Overview
The subject is a 2000 Harley-Davidson Sportster XLH standard with a displacement from the factory of 883cc. The following details three easy steps to convert the subject to a displacement of 1200cc.
This video clip is of the very last time the subject ran as an 883cc. Tear-down followed immediately afterwards. Note: I am filming and my boy does indeed have a motorcycle of his own - although you would never know it from the video.
Step 1 - Take everything apart
Things come apart fairly easily - provided you have the right tools. For example, you will spend hours trying to get the intake manifold off without the tool especially made for the job, not to mention the head bolts.
Step 2 - Prep your parts
The only prep work needed to do is have your cylinders matched to your pistons. In this project, I went with the Wiseco Reverse-Dome 9.5:1 pistons. I sent out a set of 883cc cylinders I purchased on e-Bay to Short Block Charlie's to bore to 1200cc. Remember, each piston is a different size and must be matched to your cylinders. Be sure to send your pistons to your machinist and have them indicate which piston is matched to which cylinder.
These are what 883cc cylinders look like:
These are what the cylinders look like after they are bored-out to 1200cc:
For this project, I also polished the intake and exhaust ports on the heads as well as the intake manifold. Here are some before and after pictures:
Step 3 - Put everything back together
Putting everything back together is a different story from taking everything apart. To do so successfully, you must read, understand and follow the directions in the Factory Service Manual exactly. You will also need some additional tools, such as a torque wrench.
This video clip is of the very first moments of life as a 1200cc:
Aside from a few minor details, the project is basically complete. Total time: 8 hours. Total cost: about $500. Total happiness: priceless...
Updates:
The subject has since been updated as follows:
Wiseco 10.5:1 reverse dome pistons
Larger intake and exhaust valves
Heads ported and flowed by SBC
Andrews N4 cams
Mikuni 42mm
Dyno tune by JDS - 80hp
Dual front disk brakes
Removable front windscreen from the MoCo modified to work with running lights
Stock forward controls
Sportster "Sport" Cartridge Front Suspension
Mustang saddle with driver backrest
Softail hard saddlebags:
These are 2000 Softail ABS Saddlebags I purchased on eBay (of course...) I really like the way the lines follow both the rear fender and the tank. I mounted the bags using the stock brackets to the removable "ghost brackets" I had the Shoei bags on.
