On a side note, i know its not a sportster but, theres an article in the horse where one of their regular writers says his amf fl has over 250,000 miles on it. Harleydavidson sportster evolution troubleshooting, repair, and service. New listing harley engine motor from 2001 sportster 883. You should also ensure that the shift shaft is not bent or damaged. Find the resources you need for chevrolet, chrysler, dodge, ford and honda engines. This post is intended to follow the process of the build. It takes you through a typical engine build and provides performance tips and suggestions. Get the best deals on harleydavidson complete motorcycle engines when you shop the largest online selection at. A detailed video on how to assemble an 2004later harley davidson sportster bottom end. Torque over a wide rev range is the key to useable street performance. However, this book concentrates on earlier builds of the sportster and has very few references to the current rubbermounted evolution motors. I also own a 1973 sportster that came in a bunch of boxes.
I think harleys get for the most part an undeserved reputation for unreliability. Harleydavidson sportster performance handbook, 3rd. We offer complete crate motors and short block assemblies for a wide variety of models, or we can supply a factoryfresh twincam longblock complete with your original vin to get you back on the road. Complete engines for harleydavidson sportster 1200 for sale ebay. Harley twin cam 88ci strip and rebuild part 1 youtube. Kipa carburetor rebuild repair kit for harley davidson dyna electra glide fatboy softail sportster 1200 sportster 883 xl883 carb, cv40 cv 40mm 2742199c 2749004. With harleys decision to cut back on the quality of their bottom endlesser quality flywheels, unbalanced flywheels and nontimken bearingstr has begun offering a complete bottom end rebuild. Harleydavidson evolution engene disassembly and re. Stepbystep instructions on disassembly, cleaning, machining tips, preassembly fitting, and final assembly. Weve got your gaskets, oil coolers, rocker arms, cams, points covers, oil pressure gauges, and everything else to keep your engine in top condition for. Complete engines for harleydavidson sportster 1200 for. Motorcycle engine parts rebuild kits for harley davidson, triumph. After three months, 20000 photos, and more than our share of hurdles especially finding parts, weve completed another redline rebuild.
The engine should be clean with no signs of oil leakage. Zippers hammer 88 kit for eficarb sportster models. This performance guide is a good reference companion to the factory service manual. Orange cycle parts rear master cylinder repair rebuild kit for harley tour glide flt 8485 fx, electra glide fl 8082 sportster xl 7981 xlcr 7778 kelsey repl. Unlike todays models, ironhead sportster engines were designed to be rebuilt. We offer the best prices, free shipping across the 48 contiguous u.
Lots of people charge for motorcycle service and workshop manuals online which is a bit cheeky i reckon as they are freely available all over the internet. Harleydavidson sportster vtwin ironhead engine rebuild. Motorcycle atv engine rebuild cylinder kit 54mm piston ring gasket 110 to 125cc fits. A detailed video on how to disassemble and reassemble a 9103 sportster early buell bottom end. Someone has suggested that i get someone else to do it but 1it costs a lot. Harleydavidson sportster vtwin ironhead engine rebuild time.
Harley engines are built to last, but nothing lasts forever. Fresh water use only, compression is normal 145150, engine is in good working order. From intake and exhaust tuning to cam selection, ignition and electrical modification to gearing changes, how to build a harleydavidson torque monster explains how to put together a harley that you can comfortably live with during the day but. Hundreds of photos, charts, and diagrams visually walk you through the entire rebuild. Complete engines for harleydavidson sportster for. This is exactly like the original manual, or book made for this vehicle. Depending on the year of your frame, you may want to purchase a kit. This clymer manual is organized by subsystem, with procedures grouped together for specific topics, such as front suspension, brake system, engine and. Lowbrow customs has motorcycle engine parts rebuild kits for your harley davidson, triumph and others. Motorcycle and harley engine rebuild kits get lowered cycles. Lloyd from mechanicville, new york, united states made available these pictures of the rebuild of his harley sportster bobber short chop which has a 1981 ironhead engine in a hardtailed 1975 sportster frame. I took the bike in to the hd shop, they pulled and sent the engine out and a few weeks later i rode out with what is basically a new motor. Best selection and great deals for 1979 harleydavidson sportster xlh items. The motor bookstore is a leading source for topquality diy engine rebuild and engine repair manuals.
Hopefully you wont need every engine tool listed in the factory manual. This book contains all the original vehicle parts information you need to properly lookup correct part numbers for the entire vehicle including the engine parts. How to build a harleydavidson torque monster motorbooks. The exhaust was a departure from past sportster models, but added a solid fivehorsepower gain in performance. Big twin 4 speed transmission rebuild with frank kaisler. What year model sportster engines have fuel injection. But it truly isnt that hard if you have good mechanical skills, a harley factory service manual, the right tools, and some time. The installation specs will also vary slightly from one engine to the next.
A few years ago i went through the mofoco and had the engine on my 1990 flhs remanufactured at 97,000 miles. Motorcycle engine parts rebuild kits for harley davidson. Zippers torkster 8831200 efi xl sportster engine kit. You name it we have what you need for customizing your sportster or bobber.
Sportster models are designated in harleydavidsons product code by beginning with xl. Harley davidson service manuals free pdf for sportster 883 1200, dyna, v rod, softail, touring. Free shipping, no hassle returns and the lowest prices guaranteed. Clymer repair manual harley davidson sportster webbikeworld. Unlike earlier sportster frames, the xlcr frames have room for improvement, particularly when front and rear shocks are upgraded. Parts inspection, diagnosis, reconditioning, and assembly are outlined in simple text. Lowbrow customs has motorcycle engine parts rebuild kits for your. Once i learn how to rebuild the 73, i will rebuild the 74. These models k, kk, kh, and khk of 1952 to 1956 had a sidevalve flat head engine. Harleydavidson evolution engene disassembly and reassembly. Whether youre doing some minor upkeep, a major overhaul, or a complete replacement of your harley sportster 1200 engine, has all the minor and major parts you need. If youre like most harleydavidson owners, the only thing you enjoy more than learning about your motorcycle and how it works is getting it out on the open road. Harleydavidson repair manuals diy motorcycle repair.
Harleydavidson complete motorcycle engines for sale ebay. The harleydavidson sportster is a line of motorcycles produced continuously since 1957 by harleydavidson. Free harley davidson motorcycle service manuals for download. We will disassemble, clean, inspect, and then reassemble to your specifications. Tr knows your engine is only as good as the bottom end. Stock rebuild or custom big bore, we will send your complete engine back, ready to reinstall and tune in your chassis. Ironhead sportster project classic motorcycle build. How to disassemble and reassemble a 9103 harley davidson. I mean, he said that the engine had been rebuilt but still. Harleydavidson engine rebuilding revolution performance. At, we offer you some of the best harleydavidson sportster 883 aftermarket mods for your bike so you can keep it and great shape and even upgrade it no matter how hard it is to find parts. This is simply the best harleydavidson performance book available. Harley davidson service manuals for download, free. This book gives guides you through both the easy and tricky procedures, showing you how to rebuild your engine and ensure it is working perfectly.
Full list of motorcycle service manuals for free download. The sportster 1200 engine is a reliable and quality built engine, but there are some things you should look out for when buying used. If you want explanations of the theory behind making horse power and how it applies to a hd big twin engine, this is the book you need. The sportster cafe racer was offered in black only, with wrinkleblack engine paint and black siamesed exhaust pipes which exited left and right. It is also helpful to look for a sportster 1200 engine that has low miles. In 1952, the predecessors to the sportster, the model k sport and sport solo motorcycles, were introduced.
How to reassemble a 04 later harley davidson sportster. When the heart of your harley motorcycle gets a little tired we can help wake it up. I have 1997 buell with a harley sportster 1200cc engine in it. Among the many serviceable parts are the main bearing races, which can be honed oversize and fitted with new oversize bearing rollers. Considered by many sportster purists as the last real harley engine, the ironhead is the throbbing powerhouse that lends heart and soul to a long line of sportsters produced from 1957 to 1985. If you have a smallblock ford, then you need this book. Buy and sell ironheads buy and sell ironhead parts rebuild ironheads specialty work wheel building and lacing wiring engine rebuilding transmission rebuilding flywheel trueing line lap case bearing races lap rod races valve jobs install hardened seats cylinder boring heliarc welding lathe and mill work powder coating. Harley sportster engines no matter what type of repair or upgrade youre doing on your harley sportster engine, youll find all the harley sportster engine parts you need at.
We know how important it is for you to treat your bike with the best parts, so we only carry parts from the best brands around. It has lost compression to the point that it has only 100psi front cylinder and 50psi rear. I own a 1974 sportster that is chopper and is in a rigid frame. This detailed guide covers the stepbystep rebuilding process of the popular smallblock ford engine. This engine block also works in many other seadoo models, both jetskis and boats, like the spx, gtx, gsx, sportster, challenger, explorer, etc. Dennis kirk carries more 1979 harleydavidson sportster xlh products than any other aftermarket vendor and we have them all at the lowest guaranteed prices. The harleydavidson ironhead motor is the main reason for the enduring success of the sportster. The 74 i have had for quite some time, the 73 is a recent acquisition and is meant to be a learning project.