Hey all i just picked up my 90 883 hugger shes mostly stock with the exception of some cosmetics mirrors seat foot pegs ect. i need to know if i can do a top end gasket and seal replacement with the motor in the fram or am i going to have to pull the motor i have about .5in of clearance between the rear cylcinder rocker box and the frame rail. just needing to know so i can decide where to tackle the project. thanks in advance

 

Well, I never had to do a top end job on my '89 883, but I did have to disassemble the rocker boxes a time or two, and had no trouble doing that. I'm pretty sure I've seen Evo Sportsters in the shop with the heads and cylinders removed with the engine in the frame. As I remember, an acquaintance of mine had a top end done on her Sportster last winter with the engine in the frame.


Heck, with your '90, you can strip and rebuild the transmission with the engine in the frame.

 

Hey thanks brother that's what I needed to know takes a load off my mind knowing I can finish her where she is and not have to move her in pieces.
safe rides and good winds to you

 

That's why the MoCo split the rocker boxes into three layers, so they could be disassembled with the motor in the frame. Once the rocker boxes/rocker arm assembly is out, there's enough room to pull the heads and cylinders. I'm not sure why the service manual calls for the motor to be removed first. I guess they're just explaining how it's done, not whether it's needed for a simple top-end job.

 

I'm guessing the same reason the manual call for dealer recommended fluid, legalities and fear of suit.thanks again I'll post when we're done and let ya know how it goes

 

The manual isn't real clear there. For cylinder head removal, it says to strip the bike per the section on stripping for engine repair, which has you strip it down like you were going to pull the motor. But you only need to do a part of that, like the tank, seat, throttle cables, etc. At no point does it say pull the motor.

 

If you don't have one get yourself the FSM. There is plenty of essential useful stuff in it, even if it tells you to take the motor out of the frame but you don't have to! I've taken the heads off shovels and big Evo twins while still in the frame - and Dr H is an experienced tech, so if he says a Sporty can be done in the frame too, that's good enough....!