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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
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  • 1988 Sportster
  • 1990 Sportster
  • 1992 EVO Big Twin
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  • 1992 Heritage Softail
  • 1999 Honda Shadow
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  • 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: May 2021

8 over front fork tubes…
88 Swedish Style Sportster 

8 over front fork tubes…

May 28, 2021 by Hersey

I thought the front fork tubes were 8 over, I should have measured as the fork tubes which were on the bike are only 6 over. They are getting replaced with the 8 over fork tubes from TC Bros Choppers, so it…

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Front fork tubes…
88 Swedish Style Sportster 

Front fork tubes…

May 24, 2021 by Hersey

The fork tubes on the 88 Sportster are 8″ over and they are pretty crusty. I was hoping I could save them, but they are too far gone. Lots of pitting especially under the dust cover and just at the seal. So…

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Battery Tray Mount Repair…
88 Swedish Style Sportster 

Battery Tray Mount Repair…

May 14, 2021 by Hersey

On this 88 Sportster both of the mounts on the oil tank which the battery tray bolts to are broken. Forney Easy Weld 140MP to the rescue! Removed the oil tank, cleaned it up, and did a piss poor job of welding…

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Key switch and light mount…
88 Swedish Style Sportster 

Key switch and light mount…

May 12, 2021 by Hersey

Last night I had some time in the garage and I made a mount for the key switch, oil pressure indicator light and neutral indicator light. The bike did not have oil pressure or neutral indicators. Since I am adding them I…

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First start after 15 years…
88 Swedish Style Sportster 

First start after 15 years…

May 10, 2021 by Hersey

The last time this 1988 Sportster was started was around 15 years ago, back in 2006. Well Friday night, that clock was reset. Finished putting the motor back together, added some oil and primary fluid, threw on a set of pipes, wired…

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Putting Her Back Together…
88 Swedish Style Sportster 

Putting Her Back Together…

May 3, 2021 by Hersey

Rode motorcycles, smoked cigars, and made a lot of progress on the Sportster over the weekend. Everything is pretty much cleaned up and going back together. Got the pistons and cylinders assembled. Then put together the cams, pushrods, and rocker boxes. Cleaned…

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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

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

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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Categories

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Most Viewed Posts

  • Oil Line to Tank Connections (38,696)
  • Sportster Project Wiring… (33,539)
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