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Sportster Project

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 building a 1988 Sportster. I also post information on other DIY projects I tinker on.




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  • 1988 Sportster
  • 1990 Sportster
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  • 1999 Honda Shadow
  • Riding
  • Noco Battery Charger Quick Connect
    1988 Sportster / Tools

    Charge!!! Battery Charger Quick Connect…

    August 9, 2020 by herseyc
  • Old school king queen Harley Davidson Sportster seat.
    1988 Sportster

    Old School Seat…

    July 15, 2020 by herseyc
  • Sportster Carburetor
    1988 Sportster

    Running right…

    May 11, 2020May 11, 2020 by herseyc
  • LED Headlight
    1988 Sportster

    Let there be light…

    May 5, 2020 by herseyc
  • Headlight Mount - Headlight attached to mount.
    1988 Sportster

    Headlight mount…

    April 30, 2020November 12, 2020 by herseyc
  • SportsterProject.com Tank Decal - Step 3
    1988 Sportster

    Decals…

    April 20, 2020 by herseyc
  • 1988 Sportster Project - Almost Ready to Ride
    1988 Sportster

    Almost there…

    April 16, 2020November 12, 2020 by herseyc
  • Sportster Tank and Front Fender Painted Satin Black
    1988 Sportster

    Little bit of black paint…

    April 13, 2020November 12, 2020 by herseyc
  • Sportster forward controls shift linkage
    1988 Sportster

    Shift linkage…

    March 30, 2020 by herseyc
  • Sportster Air Cleaner
    1988 Sportster

    DIY Sportster carburetor air cleaner…

    March 13, 2020 by herseyc

Month: December 2018

I see you…
1990 Sportster 

I see you…

December 27, 2018December 27, 2018 by herseyc

Picked up a mirror for the Sporty. Looking good if I do say so myself, and so does the mirror. This will probably be the last post in 2018, so have a HAPPY NEW YEAR!!! Looking back at the things I have…

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Heads and Rocker Boxes…
1992 EVO Big Twin 

Heads and Rocker Boxes…

December 26, 2018 by herseyc

Had a great Christmas with a lot going on, but had some time in the garage to tinker on the 1992 Harley Davidson Evolution motor. Got the cylinder heads on, pushrods installed, and the rocker boxes all buttoned up. Looks great, manual…

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Valve Seals, Springs, and Keepers…
1992 EVO Big Twin Tools 

Valve Seals, Springs, and Keepers…

December 20, 2018December 20, 2018 by herseyc

Cylinders have been honed, valves have been lapped, and the pistons and rings have been installed. Getting the valve oil seals and valves installed in the heads so I can get the 1992 Evolution motor top-end put back together.

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Pistons, Rings and Cylinders…
1992 EVO Big Twin Tools 

Pistons, Rings and Cylinders…

December 17, 2018 by herseyc

Making progress on the 1992 Evolution motor. Got the pistons installed and the wrist pins in. Installed the rings on the pistons and the cylinders installed. Starting to look like a motor again, instead of just a bunch of parts scattered about…

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Cylinder Honing…
1992 EVO Big Twin Tools 

Cylinder Honing…

December 15, 2018 by herseyc

The pistons seem to still be in good shape and I am replacing the rings. I measured the cylinders and pistons to make sure everything was still in specs defined in the service manual. The cylinder walls are nearly smooth. I needed…

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1992 EVO Project Budget
1992 EVO Big Twin 

1992 EVO Project Budget

December 14, 2018 by sporty

I put this budget together before I started working on the project and created a Google Sheet to track what I am spending on the 1992 EVO Project.

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Cam Gear, Tappet Guides, Oil pump…
1992 EVO Big Twin Tools 

Cam Gear, Tappet Guides, Oil pump…

December 13, 2018 by herseyc

Did some tinkering on the EVO Motor in the evenings this week. Over a couple of chilly evenings in the garage I got the cam gears, tappet guides, and oil pump installed.

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Lapping Valves…
1992 EVO Big Twin Tools 

Lapping Valves…

December 10, 2018December 10, 2018 by herseyc

The weather sucked this weekend, but at least we did not get any snow. I did make some progress on the EVO motor. Got the heads cleaned up, as clean as I could get them, and the valves lapped.

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Parts is parts…
1992 EVO Big Twin 

Parts is parts…

December 7, 2018 by herseyc

Everything has been cleaned up and ready to start putting things back together. Ordered some of the parts I need to get started with the assembly. Some of them will be here this weekend so I may get a chance to get…

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Honda Shadow Carb…
1999 Honda Shadow 

Honda Shadow Carb…

December 3, 2018December 3, 2018 by herseyc

Had to do a little work on the wife’s 1999 Honda Shadow. It has been setting awhile. Thanksgiving weekend the weather was great and she wanted to take it out for a ride, it started and idled just fine but would not…

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Tags

bars Biketoberfest black brakes carburetor chain Clutch coil cut cylinder DIY engine exhaust fender frame garage gaskets gas tank Harley Davidson headlight heads ignition iron butt leak mount oil lines oil pump oil tank paint parts piston Primary project pushrods rear ride rocker box Sportster start Street Glide tank tappet weld wheels wiring




Links and Resources

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

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

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