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| techtalk:evo:engmech03 [2022/03/29 03:48] – [Pistons & Rods] hippysmack | techtalk:evo:engmech03 [2025/10/01 04:21] (current) – hippysmack | ||
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| ===== Cylinder Pressure Test ===== | ===== Cylinder Pressure Test ===== | ||
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| It is important to make a check of your cylinder pressure (aka engine compression) as soon as you obtain your bike and, at least, on an annual basis thereafter. This is a great reference value to determine if the pistons, rings, cams, lifters, pushrods and valves are all functioning correctly together. Over time, these parts wear and your cylinder compression will reflect when these items should be checked, adjusted or replaced. | It is important to make a check of your cylinder pressure (aka engine compression) as soon as you obtain your bike and, at least, on an annual basis thereafter. This is a great reference value to determine if the pistons, rings, cams, lifters, pushrods and valves are all functioning correctly together. Over time, these parts wear and your cylinder compression will reflect when these items should be checked, adjusted or replaced. | ||
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| To check your cylinder pressure, you need a compression tester/ | To check your cylinder pressure, you need a compression tester/ | ||
| - | **Using The Compression Tester**((http:// | + | **Using The Compression Tester**((https://www.xlforum.net/ |
| * Run the engine to get it up to operating temperature (maybe a 10-15 minute ride) | * Run the engine to get it up to operating temperature (maybe a 10-15 minute ride) | ||
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| Compression test results vary on stock models but, typical rule-of-thumb is a minimum of 120PSI for 883 engines & 150PSI for 1200 engines,\\ | Compression test results vary on stock models but, typical rule-of-thumb is a minimum of 120PSI for 883 engines & 150PSI for 1200 engines,\\ | ||
| but on 2004+ the 1200 engine minimum should be 180PSI. | but on 2004+ the 1200 engine minimum should be 180PSI. | ||
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| \\ | \\ | ||
| ===== Cylinder Leakdown Test ===== | ===== Cylinder Leakdown Test ===== | ||
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| If you find you have low compression in a cylinder, you will want to do a Leakdown Test. This test will help determine the location of the leaking air, such as worn exhaust valves, worn intake valves, leaky head gaskets, or worn rings. | If you find you have low compression in a cylinder, you will want to do a Leakdown Test. This test will help determine the location of the leaking air, such as worn exhaust valves, worn intake valves, leaky head gaskets, or worn rings. | ||
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| To perform the test, you will need an air compressor, a Leakdown Tester (around $50 online) and something to listen for air leaks, like a mechanics stethoscope (with the probe removed) or a length of oil line hose. (A small air compressor can be had for under $100, but if you purchase one that can produce 5cfm or more at 90psi, you can use it for some air tools as well.) | To perform the test, you will need an air compressor, a Leakdown Tester (around $50 online) and something to listen for air leaks, like a mechanics stethoscope (with the probe removed) or a length of oil line hose. (A small air compressor can be had for under $100, but if you purchase one that can produce 5cfm or more at 90psi, you can use it for some air tools as well.) | ||
| - | **Using The Leakdown Tester**((http:// | + | **Using The Leakdown Tester**((https://www.xlforum.net/ |
| * Run the engine to get it up to operating temperature (maybe a 10-15 minute ride) | * Run the engine to get it up to operating temperature (maybe a 10-15 minute ride) | ||
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| There are many variables here [engine temperature, | There are many variables here [engine temperature, | ||
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| \\ | \\ | ||
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| ====== Cylinders ====== | ====== Cylinders ====== | ||
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| ==== Boring Cylinders ==== | ==== Boring Cylinders ==== | ||
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| Final cylinder bore sizes after honing. ((1986-1990 HD XLH FSM)) | Final cylinder bore sizes after honing. ((1986-1990 HD XLH FSM)) | ||
| ^Bore Sizes^883cc^1100cc^1200cc^ | ^Bore Sizes^883cc^1100cc^1200cc^ | ||
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| Take note:\\ | Take note:\\ | ||
| - | Since the 2009 model year, the 883 cylinder construction changed dramatically and you can no longer bore them to 1200 at all.((aswracing comment at http:// | + | Since the 2009 model year, the 883 cylinder construction changed dramatically and you can no longer bore them to 1200 at all.((aswracing comment at https://www.xlforum.net/ |
| \\ | \\ | ||
| ===== Check Your Cylinder Size With a Straw ===== | ===== Check Your Cylinder Size With a Straw ===== | ||
| - | 883 or 1200? - Check like this: ((Decman of the XLForum - xlforum.net/ | + | 883 or 1200? - Check like this: ((Decman of the XLForum - https:// |
| * Put in 5th gear | * Put in 5th gear | ||
| * Lift rear wheel | * Lift rear wheel | ||
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| | Evo Sportster Head Part Numbers | | Evo Sportster Head Part Numbers | ||
| |Year|Model|Front \\ Part#|Front \\ Casting# | |Year|Model|Front \\ Part#|Front \\ Casting# | ||
| - | |1986|883|16661-86|16663-86 ((MOREHP of the XLFORUM | + | |1986|883|16661-86|16663-86 ((MOREHP of the XLFORUM |
| - | |1987-1988|883|16661-87 \\ *16661-86B \\ *16661-86A|16663-87 ((chopper69 of the XLFORUM | + | |1987-1988|883|16661-87 \\ *16661-86B \\ *16661-86A|16663-87 ((chopper69 of the XLFORUM |
| - | |1989|883|16661-86B \\ *16661-86A|16663-86B \\ *16663-86A ((kino44 of the XLFORUM | + | |1989|883|16661-86B \\ *16661-86A|16663-86B \\ *16663-86A ((kino44 of the XLFORUM |
| |1990|883|16661-86A|16663-86A|16660-86A|16662-86A|Includes valve guides / seats.| | |1990|883|16661-86A|16663-86A|16660-86A|16662-86A|Includes valve guides / seats.| | ||
| - | |1991|883|16661-89A|16663-86B ((Maxeffort of the XLFORUM | + | |1991|883|16661-89A|16663-86B ((Maxeffort of the XLFORUM |
| |1992|883|16661-92|16663-86B|16660-92|16662-86B|Includes valve guides / seats.| | |1992|883|16661-92|16663-86B|16660-92|16662-86B|Includes valve guides / seats.| | ||
| |1993-1997|883|16661-89B|16663-86B|16660-89B|16662-86B|Includes valve guides / seats.| | |1993-1997|883|16661-89B|16663-86B|16660-89B|16662-86B|Includes valve guides / seats.| | ||
| |1998-1999|883 \\ except 883R|16661-92A|16663-86B|16660-92A|16662-86B|Includes valve guides / seats.| | |1998-1999|883 \\ except 883R|16661-92A|16663-86B|16660-92A|16662-86B|Includes valve guides / seats.| | ||
| - | |2000-2003|883|16661-89B|16663-86B ((Shu of the XLFORUM | + | |2000-2003|883|16661-89B|16663-86B ((Shu of the XLFORUM |
| |2002-2003|883R|16867-02| | |2002-2003|883R|16867-02| | ||
| |2004-2006|883 \\ except 883R|16661-04|16663-04|16660-04|16662-04|Includes valve guides / seats. \\ Silver. Last year carbed.| | |2004-2006|883 \\ except 883R|16661-04|16663-04|16660-04|16662-04|Includes valve guides / seats. \\ Silver. Last year carbed.| | ||
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| |2005-2006|883R|16867-05| | |2005-2006|883R|16867-05| | ||
| |2007-2016|883R \\ 883N|16867-07|16663-07|16865-07|16662-07|Includes valve guides / seats. \\ Black. EFI.| | |2007-2016|883R \\ 883N|16867-07|16663-07|16865-07|16662-07|Includes valve guides / seats. \\ Black. EFI.| | ||
| - | |1986|1100|16688-86|16682-86 ((dave76 of the XLFORUM | + | |1986|1100|16688-86|16682-86 ((dave76 of the XLFORUM |
| |1987|1100|16688-87| | |1987|1100|16688-87| | ||
| |1988-1990|1200|16688-88|16682-87A|16698-88|16684-87A|Includes valve guides / seats.| | |1988-1990|1200|16688-88|16682-87A|16698-88|16684-87A|Includes valve guides / seats.| | ||
| - | |1991|1200|16688-90| | + | |1991|1200|16688-90|16682-87A|16698-90|16684-87A|Includes valve guides / seats.| |
| - | |1992|1200|16688-92| | + | |1992|1200|16688-92|16682-87A|16698-92|16684-87A|Includes valve guides / seats.| |
| - | |1993-1997|1200|16688-90A| | + | |1993-1997|1200|16688-90A|16682-87A|16698-90A|16684-87A|Includes valve guides / seats.| |
| - | |1998-1999|1200 \\ except 1200S|16688-92| | + | |1998-1999|1200 \\ except 1200S|16688-92|16682-87A|16698-92|16684-87A|Includes valve guides / seats.| |
| - | |2000-2003|1200 \\ except 1200S|16688-90A| | + | |2000-2003|1200 \\ except 1200S|16688-90A|16682-87A|16698-90A|16684-87A|Includes valve guides / seats.| |
| |1998-2003|1200S|16630-98|16641-96YA|16633-98|16643-96YA|Includes valve guides / seats. \\ Black. Dual plugs.| | |1998-2003|1200S|16630-98|16641-96YA|16633-98|16643-96YA|Includes valve guides / seats. \\ Black. Dual plugs.| | ||
| - | |2004-2006|1200|16667-04|16874-02 ((rocketmangb of the XLFORUM | + | |2004-2006|1200|16667-04|16874-02 ((rocketmangb of the XLFORUM |
| |2007-2016|1200 \\ except 1200N \\ except XR1200 \\ except XR1200X \\ except XL1200X \\ except 1200CP \\ except 1200CA \\ except 1200V \\ 1200CB|16667-07| | |2007-2016|1200 \\ except 1200N \\ except XR1200 \\ except XR1200X \\ except XL1200X \\ except 1200CP \\ except 1200CA \\ except 1200V \\ 1200CB|16667-07| | ||
| |2007-2016|1200N \\ XL1200X \\ 1200CP \\ 1200CA \\ 1200CB|17485-07| | |2007-2016|1200N \\ XL1200X \\ 1200CP \\ 1200CA \\ 1200CB|17485-07| | ||
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| \\ | \\ | ||
| Torque Sequence: \\ | Torque Sequence: \\ | ||
| - | {{: | + | {{: |
| If you put an 88-03 style piston into an 04+ bike, the skirt on the side will smack into the oil squirter and break it off. \\ | If you put an 88-03 style piston into an 04+ bike, the skirt on the side will smack into the oil squirter and break it off. \\ | ||
| - | It's a full tear down to fix. ((aswracing of the XLFORUM | + | It's a full tear down to fix. ((aswracing of the XLFORUM |
| - | |Stock 88-03 1200 piston. \\ Notice how there' | + | |Stock 88-03 1200 piston. \\ Notice how there' |
| |{{: | |{{: | ||
| + | |||
| ====== Pistons & Rods ====== | ====== Pistons & Rods ====== | ||
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| The piston pin clips used on all Evolution models changed in color from silver to bronze during the 1992 season. \\ | The piston pin clips used on all Evolution models changed in color from silver to bronze during the 1992 season. \\ | ||
| This was a manufacturing request for visual verification of installation during assembly. \\ | This was a manufacturing request for visual verification of installation during assembly. \\ | ||
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| |{{: | |{{: | ||
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| ====== Rocker Arms ====== | ====== Rocker Arms ====== | ||
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| - | ====== Pushrods ====== | ||
| ====== Gaskets ====== | ====== Gaskets ====== | ||
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| Gasket thicknesses are especially useful when setting squish clearance. ((Tomcatt of the XLFORUM)) \\ | Gasket thicknesses are especially useful when setting squish clearance. ((Tomcatt of the XLFORUM)) \\ | ||
| - | The squish band is the quench area. ((rocketmangb of the XLFORUM | + | The squish band is the quench area. ((rocketmangb of the XLFORUM |
| The idea is to create turbulence in the chamber which helps the fuel air mix blend and distribute in the chamber. \\ | The idea is to create turbulence in the chamber which helps the fuel air mix blend and distribute in the chamber. \\ | ||
| So the squish is determined by the length of the barrels and the gaskets PLUS the deck height of the cases from crankshaft centerline. \\ | So the squish is determined by the length of the barrels and the gaskets PLUS the deck height of the cases from crankshaft centerline. \\ | ||
