Has anyone ever seen a 883 cylinder that has a flat spot (on the outside of the liner) when viewed from top (head gasket surface). Looks as if you bore it that you will be thru the liner. I cant tell how deep the flat spot is untill the machine shop continues boring.I thought all 883 cylinders could be bored to 1200s? Maybe Ive found 1 that cant be? Help...do I tell the machine shop to keep going or get another cylinder?

Wow!! That's the first time I've heard of that. Sorry I can't help but I would be most interested in any feedback as well.

keep going.....

I've never seen one that can't go to 1200....quite simply the outside diameter of the cast iron is bigger than the 3.5" ya need for the 1200 pistons.

You may have a slight casting imperfection on the top

And ya wont know untill ya get there :(

Never heard of anyone boring the cylinders, but I guess it could be done. Most of the
upgrade kits Iv'e seen come complete with pistons, rings and new cylinder heads, but
it's not cheap. Around 580.00 minus labor

When I had my HD 883 cylinders bored to 1200 there was a slight defect (void) in one of the sleeves. The finish honing did remove it, was low in the cylinder so I went with it. I have about 350 miles so far and no problems, time will tell. I was told that HD cylinders occasionally tho rare have this defect. Maybe BS? Are your cyls HD or aftermarket? Good luck!

Scince there don't seem to be any definitive answers to your specific question, I would suggest that if you have any doubts , pull it off the boring machine, cut your losses, and just buy replacement 1200 cylinders. Boring is generally done because the cylinders are already heat tempered from use and have less chance of getting out of round suposedly. But anything going wrong would certainly warrant rethinking the process. Just my .02

I would have thought that....

Keep going .......

was a fairly definative answer to his question as to whether he should keep going or not......

Without a photo to correctly identify what he is talking about we don't know untill he's actually bored out to that size.... as it will be bored to about 0.004" short of it's final size to allow for honing, we can than make a more acurate assessment then.

It would be far easier to leave it in the boring set-up and continue the process to completion than to remove it and try and make guesses as to whether it would have or wouldn't have...and wait untill he can get another barrell.

I would have thought that....

Keep going .......

was a fairly definative answer to his question as to whether he should keep going or not......

Without a photo to correctly identify what he is talking about we don't know untill he's actually bored out to that size.... as it will be bored to about 0.004" short of it's final size to allow for honing, we can than make a more acurate assessment then.

It would be far easier to leave it in the boring set-up and continue the process to completion than to remove it and try and make guesses as to whether it would have or wouldn't have...and wait untill he can get another barrell.


Good point. I based my suggestion on the fact that continueing the process costs MONEY. Machine shops charge by the hour. And as things generally go from bad to worse (second law of thermaldynamics) once they start going badly you start to throw good money after bad very quickly. But of course, ultimately it's his call.

Good point. I based my suggestion on the fact that continueing the process costs MONEY. Machine shops charge by the hour. And as things generally go from bad to worse (second law of thermaldynamics) once they start going badly you start to throw good money after bad very quickly. But of course, ultimately it's his call.



yeah $$$ is always the problem and it takes a few passes to bore an 883 barrell out to 1200...how many depends on the machine set up

But if it's already in the machine and it's had a pass or two thru it then pulling it out before it's done is maybe a bit premature...and is maybe wasting money if there is no prob.... and I've personally never seen an issue with this problem as described.

It becomes a judgement call which I could make without any problems if I was boring the barrels myself... unfortunately I'm not...and I don't even have a photo :(

That is true. Since there is no photo and not being there to actually see what is happening , it's hard to tell. but since his machinist was concerned enough to call it to his attention, I would err on the side of caution rather than risk it. But that's just me.

I'm curious...maybe another machine shop? Sounds like his guy is a bit nervous about it and that makes me question his experience. Not saying he can't do it or anything, but the machinist stopping the procedure concerns me. Seems he's put enough doubt in the customer's mind that I, personally, would consult another machinist...

But, hey, I'm just that way.....

Heres the deal,I went over to pick up the cylinders(they were promised to be done yesterday).When I got there he showed me the flat spot.I know he can do the work he just wants to be sure they are right.Ok I figured thats odd but keep boring.Ive never heard of anyone not being able to bore the 883s to 1200. Maybe someone else has come across this.Im getting a little nervous cause I need to put the bike back together NOW (Daytona is only 3 weeks away and a 950 mile ride ) and the cylinders have been at the shop for a month. I dont have time to take them any where else. Yes they are HD cylinders. Ill keep you posted as to the out come. Ill get a picture posted as soon as I get them back. I think Ill drop off my extra set of cylinders today just in case we decide not to use the odd one.

(Daytona is only 3 weeks away and a 950 mile ride ) and the cylinders have been at the shop for a month.

Wow, you're patient....I started raging after one week...got mine back in less than 2....

You know what? I'll just bet that it will work out fine for you....

it takes a few passes to bore an 883 barrell out to 1200...how many depends on the machine set up

http://www.nrhsperformance.com/pictures/883cylbore.jpg

The answer to that question would be one ;)

Seriously, you're right, LOTS of shops don't want to bore 883 cyls at all, because they have to do so many passes, it's time consuming and eats up tooling.

We do it in one pass, takes less than 2 minutes. Takes much longer to clean up the mess than to bore the cylinder. Does a nice job, too.

Which is why ya better off gettin a profesional to do the job ;)

Makes it a bit expensive for me to send 'em over to you tho Aaron :(

Another thing Aaron... as you've done more of these than I have... do you have any idea what the origional question pertains to????

The only thing I can think of is the there is a slight flat on the outside of the cast liner....can't say I can recall seeing anything like that on HD barrells..

[QUOTE=fbcrusier]Maybe someone else has come across this.Im getting a little nervous cause I need to put the bike back together NOW (Daytona is only 3 weeks away and a 950 mile ride ) and the cylinders have been at the shop for a month.

He's been a frickin' MONTH on the cylinders? My entire job, boring, heads and valves was only a week and a half. I would have been screaming long ago.

Hey went over and picked up the cylinders(might not be HDs after all )aint got no HD stamp on casting.Dropped off authentic HDs. Maybe problems solved. Yeah its been a month but i told him no hurry. I didnt even have the motor torn down yet. I thought the cylinders were HD (got em in a swap meet deal) I assume now that they arent.Any one need some 883 cylinders? Ones bored close to 3.5 one not! Ha Ha. Hey anyone else pay for 2.5 bore job? Ya live and learn. Moral to story:Some one out there makes an 883 replacement cylinder that cant be bored to 1200...beware.

Here is a picture of the cylinder http://www.xlforum.net/forums/attachment.php?attachmentid=1058&stc=1

I think you did the right thing sh*t canning them. Even if you had completeted the job, that flat spot looks like and excellent candidate for a major crack later. Go ahead and buy a conversion kit and be done with it. something to be learned here about swap meets I guess.

Yeah its been a month but i told him no hurry.


Recipe for a major pain in the ass and potential for disaster. NEVER tell that to anyone working on your bike.

turns out that the cylinders arent factory...any one need a set of cylinder papaer weights...how about bookends,door stop? Got my factory 883s bored and just got the bike put back together last nite. Cant wait to take it for a ride today. It sure sounds different. Its a 1228cc now with wiesco pistons and thunderstorm heads.

Never heard of anyone boring the cylinders, but I guess it could be done. Most of the
upgrade kits Iv'e seen come complete with pistons, rings and new cylinder heads, but
it's not cheap. Around 580.00 minus labor


I had my '97 cyl's done 6 yrs ago @ 4400 mi. $60 apiece. Got 23k mi with no problems.
Most guys get kits 'cause they don't have access to a machine shop with torque plates or want to do the wrenching themselves.
Boring is the better way to go if you have a few thou miles on the cyls..They're considered "Heat Treated" and will be less likely to oval or warp.

I know your going to enjoy that conversion. It's a different bike now...

turns out that the cylinders arent factory...any one need a set of cylinder papaer weights...how about bookends,door stop? Got my factory 883s bored and just got the bike put back together last nite. Cant wait to take it for a ride today. It sure sounds different. Its a 1228cc now with wiesco pistons and thunderstorm heads.

Awesome...glad everything worked out...!

Sounds to me like there's nothing to lose. 883 Cylinders and 1200 cylinders are the same casting. The liner is just bored more. If there is a problem with the cylinder, you're going to find out, but the only solution is to continue or throw it away at this point. Gotta agree with Stevo on that one.

shooter