07 883 to 1200 conversion, my experience
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Joined: Jan 2007
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From: bendigo, vic Australia
07 883 to 1200 conversion, my experience
Just thought i would share my conversion info on my 2007 xl883c,
Sunday: Removed seat, tank, pipes, air filter, inlet manifold, heads, cylinders and pistons. 2hrs
Monday: Bought piston kit, top end gasket set, Dobeck performance TFI tuner. Droped of cylinders and piston kit at machine shop to have them bored out from 3" to 3.5".
Wednesday: picked up the bored out cylinders. reassembled the engine and bike as per workshop
manual. 5hrs.
Thursday: installed the TFI fuel injection tuner and tried to start the engine, The engine was running on the rear cylinder only, shut engine down and re-checked all of my work eg; compression, spark, fuel. Found no injector pulse at the front cylinder so i called the local dealer only to be told that the wiseco k1655 piston kit would not work int the 07 sportsters as he read that there is an issue with the skirts if they were used. When i checked the piston to piston at assembly there was no interferance when both pistons were at the bottom of their stroke. and as far as i could tell the engine had no changes other than fuel injection from 06 to 07.
The dealer was not interested telling me what could be the problem.(the dealer i bought the bike off in Jan)
I then called Heavy Duty Cycles in Brisbane, who were fantastic, they told me the problem would be the map in the ECM would not be able to run the larger 1200cc capacity engine even with the efi tuner, they told me to use Thundermax tuner, so i ordered one and installed it on Saturday.
The bike started and ran like a dream, took it for a ride and the difference is incredible, The bike always had good top speed and good torque but now it also has heapa of pulling power.
I found that this conversion is a must for all 07 883 owners that love their bike but find it lacks power.
Here is my parts list .
Pistons Wiseco K1655 $335
Top end gasket set (genuine) $160
Thundermax ECM $700
Bore & hone (using torque plates) $160
Total cost of parts $1355
I already had SE High flow air cleaner kit and slip on mufflers prior to the conversion.
SPECIAL THANKS to cHarley who helped me obtain a workshop manual via HD Forums.
Cheers, Bretho.
Sunday: Removed seat, tank, pipes, air filter, inlet manifold, heads, cylinders and pistons. 2hrs
Monday: Bought piston kit, top end gasket set, Dobeck performance TFI tuner. Droped of cylinders and piston kit at machine shop to have them bored out from 3" to 3.5".
Wednesday: picked up the bored out cylinders. reassembled the engine and bike as per workshop
manual. 5hrs.
Thursday: installed the TFI fuel injection tuner and tried to start the engine, The engine was running on the rear cylinder only, shut engine down and re-checked all of my work eg; compression, spark, fuel. Found no injector pulse at the front cylinder so i called the local dealer only to be told that the wiseco k1655 piston kit would not work int the 07 sportsters as he read that there is an issue with the skirts if they were used. When i checked the piston to piston at assembly there was no interferance when both pistons were at the bottom of their stroke. and as far as i could tell the engine had no changes other than fuel injection from 06 to 07.
The dealer was not interested telling me what could be the problem.(the dealer i bought the bike off in Jan)
I then called Heavy Duty Cycles in Brisbane, who were fantastic, they told me the problem would be the map in the ECM would not be able to run the larger 1200cc capacity engine even with the efi tuner, they told me to use Thundermax tuner, so i ordered one and installed it on Saturday.
The bike started and ran like a dream, took it for a ride and the difference is incredible, The bike always had good top speed and good torque but now it also has heapa of pulling power.
I found that this conversion is a must for all 07 883 owners that love their bike but find it lacks power.
Here is my parts list .
Pistons Wiseco K1655 $335
Top end gasket set (genuine) $160
Thundermax ECM $700
Bore & hone (using torque plates) $160
Total cost of parts $1355
I already had SE High flow air cleaner kit and slip on mufflers prior to the conversion.
SPECIAL THANKS to cHarley who helped me obtain a workshop manual via HD Forums.
Cheers, Bretho.
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