Special tools needed for 2001 883/1200 build?

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Dec 28, 2009 | 04:20 PM

CPObiker

Thread Starter

6th Gear

Joined: Nov 2009

Posts: 11

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From: Southern Maryland

Special tools needed for 2001 883/1200 build?

Are there any special tools needed for a 883-1200 conversion? I am also replacing the cams.

Thanks for all the help once again.

Dec 28, 2009 | 08:23 PM

extech

Road Master

Joined: Oct 2007

Posts: 1,219

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From: Hurricane Alley

Just make sure to use the pistons that will work with the stock 883 cylinder heads. There should be no "special" tools. The cams(there is 4 of them) are a bit tricky on a Sportster, so if you have no previous experience changing them, get some help or invest in a H-D service manual, MSRP: 60 well spent dollars.

Dec 28, 2009 | 08:38 PM

kevmic28

Road Warrior

Joined: Sep 2009

Posts: 1,410

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From: Fort Worth, Texas

12 point 1/2 in socket for the head bolts and a ring compressor. Other than that a torque wrench and basic tools. mainly 1/2 and 9/16 sockets and wrenches.

Dec 28, 2009 | 10:12 PM

drum412

Road Captain

Joined: Jul 2006

Posts: 656

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From:

3/8 driver clicker torque wrench is really the only specialty you'll need. I'd say pass on the ring compressor, i've done 3 1200 conversions and it's pretty easy to slip the pistons in on the sporty's, although it's a pretty cheap tool in the $10-20 range so I guess it wouldn't hurt to get one if you want. The cams are very easy to put in, just make sure to do it while things are apart and the pushrods are out so theres no pressure on the cams. If your doing the high lift cams that require different valve springs, then it'd be a good idea to invest in a valve spring compressor tool, although in a pinch you can rig up a valve tool using a large c-clamp and some creativity like i did, but i'd recommend using the proper tool if you can, valve springs can cause serious injury if your clamp slips. Also make sure to pick up some assembly lube for the pistons and cylinder.....i've always used lubriplate available at napa stores, it'll help prevent accidental scoring in the cylinder during assembly, and also help with prelubrication when you start the bike up for the first time while it takes a few seconds for the oil to get flowing again. There are a number of tutorials about doing the conversion on the web so read up ahead of time and know what your getting yourself into, and the conversion will be a pretty smooth process. And if you don't already have a service manual, get one, it's always handy to have around anyways.

Dec 29, 2009 | 10:02 AM

SportyPig

Ultimate HDF Member

Joined: Jul 2006

Posts: 6,478

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From: Nashville, TN

I'm not sure if the 2001 is the same as my 2006, but if it is, you will need to fabricate a tool to remove the manifold. I took a hex key, and cut if off with a Drimel cutoff wheel.

You might want to replace the valve seals while you have the heads off. If so, you will need a spring compressor in order to remove the valves.

Dec 29, 2009 | 04:20 PM

CPObiker

Thread Starter

6th Gear

Joined: Nov 2009

Posts: 11

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From: Southern Maryland

Thanks Everyone! This is all great advice. I do have an HD Service manual along with a Clymer. I'll get me a ring compressor before I start this. Hoping to have it done by Bike Week, and will post pics as I go and when I'm finished.

Thanks again.