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techtalk:evo:engmech03 [2021/08/10 13:12] hippysmack [Sub Documents] |
techtalk:evo:engmech03 [2024/01/03 20:50] (current) hippysmack |
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| To check your cylinder pressure, you need a compression tester/gauge. For less than $25, you can buy (online) a tester with a gauge, hose and adapters (slightly more at your local auto supply or department store). | To check your cylinder pressure, you need a compression tester/gauge. For less than $25, you can buy (online) a tester with a gauge, hose and adapters (slightly more at your local auto supply or department store). | ||
| - | **Using The Compression Tester**((http://xlforum.net/forums/showthread.php?t=40364)){{ :techtalk:evo:engmech:compression-tester.jpg?200| }} | + | **Using The Compression Tester**((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/24369-cylinder-compression-and-leakage-tests?t=40364)){{ :techtalk:evo:engmech:compression-tester.jpg?200| }} |
| * 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) | ||
| Line 38: | Line 38: | ||
| 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. | ||
| - | |||
| \\ | \\ | ||
| Line 50: | Line 49: | ||
| 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://xlforum.net/forums/showthread.php?t=40364)) | + | **Using The Leakdown Tester**((https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/24369-cylinder-compression-and-leakage-tests?t=40364)) |
| * 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) | ||
| Line 78: | Line 77: | ||
| There are many variables here [engine temperature, precise piston position, whatever]. The test results will not be consistent from one test to the next, so multiple tries should be recorded and a consensus value established. | There are many variables here [engine temperature, precise piston position, whatever]. The test results will not be consistent from one test to the next, so multiple tries should be recorded and a consensus value established. | ||
| - | |||
| \\ | \\ | ||
| - | |||
| - | |||
| ====== Cylinders ====== | ====== Cylinders ====== | ||
| Line 115: | Line 111: | ||
| 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://xlforum.net/forums/showthread.php?t=1569673)) | + | 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/forum/sportster-motorcycle-forum/sportster-motorcycle-general-discussion-and-problems/144715-1250-kit?t=1569673)) |
| \\ | \\ | ||
| ===== 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/forums/showpost.php?p=3171730)) | + | 883 or 1200? - Check like this: ((Decman of the XLForum - https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/frame-mount-evo-sportster-talk-1986-2003-models/112707-telling-the-difference-between-a-1200-and-an-883#post2368319)) |
| * Put in 5th gear | * Put in 5th gear | ||
| * Lift rear wheel | * Lift rear wheel | ||
| Line 141: | Line 137: | ||
| | Evo Sportster Head Part Numbers ||||||| | | Evo Sportster Head Part Numbers ||||||| | ||
| |Year|Model|Front \\ Part#|Front \\ Casting#|Rear \\ Part#|Rear \\ Casting#|Notes| | |Year|Model|Front \\ Part#|Front \\ Casting#|Rear \\ Part#|Rear \\ Casting#|Notes| | ||
| - | |1986|883|16661-86|16663-86 ((MOREHP of the XLFORUM http://xlforum.net/forums/showthread.php?t=21457&page=3))|16660-86|16662-86 ((MOREHP of the XLFORUM http://xlforum.net/forums/showthread.php?t=21457&page=3))|Includes valve guides / seats.| | + | |1986|883|16661-86|16663-86 ((MOREHP of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/12881-mystery-heads/page3?t=21457&page=3))|16660-86|16662-86 ((MOREHP of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/12881-mystery-heads/page3?t=21457&page=3))|Includes valve guides / seats.| |
| - | |1987-1988|883|16661-87 \\ *16661-86B \\ *16661-86A|16663-87 ((chopper69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=364183))|16660-87 \\ *16660-86B \\ *16660-86A|16662-87 ((chopper69 of the XLFORUM http://xlforum.net/forums/showthread.php?t=364183))|Includes valve guides / seats.| | + | |1987-1988|883|16661-87 \\ *16661-86B \\ *16661-86A|16663-87 ((chopper69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/61779-what-sportster-heads-are-these?t=364183)) \\ *16663-86B \\ *16663-86A|16660-87 \\ *16660-86B \\ *16660-86A|16662-87 ((chopper69 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/61779-what-sportster-heads-are-these?t=364183)) \\ *16662-86B \\ *16662-86A|Includes valve guides / seats.| |
| - | |1989|883|16661-86B \\ *16661-86A|16663-86A ((kino44 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1610552))|16660-86B \\ *16660-86A|16662-86A ((kino44 of the XLFORUM http://xlforum.net/forums/showthread.php?t=1610552))|Includes valve guides / seats.| | + | |1989|883|16661-86B \\ *16661-86A|16663-86B \\ *16663-86A ((kino44 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/148239-heads-and-pistons-1200-conversion?t=1610552))|16660-86B \\ *16660-86A|16662-86B \\ *16662-86A ((kino44 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/148239-heads-and-pistons-1200-conversion?t=1610552))|Includes valve guides / seats.| |
| - | |1990|883|16661-86A| |16660-86A| |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 http://xlforum.net/forums/showthread.php?t=2074374))|16660-89A|16662-86B|Includes valve guides / seats.| | + | |1991|883|16661-89A|16663-86B ((Maxeffort of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-bottom-end/197696-mysterious-head-please-help-id?t=2074374))|16660-89A|16662-86B|Includes valve guides / seats.| |
| - | |1992|883|16661-92| |16660-92| |Includes valve guides / seats.| | + | |1992|883|16661-92|16663-86B|16660-92|16662-86B|Includes valve guides / seats.| |
| - | |1993-1997|883|16661-89B| |16660-89B| |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| |16660-92A| |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 http://xlforum.net/forums/showthread.php?t=21457&page=3))|16660-89B|16662-86B ((Shu of the XLFORUM http://xlforum.net/forums/showthread.php?t=21457&page=3))|Includes valve guides / seats.| | + | |2000-2003|883|16661-89B|16663-86B ((Shu of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/12881-mystery-heads/page3?t=21457&page=3))|16660-89B|16662-86B ((Shu of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/12881-mystery-heads/page3?t=21457&page=3))|Includes valve guides / seats.| |
| |2002-2003|883R|16867-02| |16865-02| |Includes valve guides / seats.| | |2002-2003|883R|16867-02| |16865-02| |Includes valve guides / seats.| | ||
| |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.| | ||
| |2007-2016|883 \\ except 883R \\ except 883N|16661-07|16663-07|16660-07|16662-07|Includes valve guides / seats. \\ Silver. EFI.| | |2007-2016|883 \\ except 883R \\ except 883N|16661-07|16663-07|16660-07|16662-07|Includes valve guides / seats. \\ Silver. EFI.| | ||
| |2005-2006|883R|16867-05| |16865-05| |Includes valve guides / seats. \\ Black. Last year carbed.| | |2005-2006|883R|16867-05| |16865-05| |Includes valve guides / seats. \\ Black. Last year carbed.| | ||
| - | |2007-2016|883R \\ 883N|16867-07| |16865-07| |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 http://xlforum.net/forums/showthread.php?t=591572))|16698-86|16684-86 ((dave76 of the XLFORUM http://xlforum.net/forums/showthread.php?t=591572))|Bare.| | + | |1986|1100|16688-86|16682-86 ((dave76 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/80734-picked-up-a-set-of-1100-heads?t=591572))|16698-86|16684-86 ((dave76 of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/80734-picked-up-a-set-of-1100-heads?t=591572))|Bare.| |
| |1987|1100|16688-87| |16698-87| |Includes valve guides / seats.| | |1987|1100|16688-87| |16698-87| |Includes valve guides / seats.| | ||
| |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.| | ||
| Line 163: | Line 159: | ||
| |1998-1999|1200 \\ except 1200S|16688-92| |16698-92| |Includes valve guides / seats.| | |1998-1999|1200 \\ except 1200S|16688-92| |16698-92| |Includes valve guides / seats.| | ||
| |2000-2003|1200 \\ except 1200S|16688-90A| |16698-90A| |Includes valve guides / seats.| | |2000-2003|1200 \\ except 1200S|16688-90A| |16698-90A| |Includes valve guides / seats.| | ||
| - | |1998-2003|1200S|16630-98| |16633-98| |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 http://xlforum.net/forums/showthread.php?t=1493442))|16666-04|16877-02 ((rocketmangb of the XLFORUM http://xlforum.net/forums/showthread.php?t=1493442))|Includes valve guides / seats. \\ Black. Last year carbed.| | + | |2004-2006|1200|16667-04|16874-02 ((rocketmangb of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/137631-reading-casting-numbers-heads?t=1493442))|16666-04|16877-02 ((rocketmangb of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/137631-reading-casting-numbers-heads?t=1493442))|Includes valve guides / seats. \\ Black. Last year carbed.| |
| |2007-2016|1200 \\ except 1200N \\ except XR1200 \\ except XR1200X \\ except XL1200X \\ except 1200CP \\ except 1200CA \\ except 1200V \\ 1200CB|16667-07| |16666-07| |Includes valve guides / seats. \\ Black. Fin Highlights. EFI.| | |2007-2016|1200 \\ except 1200N \\ except XR1200 \\ except XR1200X \\ except XL1200X \\ except 1200CP \\ except 1200CA \\ except 1200V \\ 1200CB|16667-07| |16666-07| |Includes valve guides / seats. \\ Black. Fin Highlights. EFI.| | ||
| |2007-2016|1200N \\ XL1200X \\ 1200CP \\ 1200CA \\ 1200CB|17485-07| |17488-07| |Includes valve guides / seats. \\ Black. No fin highlights. \\ EFI| | |2007-2016|1200N \\ XL1200X \\ 1200CP \\ 1200CA \\ 1200CB|17485-07| |17488-07| |Includes valve guides / seats. \\ Black. No fin highlights. \\ EFI| | ||
| Line 173: | Line 169: | ||
| \\ | \\ | ||
| Torque Sequence: \\ | Torque Sequence: \\ | ||
| - | {{:techtalk:evo:engmech:head_torque_sequence_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack http://xlforum.net/forums/showthread.php?p=5793537#post5793537)) \\ | + | {{:techtalk:evo:engmech:head_torque_sequence_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-motor-top-end/198541-repairing-cylinder-studs-cases/page3#post4360598)) \\ |
| 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 http://xlforum.net/forums/showthread.php?t=1842712&highlight=rocker+box&page=3)) \\ | + | It's a full tear down to fix. ((aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/171860-intake-valve-issues/page3?t=1842712&highlight=rocker+box&page=3)) \\ |
| - | |Stock 88-03 1200 piston. \\ Notice how there's a skirt on the side. ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1842712&highlight=rocker+box&page=3))|Stock 04 1200 pistons. \\ Notice how there's no skirt on the side. ((photo by aswracing of the XLFORUM http://xlforum.net/forums/showthread.php?t=1842712&highlight=rocker+box&page=3))| | + | |Stock 88-03 1200 piston. \\ Notice how there's a skirt on the side. ((photo by aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/171860-intake-valve-issues/page3?t=1842712&highlight=rocker+box&page=3))|Stock 04 1200 pistons. \\ Notice how there's no skirt on the side. ((photo by aswracing of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-era-specific-and-model-specific/rubber-mount-sportster-motorcycle-talk-2004-2006/171860-intake-valve-issues/page3?t=1842712&highlight=rocker+box&page=3))| |
| |{{:techtalk:evo:engmech:stock88-03xl1200pistonweight_by_aswracing.jpg?direct&200|}}|{{:techtalk:evo:engmech:stock04-upxl1200pistonweight_by_aswracing.jpg?direct&200|}}| | |{{:techtalk:evo:engmech:stock88-03xl1200pistonweight_by_aswracing.jpg?direct&200|}}|{{:techtalk:evo:engmech:stock04-upxl1200pistonweight_by_aswracing.jpg?direct&200|}}| | ||
| - | ====== Pistons & Rods ====== | ||
| + | ====== Pistons & Rods ====== | ||
| 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. \\ | ||
| - | The part number was changed from 22589-83 to 22589-83A. The changed occurred in production approximately in September of 1991. ((HD Tech Tip $TT030 dated July of 1992)) \\ | + | The part number was changed from 22589-83 to 22589-83A. The changed occurred in production approximately in September of 1991. ((HD Tech Tip #TT030 dated July of 1992)) \\ |
| |{{:techtalk:evo:engmech:piston_pin_lock_ring_22589-83b_by_hippysmack.jpg?direct&300|}}| | |{{:techtalk:evo:engmech:piston_pin_lock_ring_22589-83b_by_hippysmack.jpg?direct&300|}}| | ||
| + | |||
| ====== Rocker Arms ====== | ====== Rocker Arms ====== | ||
| Line 193: | Line 190: | ||
| 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 http://xlforum.net/forums/showthread.php?t=2075731&page=13)) \\ | + | The squish band is the quench area. ((rocketmangb of the XLFORUM https://www.xlforum.net/forum/sportster-motorcycle-forum/sportster-motorcycle-motor-engine/sportster-motorcycle-engine-conversions/198922-my-1275-hammer-conversion/page13?t=2075731&page=13)) \\ |
| 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. \\ | ||
