aprart than the stock heads so you will need to get either 2 bolts @ 7/16" X 1-1/4" length or 1 bolt @ 7/16" X 1-1/4" lenght and one 7/16" X 1-1/4" lenght stud and a nut for the stud on the left side of the front head. You will also need to modify the front head mount bracket for the larger holes and spacing.

If you go with the 2 bolts (that is what I did) you will need to attach the front mount to the head before you put the head on the cylinder and torque the head down.

When doing the cams don't be surprised if when you take the cam cover off that all the cams stay with the cam cover. It is common for this to happen however the first time doing this you expect the cams to stay in position with the engine. so be prepared for this to happen.

Evan,

I did a T-Storm conversion myself. I am sure you are aware but just in case, my understanding is the new XB heads may be a little better than the T-Storms. Whatever the case, the T-Storms are excellent heads and a performance bargain. I assume you are going to be doing the work yourself judging from your post. I had a couple of issues with mine. The cylinders did not come off as easy as expected. Had to rotate the rear wheel several times and tap them gently with a rubber mallot. If you plan on changing the cylinder studs (as some recommend), you'll find very little info about it in the posts or service manuals. They are tricky to get off. I had to use a stud remover. There are two ways to install cylinders over pistons. One with pistons connected to the rod and one with the cylinder/piston on the bench. If you do it on the rod, you'll need a special ring compressor. I did mine on the bench and had to use a $6.00 craftsmen ring compressor. No problem. Another thing is the manifold wrench. You will need it to get the pesky manifold off. You can find the tool at a Home Depot in the appliance section marked as a garbage disposal tool. Will cost you about $5.99. Also, be vigilant in attaching the clamps at the base of the push rods. These things have a way of leaking if you don't get the o rings in just right. Other than that, it went step by step for me. It was alot of fun and a very worthwhile education. It runs very strong and is a total blast to ride.

Thanks alot guys!! Also are the head gaskets for the t-storm head the same as a stock 1200? I plan on using the S.E. head gaskets.

Thanks again
Evan

Thanks alot guys!! Also are the head gaskets for the t-storm head the same as a stock 1200? I plan on using the S.E. head gaskets.

Thanks again
EvanI use the SE high performance head gaskets. With these gaskets you don't need the o-ring that goes over the brass studs on the top of the cylinder.

Also, a couple of things that came to mind after reading the post from baddog.

You don't really need a ring compressor to install the pistons into the jugs, you can use your hands and fingers to compress the rings and install the piston into the cylinder before you connect the piston to the rod.

To do this place the cylinder upside down on a table. Smear some engine lube or oil on the inside of the cylinder wall a couple of inches at the bottom of the cylinder where the rings will contact the cylinder wall. Orintate your piston (Arrow points forward.) and install one retaining ring into the groove on the left side of the piston. This will act as a stop when installing the piston pin/wrist pin.

Next, put the rings on the piston and place the piston (Arrow forward.) into the cylinder. Use your fingers to compress the rings one at a time until the last ring is in. Leaving enough piston exposed for the wrist pin to connect to the rod and slip the cylinder with the piston in it over the cylinder studs, slip the wrist pin in and attach the retaining ring into the groove. (Rotate the rear tire until the connecting rod is at its lowest point before inserting the wrist pin.)

The trick to this technique is to get the ring started at one point and work it around in one motion. It's a little tricky at first but after you figure out a technique and get it down, it is extremely fast.

That's a good tip baddog has with the manifold wrench. I use a modified hex wrench with the ball end for this.

Also, as maddog pointed out those bottom seals on the pushrod covers are a pain in the ass. They don't seem to be consistant in size (Some are slightly larger than others and these work the best.) so I buy about 20 of these and use the ones that fit the best and return the others to the dealer.

Also, don't forget to replace all the gaskets, intake and exhaust, top and bottom pushrod cover, gear case, base gasket, head gasket, rockerbox gaskets, carburator manifold seal might as well be changed too. Did I forget any?

Thanks gyahmers!

Did you use the Buell piston kit with the t-storm heads? From looking at the Buell website it looks like the piston kit and heads only have one part number so I shouldnt have to worry about them matching my 03'. I know it sounds like a stupid question but the Buell website doesnt tell you they can be used on sportsters. Thanks again.

Evan

If you want you can use Wiseco pistons (K-1700) instead of the Buell pistons. They are a closer match (in weight) to the 883's so they tend to not increase the vibes after the conversion. The Buell will work fine and are slightly cheaper, I believe, just another option.

Thanks gyahmers!

Did you use the Buell piston kit with the t-storm heads? From looking at the Buell website it looks like the piston kit and heads only have one part number so I shouldnt have to worry about them matching my 03'. I know it sounds like a stupid question but the Buell website doesnt tell you they can be used on sportsters. Thanks again.

Evan
Yes, I used the Buell piston and ring kit - part # 22676-98Y. (Stock 1200 bore.)

If you go .30 over (on 1200 jugs) use part # is 22681-98Y. That's the .30 over piston and ring kit.

I know that you can use other piston and ring kits however, in this case I prefer to match the Buell parts. I went so far as to buy the Buell cylinders too. Just my 2 cents on the subject.

And, you are going to find that the rear head has a wire coming out of it. This is a sensor for the EFI on the Buell models. You don't need to concern yourself with that and can either cut it off or tuck it in out of the way.

Do you notice alot of vibration with this set-up? I have heard that the vibes are more noticable.
Evan

Do you notice alot of vibration with this set-up? I have heard that the vibes are more noticable.
Evan
Yes, the vibration did increase. I use a roll of pennies in each handle bar to help control the vibration there. Foot pegs are about the same. I also believe that some of the vibration is due to the SE .536 cams I have too. Kind of a high lift, and I have a 6800 rev limiter and keep the rpm's up a lot. That doesn't help, lol.

One of these days, when I go to an 88" I'll do the bottom end and have it balanced to reduce the vibs and find some rubber hardware for the motor mounts.

It's always a WIP as it is for most owners... :D

[QUOTE=Gyahmers]

You don't really need a ring compressor to install the pistons into the jugs, you can use your hands and fingers to compress the rings and install the piston into the cylinder before you connect the piston to the rod.

QUOTE]

Man, I tried and tried to do this way but despite all my efforts, I could not get the rings closed enough to slide the piston into the cylinder. So, I went and bought the low cost ring compressor. It worked extremely easy with this tool.

Man, I tried and tried to do this way but despite all my efforts, I could not get the rings closed enough to slide the piston into the cylinder. So, I went and bought the low cost ring compressor. It worked extremely easy with this tool.
It does take a little practice and you need to kind of wiggle the piston just slightly as you work the rings in.

I have also found (of all things) that a volkswagon ring compressor works extremely well.

That's a good tip maddog has with the manifold wrench. I use a modified hex wrench with the ball end for this.


Don't credit me...It was BADDOG's tip

That's a good tip maddog has with the manifold wrench. I use a modified hex wrench with the ball end for this.


Don't credit me...It was BADDOG's tip
Good eye catching that maddog -- it's been edited...

Thanks Maddog. No sweat Ray. I got the tip from another do-it-yourselfer so just passing it on. Evan, the fancy manifold wrench from one of the parts dealers will run you $24.99! Its the same stinkin' tool with the exception of one end having a ball end which is no big deal when removing or re-installing the manifold. I tried fashioning my own manifold tool using an old hex wrench and a dremel. Didn't work out as good as it did in my mind. Oh well, it was worth a shot.

One other tip for you. If you do not have a hex set with ball ends, it might be a good investment, at least one particular tool would. Its for the rear rocker box. At least one of the bolts is next to impossible to get off with out the ball end due to its position under the frame. Forget trying to torque it with a torque wrench. You'll have to do it by feel. I did make multiple trips to the Sears looking for the right tools to solve whatever problem cropped up (cha-ching). But, a man can never have to many tools!

Just out of curiosity, why would you use the older T-Storm heads when the 04' XB/1200 heads are readily available with an improved design?

I decided to go with the T-Storm heads because of the amount of articles I found on the subject. Basically because it has been well documented with little or no problems when converting with these heads. Also does anyone know the difference in weight between the 1200 pistons and the stock buell pistons. A local drag shop told me if they weigh more, the vibes will be more but it will not harm the motor in any way. I thought the buell pistons would be close in weight because they are forged.
Thanks for the tips guys!!!
Evan

You won't be dissapointed with your choice. They are very good heads. I bought mine at Chicago HD and I believe with shipping they were right at 250 ea. A bargin IMO.

I decided to go with the T-Storm heads because of the amount of articles I found on the subject. Basically because it has been well documented with little or no problems when converting with these heads. Also does anyone know the difference in weight between the 1200 pistons and the stock buell pistons. A local drag shop told me if they weigh more, the vibes will be more but it will not harm the motor in any way. I thought the buell pistons would be close in weight because they are forged.
Thanks for the tips guys!!!
Evan

Evan,

Did some quick research at sportster.org and found some numbers for you.
These weights are with the wrist pins, circlips and rings.

Buell-545g
1200 stock-517g
wiseco- k1700-471g
stock 883-425g

Looks like the Buells weigh the most. I used Nallin Hurricane pistons and wrist pins. Don't know the weight numbers so I can't comment on that. Vibrations don't seem to be bad though. Common wisdom is that you should choose a piston kit that approximates the weight of your 883 as closely as possible. The wrist pins play a big factor in weight. You can find lighter wrist pins to shave weight. Most people recommend the Wiseco's as they are closer in weight. Remember that the 883 runs at a higher rpm at highway cruising speeds due to the gearing. Something to consider when making your choice.

BD