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Sportster Project

Trials and Tribulations (and good times) of my motorcycle projects and other motorcycle tinkering. Building, Wrenching, and Riding Harley Davidson Evolution Sportsters, Big Twins, and anything else with two wheels. Currently working on building a 1988 Sportster.




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  • Gear cover and oil lines
    1988 Sportster

    1988 Sportster Project Check In…

    December 10, 2019
  • Front forks disassembled.
    1988 Sportster

    Thanksgiving tinkering…

    December 2, 2019
  • 1988 Sportster Engine in Frame
    1988 Sportster

    Engine meet frame…

    November 26, 2019
  • 1988 Sportster Frame Painted
    1988 Sportster

    Just some paint…

    November 12, 2019
  • 1988 Sportster

    Motor Mount Nuts and Bolts…

    October 14, 2019
  • 1988 Sportster Frame
    1988 Sportster

    Slow progress is still progress…

    October 7, 2019
  • 1988 Sportster

    Titled 1988 Sportster Frame!!!

    September 23, 2019
  • Oil Pump, Cam Gears, Tappet Guides, Pushrod covers...
    1988 Sportster

    Sportster Cam Gear Box…

    September 8, 2019
  • 1988 Sportster

    Sportster Tinkering, Heads and Cylinders…

    August 29, 2019
  • 1988 Sportster Engine - Cam Side
    1988 Sportster

    Tearing things down and making a list…

    August 26, 2019

Month: December 2018

I see you…
1990 Sportster 

I see you…

On December 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…

On 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…

On December 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…

On 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…

On 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

On 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…

On 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…

On December 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…

On 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…

On December 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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J&P Cycles

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bars black brakes carb carburetor chain Clutch coil compression controls cut cylinder engine EVO exhaust fender frame garage gas gaskets gas tank Harley Davidson headlight heads ignition iron butt mount oil lines oil pump oil tank paint parts piston Primary project pushrods rear Sportster start Street Glide swap meet tappet valve weld wiring




Links and Resources

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

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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