Well folks, I've done the deed and converted my '07 Sportster to a 1200. Because I wanted a simple and reliable upgrade I decided to do jugs and pistons and stick with the 883 heads. I want to post this info because there's not a whole lot of complete info on doing this conversion on post '07 Sporty's ie the fuel injected ones. And there's quite a bit of confusion on what you need to do exactly and what the options are.
The various shops that I spoke to about getting the conversion done gave me a wide range of quotes with different options every time. Quotes I got varied from around $2500 from the local Adelaide dealer to around $1200 from another shop. Various options that were given to me were:
1) Bore the 883 cases and replace pistons with Wisecos, no fuel option $1200
2) Bore 883 cases and fit SERT from dealer $2500
3) Bore 883 cases and fit Thundermax $2000
4) My option was to get the V-Twin Kit off ebay $570, get it fitted $615 and initially to re-flash the 883 EMC to 1200 with stage 1 $1185
- The 1200 ECM flash worked ok but I eventually went with the Thundermax auto-tune ECM for $860, so in total upgrade cost me around $2000
Another option would be to go with the Harley Screamin Eagle kit which comes complete with 1200 jugs, pistons and heads. I priced the kit from Zanotti's at about 1200 delivered to AU, then you would have to get it installed but this seemed like a pretty good option as it also comes with the Screamin Eagle Air Filter.
Probably the most confusing thing about doing the conversion on a '07 and up Sporty is finding out what the options are in terms of the fuel injection. This is what I found:
- Regardless of whether or not you have a fuel tuner on your 883 you will still need to flash your ECM to 1200 specs.
- If you have the V&H Fuelpak it won't work, even if you flash your 883 ECM to 1200 and set your Fuelpak to 1200 settings. V&H don't have a map as yet for the 883/1200 setup. I spoke to them and they said they will have one soon. With the Fuelpak I found it was best to remove it because the bike ran better with just the flashed 1200 Sporty ECM.
- I've heard of others successfully using a combination of 1200 Spory ECM and the PCIII, although the PCIII needs to be dyno tuned for the upgrade.
- The other option for fuel management is to go with the Thundermax with auto-tune as this replaces the 883 ECM and can be tuned for any setup. Main drawback with this is the $900 cost.
The engine kit I went with was the V-Twin Manufacturing 1200 Big Bore Kit for '04 and up Sporty's, kit comes with:
- Wiseco 9.5:1 dish top pistons,
- Hastings rings.
- Base and head gaskets, head gasket was James but base gasket was a paper gasket so I got the shop to replace it with a James.
- Wrist pins and all clips etc
The kit I bought only came with head and base gaskets but you can buy kits off ebay with complete James top end gasket kits for a bit more. The kit comes in black with milled edge fins or silver with fins closely matching the look of the 883 heads. I decided to go for a mixture of black jugs with my silver 883 heads.
On inspection of the VTwin kit the castings and machining on the jugs looks pretty good. Overall I was pretty happy with the look of kit's quality. I got if fitter at KM Motorcycles in Adelaide and the guys there were pretty impressed with the look of it and even more impressed when I told them what I paid for it.
Biggest bummer of this whole story is that the work on my bike is done but I couldn't get down there today to pick it up so it'll be tomorrow morning now. I'll give you a first hand update as soon as I get one.
V-Twin Manufacturing 1200 replacement barrels
Wiseco 9.5:1 dish top pistons
A pic from the right side of the bike with the V-Twin kit fitted:
Picture of the left site with V-Twin kit installed: