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Sportster Project

Sportster Project

Build. Tinker. Ride. Trials and Tribulations (and good times) of my motorcycle projects and other garage tinkering. Learning and building things. Building, wrenching on, and riding Harley Davidson Evolution Sportsters, Big Twins, and anything else with two wheels. Currently working on restoring and preserving a 1988 Harley Davidson Sportster chopper. I also post information on other DIY projects I tinker on.




  • Home
  • eBay
  • Tools
  • OEM
  • 1988 Sportster
  • 1990 Sportster
  • 1992 EVO Big Twin
  • 2014 Street Glide
  • 1992 Heritage Softail
  • 1999 Honda Shadow
  • Riding
  • Other Stuff
  • Tested the rear brake bracket fit using the hardware supplied in the kit.
    1990 Sportster

    Sportster Hardtail Rear Brake Bracket…

    December 27, 2023 by Hersey
  • Checking Engine Fit after Welding the TCBro's Hardtail
    1990 Sportster

    Sportster Hardtail Progress…

    December 14, 2023 by Hersey
  • 1990 Sportster

    Cutting the Sportster in Half…

    December 1, 2023 by Hersey
  • TC Bros Sportster Weld-on Hardtail Kit
    1990 Sportster

    Measure 3157 times…

    November 27, 2023 by Hersey
  • Sportster Stripped Down Ready for the TC Bros Hardtail Kit
    1990 Sportster

    Hardtailing the 90 Sportster…

    November 25, 2023 by Hersey
  • Antique Motorcycle License Plate
    1988 Sportster / 1990 Sportster / 1992 Heritage Softail / 88 Swedish Style Sportster / vlog

    Registering an Antique Motorcycle

    August 30, 2021 by Hersey
  • Front Forks Reassembled on the 1990 Sportster
    1990 Sportster / vlog

    90 Sportster Leaky Fork Seal…

    August 25, 2021 by Hersey
  • All Balls Carburetor Rebuild Kit - Everything needed for a CV Carburetor Rebuild - Gaskets, Jets, Screws
    1990 Sportster / vlog

    Rebuilding the carb for the 90 Sportster…

    August 16, 2021 by Hersey
  • Harley Davidson Carburetor Cleaned and Ready for Rebuild
    1990 Sportster / vlog

    Cleaning the carb for the 90 Sportster…

    August 14, 2021 by Hersey
  • Sportster Project Build. Tinker. Ride.
    1988 Sportster / 1990 Sportster / 1992 EVO Big Twin / 1992 Heritage Softail / 1999 Honda Shadow / 2014 Street Glide / 88 Swedish Style Sportster / vlog

    Sportster Project YouTube Channel…

    July 20, 2021 by Hersey

Month: November 2018

Valve Removal…
1992 EVO Big Twin Tools 

Valve Removal…

November 26, 2018 by Hersey

Removed the valves from the EVO motor heads. The valve springs are held with keepers on the valve stems. To remove the valves the springs need to be compressed to remove the keepers.

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Wrist Pins Pulled…
1992 EVO Big Twin Tools 

Wrist Pins Pulled…

November 25, 2018 by Hersey

Needed a tool to remove the piston wrist pins. The service manual says the pins are loose fit and should push out once the clips are removed, this was not so. Ordered this piston pin puller from Amazon and it got the…

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EVO Motor Teardown…
1992 EVO Big Twin 

EVO Motor Teardown…

November 19, 2018 by Hersey

Started tearing down the 1992 EVO motor this past weekend. Removed the rocker boxes, cylinder heads, pushrods, tappet guides, etc. Nothing too exciting. Just getting it all stripped down to hopefully bring it back to life and use it as the base…

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Sissy Bar Bag…
1990 Sportster 

Sissy Bar Bag…

November 17, 2018 by Hersey

Wanted a small bag for the Sporty. Just something to keep the registration, glasses, etc. Didn’t want anything too big. Looked at a bunch of different options and found this nylon bag from Deadbeat Customs.

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Street Glide Upgrades…
2014 Street Glide 

Street Glide Upgrades…

November 9, 2018 by Hersey

I have had the 2014 Street Glide since Biketoberfest 2013. We rode down there on a 2000 Electra Glide and rode home on the 2014 Street Glide. I really like the Street Glide but have not really done anything to it over…

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EVO Repair Manual…
1992 EVO Big Twin 

EVO Repair Manual…

November 4, 2018 by Hersey Cartwright

Picked up the Clymer Repair Manual for 1984-1999 Harley Davidson FLS/FXS Evolution. I already have the factory service manual.

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Street Glide Fuelpak Install…
2014 Street Glide 

Street Glide Fuelpak Install…

November 1, 2018 by Hersey Cartwright

I installed the Vance & Hines Fuelpak FP3 Fuel Management System on my 2014 Harley Davidson Street Glide. I am planning to do some upgrades on the Street Glide and I need to be able to tune the bike’s fuel injection system…

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Tags

battery black brakes caliper carburetor chain cut cylinder engine exhaust fender frame garage gaskets gas tank hardtail Harley Davidson headlight heads honda shadow ignition intake iron butt jeep mount oil lines oil tank paint parts piston Primary project pushrods rear ride sissy bar Sportster start Street Glide tank TJ Brutal Customs valve weld wheel wiring

Links and Resources

  • 1992 EVO Project Budget
  • Biker Direct – Aftermarket Parts
  • TJ Brutal Customs
  • Billet Proof Design
  • The Good Old Motorcycle Parts Company
  • SportsterProject on Instagram
  • Dime City Cycles
  • Lowbrow Customs Sportster Parts
  • Deadbeat Customs
  • CV Performance – Harley Carb Parts
  • TC Bros Choppers
  • Tidewater Motorcycles – Local Shop
  • HD OEM Parts Finder
  • JP Cycles – Aftermarket Parts
  • XL Forum – Sportster & Buell Community
  • My 1990 Sportster Project Pinterest Board

Manual

If you own a 1986-2003 Sportster this is a must have manual.


Clymer Harley-Davidson XL/XLH Sportster
(1986-2003)
Maintenance, Troubleshooting, Repair

Recent Comments

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Most Viewed Posts

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