Sportster Performance Parts

[Hillside Motorcycle]

we`ve done a lot of very bad ass XL`s over the years, using S&S cylinders,F/W`s & our headwork.from 10 second street bikes to AHDRA & AMRA champs

what is the max you can bore a stock 2002 case out to ,with full cast iron cylinders ?
I guess what I want to know is ,can you bore the stock case to 4.0 or  95.8 ci with a stock 3 13/16 crank ?
or is 3 7/8  89.9  ci the limit?
thanks Kirby.

3.812" bore is where we call it quits.
4.000" requires a raised deck case to clear, and have a skirt intact, at BDC.
Scott

Any special modification to the harley cases to slide the 5 " arm in ?

Gotta' check to see if the crank pin nut clears, and need to bolt the cyls on the left case half, with pistons on the rods, and slowly rotate in the direction of rotation, to see if you need to clear for the rods, at the spigot, and the case spigot bore.
Scott

[strokerjlk]

we`ve done a lot of very bad ass XL`s over the years, using S&S cylinders,F/W`s & our headwork.from 10 second street bikes to AHDRA & AMRA champs

what is the max you can bore a stock 2002 case out to ,with full cast iron cylinders ?
I guess what I want to know is ,can you bore the stock case to 4.0 or  95.8 ci with a stock 3 13/16 crank ?
or is 3 7/8  89.9  ci the limit?
thanks Kirby.

3.812" bore is where we call it quits.
4.000" requires a raised deck case to clear, and have a skirt intact, at BDC.
Scott

Any special modification to the harley cases to slide the 5 " arm in ?

Gotta' check to see if the crank pin nut clears, and need to bolt the cyls on the left case half, with pistons on the rods, and slowly rotate in the direction of rotation, to see if you need to clear for the rods, at the spigot, and the case spigot bore.
Scott

Thanks Scott
if using S&S cases ,is the crank pin nut clearance increased? or are the cases just beefier and bore area larger?

[Hillside Motorcycle]

Jim,
On those cases, I believe they are cleared in that area.
Hotbo, is thinking about having you tune his 124"/.625/bored G.
Scott

[WhipLash96]

Who here gas experience eith the Hammer performace upgraded pinion gears and bronze oil pump gear from Happer Performance?

[saltcaveminer]

I have an 03 sporty with a Zippers 99 hammer kit.This company makes great products.I am sure there are other companies out there that make great products too.My real point is that who ever does your machining better know that with hp engine mods the tools must be sharp and the machining true.Salty

[WhipLash96]

I have an 03 sporty with a Zippers 99 hammer kit.This company makes great products.I am sure there are other companies out there that make great products too.My real point is that who ever does your machining better know that with hp engine mods the tools must be sharp and the machining true.Salty

Good to know. Thank you. Will be a fun project.

[sportsterpaul]

My 2000 "C" sports an S&S 89" kit, couldn't find any one locally to bore the cases so they were sent back to S&S for that part of the job.  Probably 20,000 miles on the build, almost 90,000 on the bike, and the only issue was a head gasket.