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| techtalk:evo:engmech03 [2021/08/10 05:09] – [Sub Documents] hippysmack | techtalk:evo:engmech03 [2025/07/20 00:46] (current) – [Cylinder Pressure Test] hippysmack | ||
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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) | ||
| 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. | ||
| - | |||
| \\ | \\ | ||
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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) | ||
| Line 78: | Line 77: | ||
| There are many variables here [engine temperature, | There are many variables here [engine temperature, | ||
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| \\ | \\ | ||
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| - | |||
| ====== 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:// | + | 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 | ||
| Line 141: | Line 137: | ||
| | 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|16660-86|16662-86|Includes valve guides / seats.| | + | |1986|883|16661-86|16663-86 |
| - | |1987-1988|883|16661-87 \\ *16661-86B \\ *16661-86A| | + | |1987-1988|883|16661-87 \\ *16661-86B \\ *16661-86A|16663-87 ((chopper69 of the XLFORUM https:// |
| - | |1989|883|16661-86B \\ *16661-86A| | + | |1989|883|16661-86B \\ *16661-86A|16663-86B \\ *16663-86A ((kino44 of the XLFORUM https:// |
| - | |1990|883|16661-86A| | + | |1990|883|16661-86A|16663-86A|16660-86A|16662-86A|Includes valve guides / seats.| |
| - | |1991|883|16661-89A| | + | |1991|883|16661-89A|16663-86B ((Maxeffort of the XLFORUM https:// |
| - | |1992|883|16661-92| | + | |1992|883|16661-92|16663-86B|16660-92|16662-86B|Includes valve guides / seats.| |
| - | |1993-1997|883|16661-89B| | + | |1993-1997|883|16661-89B|16663-86B|16660-89B|16662-86B|Includes valve guides / seats.| |
| - | |1998-1999|883 \\ except 883R|16661-92A| | + | |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| | + | |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| | + | |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| | |2005-2006|883R|16867-05| | ||
| - | |2007-2016|883R \\ 883N|16867-07| | + | |2007-2016|883R \\ 883N|16867-07|16663-07|16865-07|16662-07|Includes valve guides / seats. \\ Black. EFI.| |
| - | |1986|1100|16688-86| | + | |1986|1100|16688-86|16682-86 ((dave76 of the XLFORUM https:// |
| |1987|1100|16688-87| | |1987|1100|16688-87| | ||
| - | |1988-1990|1200|16688-88| | + | |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| | + | |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| | ||
| Line 173: | Line 169: | ||
| \\ | \\ | ||
| 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 ====== | ||
| 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)) \\ |
| |{{: | |{{: | ||
| + | |||
| ====== 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 | + | 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. \\ | ||
