HarleyTechTalk

I have a 2004 883 with a hole melted in the front piston. I got it that way and so I don't know why. Back cylinder has good compression. I'm thinking of just switching out Engines, can anyone help with what years I should be looking at? I have no problems with the Big Twins but not up to speed on the Sportsters. Also if I go with a 1200 will it present any problems?

I'm no Sportster specialist. But why go through the trouble?
Just do a top end. At least break it down and diagnose it.
Read up a little Here

2004-2006 will drop right in.

2007+ will fit and work, with a caveat. You'll need a little wider intake manifold, because when they went to EFI in 2007, they made the throttle body manifold 1/8" wider than the carb manifold used on the prior years, and the intake port mating surfaces on the EFI heads are milled down 1/16" each to match (as compared to your 2004 heads). If you use your carb manifold on those heads, you may have issues with the seals getting sucked into the ports on decel. A wider manifold to solve this problem of using a carb with EFI heads is readily available in the aftermarket.

Swampking, pull the covers and the Heads in the Frame put in reverse dome 1200 pistons Bore the Cylinders to fit the New Pistons, then a set of cams little carb tuning or a bigger CV or Super E carb and Walla all done and you'll have a 883/1200 that will knock your socks off. Been there done that a Few times and always impressed. Or you can buy a kit from a couple of the Company's doing Sporty Performance Parts.

Where did the material from the hole in the piston go?

Quote from: Hossamania on January 12, 2022, 04:14:55 AMWhere did the material from the hole in the piston go?

Every where the oil went?

Quote from: rigidthumper on January 12, 2022, 04:40:52 AM

Quote from: Hossamania on January 12, 2022, 04:14:55 AMWhere did the material from the hole in the piston go?

Every where the oil went?

My thought also. Either it gets cheapest fix possible and run it hoping for the best, or complete teardown and rebuild or replace to ensure longevity.
$2000 Sportster for me would get a piston, rings, hone, couple quick oil changes, and run. If it blows, find a cheap motor.
A really nice Sportster worth a few more bucks, some choices would need to be made.