Question about Harley Davidson XLH Sportster 883 Motorcycles

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883 to 1200 conversion.

I have a set of jugs and pistons . Was told they are the ones for the conversion. How do I tell they are actually 1200 piston and jugs ? There is the numbers 076167 on inside of piston and ks1295 and on the outside and 22640-04A on the top of the piston.

Posted by Anonymous on

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Hi Anonymous, the only sure way to figure out what you have is measure the bore of the cylinders and the diameter of the piston skirt and should be some where in the neighborhood of 3.5" for a 1200 cc bore and 3.0" for and 883 cc bore. Good luck

Posted on Jun 10, 2015

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Posted on Jan 02, 2017

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SOURCE: white smoke from one tail pipe

As u know - that smoke is oil . can be cause by restricted breather or oil filter, worn valve guide or seals. or a bad piston ring which seems the most likely if its just coming outa one pipe. A compression test will tell ya if thats it

Posted on Mar 13, 2009

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SOURCE: RMX 250 model

Your bike is a 2000 model year. The 10th digit is the year designation.

Top rating on this answer please. Thanks!

Posted on May 29, 2009

  • 132 Answers

SOURCE: kawasaki zx 400

yes the pistons are removable,there is only a seal in the lip and nothing else inside just brake fluid. if the pistons wont come out it would be better to get a good second hand one from a good m/cycle breaker.if you pump the brake and the pistons dont move i would replace it. hope this helps

Posted on Jun 04, 2009

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SOURCE: 1977 ke125 looking for a piston ring set

Posted on Jul 22, 2009

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SOURCE: We need to order a new piston and rings kit for a

take your cylinder to a mechanic and have them measure it. If you're using Weiseco forged pistons you could use a 66.50 but the factory tolorance is .003 so you are right on the edge of needing to have the cylinder re-bored. Weiseco pistons are set for the size of the bore and then they compensate for the tolorances. Don't forget that you will loose a little when you have it honed too.

Posted on Jul 22, 2009

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How to change piston on Jonway 50 cc 2012

Air cooled 50cc motors usually have 4 long bolts holding the head on, they go up through the 'jug' and through the head to bolts under a decorative cover or just out inthe open. remove nuts or entire bolts and then use a mallet to whack the 'jug' (cylinder) to break it free of the lower gasket, pull jug up and off piston, remove old piston by circlips or other retention and install new one. pinch rings and work jug back over piston, lower onto case gasket (if you didnt rip it removing it) and button back up. Check cylinder before replacing piston to make sure a new one will work. If the walls are scored, you will have to get it bored and use a +.25mm piston.

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I have a 88 sportster 883 /1200 is what I was told .How can I know or tell for sure a kit was put in it ??without tearin it down ..It now also has a s&s short E carb and samson double tube exhaust...

There was a way the drag strips used some sort of instrument to determine the displacement of an engine without a teardown. Seems it was called a P&G tube or something like that. I've never seen one. The only way I know of telling if your engine has be bored to the 1200 cc. piston size is to take the head off of a cylinder.

The S&S carb is an old design but it's simple to tune, that's what most people like about them. The CV type carbs are much better but American riders don't like them much. Although Mikuni is making headway under the Screamin' Eagle trademark.

Now, if you bike was orginally and 883 and it was converted to a 1200, there are two ways of doing it. One, was to buy a complete kit with pistons and heads. The other was to bore the original 883 cylinders and use the original 883 heads but the pistons had to be special drop top type pistons to keep the compression to a reasonable amount. The combustion chamber of the original 883 heads are much smaller than the chamber in the 1200 head. If you don't use the special pistons, you won't be able to keep head gaskets on the engine. Wiseco makes the pistons for the conversion.

As long as the engine is running good, don't worry about it.

Ride Safe

Sep 17, 2010 | 1993 Harley Davidson XLH Sportster 883

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1999 sportster lost power

it might be excessive piston slap,=pistons too loose in bore so loosing compresion.ignition timing too advanced so pinking.carberation too weak,

Jun 29, 2010 | 2000 Harley Davidson XL 1200 C Sportster...

1 Answer

Engine Problem

you should be able to find used jug and just replace it along with new piston fitted to new jug or {cylinder}

Jan 03, 2010 | 2002 kawasaki KDX 125

2 Answers

Change jugs and pistons from 883cc to 1200cc

There is just way too much info to put here so I am giving you a link to a webpage that walks you through this conversion. Actually I am sending you two links:

In the long run this will be your best bet.

Sep 25, 2009 | 2000 Harley Davidson XL Sportster 883

1 Answer

White smoke from one tail pipe

As u know - that smoke is oil . can be cause by restricted breather or oil filter, worn valve guide or seals. or a bad piston ring which seems the most likely if its just coming outa one pipe. A compression test will tell ya if thats it

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