Zipper’s Big Bore Cylinders For Sportster® And Buell® Engines

ZippersSportstersIf you want to increase the engine size of your 883/1200 Harley Sportster or Buell engine, Zipper’s has developed 3-13/16” bore aluminum alloy cylinders to ley you go to 88″ while still keeping the stock stroke crankshaft. Cylinders are manufactured with high quality cast-in iron liners and will work in all types of performance applications. Includes design improvements for structural integrity, plus cooling fins have been increased to improve heat transfer.

ZippersSportstersBisUn-honed cylinders can be fitted with your choice of several piston designs to accommodate specific usages, a service that Zipper’s can provide. (Order pistons, head and base gaskets separately. Multiple thickness base gaskets are available to allow the engine builder to set piston-to-head squish. (3-13/16” is the largest bore size that the stock H-D® XL cases can be safely bored for. 3-5/8” bore is the maximum S&S replacement XL/Buell cases can be bored for.) You can view and downloard a Dyno Chart by clicking HERE. More info at: Zipper’s Performance Products.

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12 Responses to “Zipper’s Big Bore Cylinders For Sportster® And Buell® Engines”


  1. 1 LenNY Jan 10th, 2013 at 10:43 am

    The Sportster is a great platform for a performance engine build. This should do the trick great product from Zippers add a good cam and head work and you would have plenty of bang for the bucks.

    LenNY Sinnet

  2. 2 Chris Jan 10th, 2013 at 11:58 am

    Maybe somebody from Zippers can chime in here. Once you bore that stock case to 3 13/16″, how much material is left on the case where the cylinder bolts on? On a stock evo case, it gets paper thin at that bore. And paper thin isn’t an exaggeration here, there is very little material left.

  3. 3 Sportster Mike Jan 11th, 2013 at 3:31 am

    Nice to see some proper looking aftermarket cases with the big fins, still wondering what do to my 2009 model year 883 now that I can’t just bore the cylinders out, Shame I’m the wrong side of the pond…
    88ciR instead of a 883R would be good though…

  4. 4 A 1 CYCLES INC. Jan 11th, 2013 at 9:18 am

    HARD TO FIT THE FUEL INE THROUGH THE CENTER OF THOSE CYLINDERS..LOL, BUT IVE USED ZIPS STUFF BEFORE QUALITY AND PERFORMANCE! AMRICAN MADE POWER

  5. 5 Lyle Landstrom Jan 11th, 2013 at 1:30 pm

    Geeze, you can route the fuel line between the heads or around the jugs…

  6. 6 Zipper's Jan 11th, 2013 at 2:21 pm

    With a 3.812 bore XL, the structural integrity of the crankcase is solid. The material thickness of 1991- Current castings has over 40% more material in the thinnest area vs. the old stock EV castings.

    The only area of concern is the clamping of the head gasket. Sealing surface must be true, surface finish must match gasket requirement, cylinder studs are properly secured in crankcase, head bolts are torqued to proper value.

    Proper assembly procedure will yield many miles of pure fun riding a Sportster, XR or Buell engine with this package. We can truly say It’s a lot of fun to ride.

    Will post a link to a downloadable dyno chart shortly.

  7. 7 BobS Jan 11th, 2013 at 4:39 pm

    Will it make over 100hp and tq?

  8. 8 BobS Jan 12th, 2013 at 7:32 pm

    No dyno yet?

  9. 9 BobS Jan 12th, 2013 at 8:02 pm

    Cool found it. Very nice.

  10. 10 Hot Rod Jan 14th, 2013 at 12:54 pm

    I used a competitors 3 13/16″ cylinder kit and the cases needed to be bored out to where half of the oil return hole was cut away but still had lots of meat for the cylinder base. That engine was super smooth (square motor) and made 109 HP (with some head work).

  11. 11 deadwood1783 Jan 14th, 2013 at 1:44 pm

    Zippers Performance is a top shelf operation and I regularly use and recommend their products and services. I have had nothing but positive experiences with Zippers and have no reservations endorsing this company.
    Russ Fullen
    Thunder X Performance
    Tennessee

  12. 12 fat greg Mar 31st, 2013 at 9:59 pm

    I had this kit installed last spring in a 2000 sportster s. With very minor tuning it has 99 HP and 103 TQ at the rear wheel. I bought the torque monster package. Most of the TQ and HP is in at around 3k rpm. This bike is scary fast!!!

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