Big Bore Kit

[lawdog]

Just wanted to document my big bore kit. I purchased a Big Bore Kit from Hammer Performance. They are fantastic to work with and I strongly recommend them! I spent $2k for headwork, cams, pushrods, bore out throttle body, 1250 kit, and gaskets. It is a nice package.

First remove the motor following these instructions.

Then remove the heads, cylinders, cams, etc.

Clearance the cambox so the cam lobes will clear the case and pinion race.

Install the cams and verify the timing.

Assemble rest of the motor.

Ceramic coated headers from CCP Coatings in Detroit MI.

Install motor back into bike.

Along the way I also did the following:
Installed higher pressure fuel pressure regulator to handle increased demand for fueling. (FP10153)
New fuel pump strainer. (Airtex FS213)
New fuel pump filter. (Puralator F29160)
Replaced drive belt. (Found a crack)
New plugs and wires. (Found several cracks in wires)
Handlebar risers for more comfort.
New oxygen sensor. (12014)
Mueller clutch for easier pull.
Sent fuel injectors out to be cleaned.
New fan. (Squeak, squeak, squeak)
Built a muffler with 2.5 dual outlets. It's a chest thumper.

So far did several short runs to heat cycle the motor and an oil change. Got a leak at one of my front brake crush washers from the handlebar swap so need to swap and bleed. Hoping to have time this weekend to work on the break in some more.

Runs fantastic. I did richen up the mixture to around 13.2 to be safe for the time being. Once broke in I will tune. Right now I have the wideband on the front cylinder just to monitor.

 

[08herobolt]

Question Lawdog. Did you always want the Hammer 1250 or did you look at others? Just wondering if you found any issues with other 1250 kits.

 

[Chicknstripn]

Sounds like he did real good! I spent about $2500 with NRHS for almost the exact same kit! Only thing is mine DID NOT include boring out the throttle body!
Great write up!

 

[lawdog]

I did look around and several reasons brought me to Hammer Performance.
1.They had fantastic customer service. Dan and Aaron answered every question, didn't act annoyed like I was bothering them, and was straightforward about everything.
2. They had a good internet reputation on multiple forums. Heard nothing but good things as to the quality of their work, especially head work.
3. They gave me a substantial price discount for being a BuellXB member off retail price. I told them my budget of $2k and they made it work! Even came with pistons installed in bore.
4. The instructions on their website were easy to follow. Took about 1.5 hrs to tear bike apart and ship heads, cams, and tb. Took about an hour to clearance the cam chest. And probably around 3-4 hours over several evenings to assemble.

Issues I ran into.
As I took everything apart I stuck the bolts in zip lock bags and labeled so that made it super easy. During the teardown I found some parts that were worn and replaced since I had it apart.

Had two bolts that I had to heat them to get out and ended up replacing them.

The fuel injector guy took a while to clean my injectors and made me nervous I wasn't getting them back. Hence no name promotion here!

UPS was rough on my headers and they have a scratch. Petty but still annoying. When removing my headers one of the studs came out so I replaced the studs.

I used crush washers from AutoZone for the front brake line for the risers. They were thinner and crappier quality and leaked. Replacements are suppose to come in today.

Otherwise it was an easy job. No wtf did I get myself into moments or will I ever get this back together again! Lol

I went with the 1250 kit because any larger I would need to send the engine to be bored out for the jugs. Out of my budget for the build.

Also love the Mueller clutch. Such a nice pull! Well worth the price.

Brett

 

[heagachongoose]

Awesome [up] Glad to see it worked out nicely

 

[lawdog]

Thanks.
Here are the specs.
1250 Big Bore Kit
"Crush" head work (Stage 3)
Redshift 585/591 cams
Pushrods
Ported Intake/TB
Cosmetic Gasket Set

Supporting mods.
Fuel Pressure Regulator
Open airbox and K&N Filter
Drummer style muffler
Wideband tune using ZT1

 

[lawdog]

Starting up for the first time.
Youtube


Second statup
Youtube


Sorry for the quality. Taken with my cell phone.
Brett

 

[JasonandMichelle]

This is awesome. If I had the cash sitting around (and the free time: I have three young kids), I'd be on this.

 

[fireinxb]

awesome man! I cant wait to see some WOT videos and hear your impressions on the difference with the work done.

 

[lawdog]

For sure. I will keep you updated. I am a single dad with two kids so things move at a slow pace! This weekend is moms weekend so hoping to get some good break-in done. I especially want to dyno it and see the results. Too soon to provide any feedback.

Cost wise I have $2k in the kit and another couple hundred in oil, filter, parts, etc. Time wise I have about 5 hours into it and will probably spend another couple hours tuning it as I ride.

 

[Matteson]

pretty cool man.