Top End Disassembly

Complete Disassembly of a XL/ Buell Top End

[@FATALMONSTROCITY]

Dude, honesty this is the most detailed video. Thanks a bunch. Had a exhaust bolt bust the stud so I have to remove the head to get to it.

[@robertmitchell2289]

ugh. i'm doing that right now.

[@GixxerFoo]

Your videos fill in a lot of the blanks and answer a lot of questions! Can't wait to do my build!

[@NigelsModellingBench]

Thanks a lot for this series. I love the way you do unedited filming with no ads and no interruption. Even YOU didnt know that valve was broken!! COOL!! Did you actually say that bike had done the TT a few times? It must cost a fortune to ship the bike back and forth from the USA?

[@HAMMERPERFORMANCE]

This bike is a customer of ours who is a marshal for the TT. So he has had a chance to run the course a hand full of times. He brought the bike to us for our 120+ HP package.

[@CFHmetalorama]

These videos are a huge help for newbies to sportster engines like me. Thanks for sharing the knowledge.

[@houseofstylz]

Great real-time video without distracting/annoying music, thanks so much.

[@matchplayer9046]

Amazing video, will be a lot of help when I tear down my Top end this weekend. +

[@ericcrusen1012]

Excellent video You helped me better than my Manuel did Thank You

[@joshuadixon7395]

I've rebuilt a few different dirtbike motors but never a Harley. I just bought an 883 and plan on the 1250 upgrade. Love these videos! Huge help to educate the average guradge mechanic.

[@bibleboys3560]

The videos are great because we can watch you do it and understand each step. The safe tips and exact methods tips are very important also. Thank You

[@imfattcracker6511]

do you have a Video splitting the main case, like on '87-99 Sportsters?

[@tattooglisha]

The best video on YT definitelly. Thank you and keep sportster line the best line in your company . That made you strong and will keep you there. Lots of companieas work on big twins and i know you will get there strong but i would like to see you on top in 20 years too. And i would like support and parts for us ,furst customers for 1250cc kit. Thanks again. P.s.Btw Cometic gaskets are great and reuseable on my suprise. Your gaskets and o rings and rubbers are great too! Nothing made me regret buying a kit. Its a world changer for bike. Its now race able vs. sport bikes on start and first 100-200 meters easy. Mileage stayed the same with normal riding while up when racing. Ofcourse. New customers should know that if they are not track racers they could easy over power their bike and it becomes bad ass but for some guys uncontrolable and higher idle makes them ask why it is like thst. But if you overpower bike youll get a bike that is throttle thirsty .

[@Ashroyer86]

I was pulling on gsxr600 and 600rr up to 3rd gear with my 1200. Not sure what work it had done to it but sure the 1250 kit would have helped. Would love it with the 1275 kit. Looking for another cheap sportster to build now.

[@jolyh558]

I watch your videos and I have learned so much from watching you work on that bike of yours. Thank you for all the knowledge you share.

[@mikechildress6073]

Yes they do excellent work very good instructions

[@stephensheridan6332]

Fantastic and professional video, thankyou, regards, Steve, uk 🇬🇧

[@jacklynn4424]

Great video, extremely helpful and well laid out, much appreciated. I think now even a noob like me could accomplish this. Thx

[@leonardobarba4231]

just wanted to say thank you from guadalajara mexico! i have learned more from your videos, than from expensive training courses.

[@adamlahham28]

Is the engine still inside the frame? Would it be difficult to take out the rear cylinder? Just the space there is very small, haven't done it yet but willing to order your kit coz the videos are very informative and straight forward! Thank you

[@HAMMERPERFORMANCE]

Yes, everything can be done with the engine still inside the frame no problem

[@jovi___]

THANK YOU for these videos! Its a huge help.

[@freedommonger4512]

thank you so much for doing these videos. i have loved sportsters my whole life. i will buy everything you make. you guys are great:)

[@car5car5]

I will install pistons and cylinders from Kawasaki 2000! :)

[@Ghost.Of.Norway]

Great video! Doing a teardown on a 91 sportster 1200. Last owner did a bad paint job (spray can) and there was a few leaking seals so im redoing that stuff and your videos help alot. Any advise on how to remove the old base gasket? Its stuck, almost like it has become a part of the engine. Thank you. -Martin

[@HAMMERPERFORMANCE]

Go to any auto parts store and pick up some gasket remover spray. It will dissolve the old paper.

[@fernando3551]

Back in the old days, I used to just put my finger on the spark plug hole, until I felt the compression starting to build up, then put the straw in the spark plug hole, to see where the piston is, as both rocker arms remained up. ~ Fernando

[@stevenweede7184]

Love your videos. I bought my bike because I was supposed to get an older classic car to rebuild with my dad but he passed in 2012. I don’t have the garage space so I got a rubber mount Sportster. Lots of parts available & one of the easier bikes to work on. What would you recommend would be the simplest cam upgrade for an ‘05 1200C? Just looking to get a little more power. Mostly on the low to midrange. After watching this video it seems like no matter what I have to remove the rocker covers & pushrods (& replace gaskets). So, what’s the best option for me to bolt in cams without having to chamfer any cases? Also, any other recommendations would be appreciated. Thanks guys

[@Darkerthrone]

Greetings from Australia! Ive just purchased a stripped down 99 Sportster and looking to do the 1200 conversion, this video has been an amazing insight into getting my hands dirty on the build. Thank you!

[@jeffersonbolt4347]

Ha! You kept saying “ball end mill”!!! May dad used to call them that. 😂 As a machinist I can’t help but chuckle. Thanks for the video. Extremely helpful.

[@bobsmith4121]

Slightly off topic question. What brand/part number is that massive oil filter, and can it work on a Sportster?

[@karinsdad1]

Guaranteed if I do make any modifications to my 99 XL, it will be with your company. Great Stuff!

[@ronlheureux7623]

Thanks for great the great demo and tutorial. Best one I've seen and leaves me not worrying that I flunked rocket science.

[@garycb8592]

Great informative videos. Thanks for posting.

[@jewballee]

How well do the stock 883 crank and connecting rods hold up to the power of the 1275 kits?

[@HAMMERPERFORMANCE]

For just the basic conversion there is no problem at all. We feel that the stock crank will support up to 120hp at the wheel and be ok as long as you are not drag racing it. Now, keep in mind anything can happen. If you are a very aggressive rider than we would suggest maybe doing something to address the bottom end just to help with reliability

[@waltercheeks5309]

Your videos are the best. Thank you for what you do.

[@MarkDupreLSD-25]

Dan, I now watch these just to check myself when working on my 93 Sporty. Quite informative, since my local H-D dealer hires millennial idiots.

[@WetBananaMike]

👍👍 Thanks Dan! Loving the video series!!

[@benh2422]

great video! very informative gonna be a real help when I pull the trigger on a 1275 kit

[@planejoxcrazyhorse7486]

Thanks for these been waiting for a complete Big bore upgrade set of Vids cant wait

[@AustinSliker]

Thank you...I'm back on the road again...did the gasket change in 3 hours disassembled and reassemble of engine from and to bike again .really help me with this vid.thanks.

[@drwombat]

Is the 88" kit well enough built to provide at or near OEM reliability as 883/1200cc motors?

[@respt46]

How much one of these weigh when assembled? I'll be picking one up this weekend but I don't know it I can carry it in the garage by myself.

[@josephsimons5513]

I have a 91 883XL Deluxe I want to replace the pressure regulator plunger valve on the filter mount if I can find the part Can I put the old cams back in if they come out when I take to cam cover off

[@josephroy4132]

If..i didnt put my motor t.d.c..would that explain why the heads wont come off?..and can i still put it tdc without rockers on..i took them off beforw putting it t.d.c...i have amanual and still somewhat confused..im not scared to make mistakes. How else ima learn

[@Gvonpohl]

You know its gonna be something you can DIY when they say harbor freight in the first 3 minutes.

[@zechariahliszewski]

Is there a way to get TDC without the cams or transmission in? Would there be damage if those were taken out before top end disassembly?

[@newlinedetails]

Thanks guys. Keep up the great work!!!

[@robertlumsden1579]

this is one of the best videos is have seen. I learned a lot on this one. and the broken valve stem was cool as it showed us why we were not getting the situation we expected. just great man. new subscriber now.

[@LoSGaines]

This video has probably given me more riding days! The less time I spend trying to figure out how to do this and redo it after I screw it up, the better.

[@jaklyca8124]

Hi Dan great videos. I have a request. When I bought my 1250 kit from you I also bought the billet base kits for the stock pushrod tubes. However I never did fit them after I heard a lot of horror stories about how hard they are to fit. So not to slow me down I fitted the old single ones back. It would be great if you could include fitting the billet ones on one of the rebuild films. Mine are leaking so I must do them again soon. Thanks

[@HAMMERPERFORMANCE]

Hi Jak We will be doing a video on this soon. Keep an eye out!

[@jaklyca8124]

Cheers Dan will do

[@planejoxcrazyhorse7486]

Oh man i would love to see the case spiting as well

[@pundamilia1191]

The pin on my bike is hanging up after it comes out about an inch and wont come any farther. Cant figure out what Im doing wrong.

[@steveyleeadkins]

Can you replace 1984 iron head with any other year SPORTSTER motor Thanks

[@HAMMERPERFORMANCE]

not sure on that one.

[@GregCaspa]

What is this sensor in the cylinder head ? I have broken cable and check engine indicator on. Thanks

[@darrenhawkins3014]

thanks for this.

[@marcpinion]

Thanks please keep going and split the cases and build it back up.

[@SUPPORTYOURSELF]

super helpful, thanks guys

[@Paulseveign]

3:18 Hammer you Are the best and God loves you

[@osdreadlord3205]

I'd go ahead and replace that stator too. It looks pretty cooked.

[@lylescheppmann4935]

Good job on the video...I am starting to tear down my XL1200L Sportster I am sure the video's will help out alot. Thank You

[@frankino75]

many thanks for your videos🤗

[@guipedr]

If I disassembly the top end only to access the cylinders in order to change the cylinder rings, which gaskets should I have in hands to replace beyond head cylinder and base cylinder's?

[@HAMMERPERFORMANCE]

rocker boxes as well

[@robertweeks2039]

good job.I see there is no chicken strips on that rear tire.

[@mumbler5644]

great video thank you

[@Luftbubblan]

Is there any other way of removing the rings that hold the piston in place? I noticed you left some parks on the piston, doesn't seem optimal. I tried with some pliers and got the first one off but the other one i had to use a skrevdriver(Ended up leaving a small mark my self).

[@danielbrown6847]

Hi, I have a late model Evo SE120 built by Merch Motors in Canada, and am looking to rebuild the top end. Do you guys offer a kit for this engine? I'm getting rear cylinder position slap type sounds and an about to pull the heads and take a look.

[@cosmiccharlie8294]

Nice job, thanks!

[@anthonyskorner4511]

Bro, I would trade you a drill to take those nuts out quicker for a case bore. Seems like an uneven trade, BUT imagine how much time you'd save. Time=money.

[@tvd1188]

is there a link to the re-assemble video?

[@leanmario]

very good video

[@chrisnichols9187]

Great info man.You have a new subscriber

[@HAMMERPERFORMANCE]

Awesome, thank you!

[@mikeinvegas1]

Would this be yhe same for a 2001 harley softail?

[@HAMMERPERFORMANCE]

Hi Mike, for the most part yes. We will eventually be doing some vids on the twin cams.

[@danholloway892]

I noticed, that when you remove the Rocker Box you removed the bolts in circle pattern. Would it be better, (less strain on the bolts) to remove in a cross hatch pattern?

[@ace7626]

Good stuff guys

[@gregburgess6884]

Very cool 👍

[@predator_boiz336]

Do you drain the motor of oils before starting the disassembly??

[@DAVIDJACKSON-gu7nc]

The mystery is gone. I can handle this. Thank you for making these videos and helping us do it ourselves.

[@loveisouneed]

thx for ur video

[@DoRC]

Do you guys do pro bono? Ive got a sad story and "need" 1250ccs;)

[@gabrielgarcia1970]

haha!

[@trevorhenry1003]

Odd question but why did you use two pliers instead of the wrench and one set of pliers?

[@royswing5024]

The easiest way I’ve found to get tdc on compression stroke, at least very close is lightly put a piece of Kleenex, tissue, in the spark plug hole and it will pop it out when it gets to tdc, then you can get it exact from there

[@HAMMERPERFORMANCE]

good Idea!

[@royswing5024]

HAMMER PERFORMANCE of coarse in the case of a broken, bent, stuck open valve that wouldn’t work cause it would never make any compression.

[@dannybam1]

You have to take the exhaust pipes off or the top cylinder head won't come off is that correct thank you??

[@HAMMERPERFORMANCE]

yes, you will have to remove the exhaust to remove the heads

[@dannybam1]

@@HAMMERPERFORMANCE thanks man just doing the front cylinder cause the spark plug hole had a heater coil in it stripped so it's the first time I've ever done this Could I ask you more questions or is there a better way to do that? thank you dan

[@HAMMERPERFORMANCE]

you can always shoot us a call and we can try and help as much as possible.

[@vontegethoff]

Excellent video. Thank you

[@dalemasyk1583]

thank you you guys for theses videos , thats quite a job n a hafl :) n learn alot too

[@micahlewis5]

Another excellent tutorial video, hiccups and all. That's how it really goes! Lots of little tips and tricks of the trade along the way really help. I learned a lot from this video, especially concerning TDC. This came just in time right before I disassemble my rear head for a gasket refresh. Keep on hammering away. Looking forward to assembly tutorial!

[@lucasdasilva5631]

I've always wanted to do something like this. I will be doing a 1275 kit. What does a 1275 kit with the best cam and head work go for? Since I'm gonna do it. I wanna do it big.

[@HAMMERPERFORMANCE]

Our flagship package is the 120+hp package which is described here: www.hammerperf.com/883conversions.shtml#120hp . Download the sample quote for your year bike to see everything included, the price for each, and you'll find the total on the last page.

[@fmwoodswoody8018]

I cannot seem to find anyone who can answer my question! I’ll bet you will know. I have an ‘84 XLX 61 and want to do a 1200 conversion. Will 1200 heads bolt up?

[@HAMMERPERFORMANCE]

The 1200 didn't come out until 1988. All 1200's are Evolution motors. Your bike is an Ironhead. There are massive differences in the top ends between Evolutions and Ironheads and basically nothing interchanges. Everything you can imagine is different between the two, including the bolt pattern.

[@danielleridlon]

Thank you SO MUCH for this video!! Am I okay to not disassemble my rockers if I only need to remove the cam cover, leaving the gears in place?

[@HAMMERPERFORMANCE]

you will need to remove the rocker boxes to take pressure off the cams if you are going to remove the cams

[@grimeyhonkyracing3938]

How do you get the rocker arms themselves out on the 07 XL? Mine seem to be stuck can't slide the pins out

[@HAMMERPERFORMANCE]

Sounds like you're probably trying to remove them without first removing the rocker box? If so, that's a really bad idea. You could damage something, and also you're not going to be able to reassemble it anyway without removing the box due to the fact that the lifter will be full of oil and prevent you from putting the rocker back into position. So just do it right and remove the rocker box. The pin will basically fall out at that point.

[@grimeyhonkyracing3938]

@@HAMMERPERFORMANCE I admit im not known for being too bright but both my rocker boxes are off the bike and sitting on a table. My heads are at your shop as i type this. The rocker arms spin freely but i can't get the rocker shafts out or remove the arms from the assembly. Your videos didnt cover this particular piece of installation or removal, i know you did it because i can see the red assembly lube on the ends of your rocker shafts it just not in the videos. Thanks Hammer!! 🙏

[@grimeyhonkyracing3938]

@@HAMMERPERFORMANCE i tapped it out slowly it came out it was just really snug

[@dillionboshell6062]

When will the assembly he posted ?

[@HAMMERPERFORMANCE]

starting now

[@robertmitchell2289]

man, this is really helpful.

[@bustersophie7502]

what did the valve being stuck open have to do with the piston coming to TDC, I'm kinda lost on that one

[@Ricky-mouser]

I've been looking at that too. It looks to me like the intake and exhaust are timed together but they aren't timed correctly to the crank. It would be interesting to see the cam chest off and see if the timing marks line up. Here's a guess .... someone put the cams in wrong and when they went to start it the back cylinder fired forcing the front piston up on an open valve?

[@BryanHemedinger]

would you recommend using a thread chaser to clean before installing new bolts?

[@HAMMERPERFORMANCE]

normally not. We try not to at all costs, or you may take the chance of weakening the the threads.

[@brotherjason8635]

Great videos Love if you could make a video how to remove engine from buell x1 👍😁😎

[@HAMMERPERFORMANCE]

You don't so much remove the engine, as you remove the frame/forks/front wheel assembly. Support the bottom of the engine, disconnect the things that connect the frame to the engine/rear wheel assembly, and roll the frame and front wheel assembly away like a wheelbarrow, leaving the engine/swingarm/rear wheel assembly as shown in the video. It's not hard to do.

[@brotherjason8635]

@@HAMMERPERFORMANCE thanks for quick and detailed reply As they say, easy when you know how, I'll get there some day 😎 Thank you for the info 👍

[@camarocruser69]

At 36:03 what is that noise 😂

[@cro2711]

Fantastic video

[@daveg1208]

A few questions: How similar are the Buell and Sportster lower ends? And are there limitations as to how many miles can be on a bike lower end for a safe upgrade to the 1250 - 1275 kits? Thank you in advance. God bless you brother.

[@HAMMERPERFORMANCE]

Through the 2002 model year, Buells and XL's shared the same crankcase. Buell flywheels were lighter than XL flywheels however, for all but the S2 models. But all the parts interchanged including the cams. Beginning with the 2003 Buell XB, Buells got a different crankcase and interchangeability almost completely went away. Then in 2008, there was another big change in the XB lower end, diverging it from the Sportsters even more - except the new for 2008 XR1200, which shared many of the new XB pieces.

[@HAMMERPERFORMANCE]

As far as miles go, it's really the luck of the draw. I've seen cranks fail on stock 883's before they've hit 10K miles, and I've seen hot rodded bikes go over 100K miles on the stock lower end. The other big factor, besides luck, is how the bike is ridden. Spend a lot of time at high rpm and the life is shortened and the risk of failure goes up. Ride it normally with only occasional visits to high rpm and they generally last a long long time. Bottom line, we can't nail down a number of miles, there are too many other factors beyond just miles that factor into it.

[@jonmoney6289]

Love your videos but I have a hard time finding the reassemble video

[@HAMMERPERFORMANCE]

You can find our full library of videos here: kzbin.info/door/m-C_FPfbVCNIjgg7N7qh4Qvideos

[@willjohnson211]

First view

[@GixxerFoo]

Guess I got the second lol

[@BrianMikasa]

Solid video but man that stuck intake valve bit really made such a crucial point in the video a bit confusing.

[@flyingzebra311]

Good old Hopeless freight ...(Hazards freight) NO those tools will cost you more in the long run

[@audiloves4284]

This is a great video to learn thank you, though I have 1 question. While I plan to do a 1275 kit once im a bit more comfortable with riding i do have to do top end gaskets to my 01 sportster. I plan to leave the pistons in the cylinders much like how you guys ship the pre-assembled 1275 kits. If I have to deal with that ridge on the wrist pin, will it cause me trouble me trying to put it back in? Thanks for your input.

[@jacobaltman1547]

the kits all have bigger cylinders which means bigger pistons. the new pistons shouldnt have any wear to them.

[@audiloves4284]

@@jacobaltman1547 im aware of that. But currently I'm just doing a top end gasket replacement because my cylinder base gaskets are leaking as well as my pushrod tube seals. So at the moment im not actually doing the big bore kit. But this video is still a great reference for disassembly. So my question is if I have to deal eith a wrist pin ridge, will it be a problem gojng back in?

[@audiloves4284]

@@jacobaltman1547 thank you for trying to help btw. Not trying to come off like a dick.

[@jacobaltman1740]

@@audiloves4284 ahh gotcha didnt pick up on that. Sorry I don't have experience putting the same pjstons bacl in so cant say, I feel like it would be easier for them to go back in tho. If its not leaking too bad, I would carry extra oil and add it as it leaks out until you could save up for the big bore bc doing the whole top end gaskets twice would be alittle pricey in the long run and just kinda a pita. hammer sells a topend set for pretty cheap with their kit. Good luck on whatever u go for

[@audiloves4284]

@@jacobaltman1740 yeah im an auto tech so not afraid of the work. Though bikes are a bit different obviously, they're still engines, so they still gotta work ha. And i wanted to just baby it till winter and do the 1275 kit but as soon as I got it registered and went for like a 10 mile ride I stopped for some food and looked at the bike and noticed it was spraying all over the rear tire and was like well, tjats not fuckin safe and babied it home and started tearing it apart. So between that fact that don't really have the money for a big bore kit right now and the fact that this is my first bike since my dirt bike in my teen years, I felt its probably better to jist fix the leaks and get better/more comfortable on the bike before almost doubling the power output of it ha