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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.




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  • 1988 Sportster
  • 1990 Sportster
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  • 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

Author: Hersey Cartwright

Hersey Cartwright

1992 EVO Project Budget

1992 EVO Project Budget

December 14, 2018 by Hersey Cartwright

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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EVO Repair Manual…

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…

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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EVO Motor Project…

EVO Motor Project…

October 31, 2018 by Hersey Cartwright

Yeah, I know this is not a Sportster but this is my next project. This 1992 Harley Davidson 80″ Evolution motor was replaced with a 96″ S&S motor in my 1992 Heritage Softail many years ago. It has been sitting on the…

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Sissy bar…

Sissy bar…

October 29, 2018 by Hersey Cartwright

Mounted the sissy bar on the Sportster this weekend. The pad is new, but the other parts are swap meet finds. I may paint the support brackets at some point but it doesn’t look too bad as it is.

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Front Brake Caliper Rebuild…

Front Brake Caliper Rebuild…

October 23, 2018 by Hersey Cartwright

There is always something… Everything is put back together. Thought we were ready to ride. Before we left for Biketoberfest I noticed a leak up front. Thought it might be fork oil but it was brake fluid. The front brake caliper was…

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RPM…

RPM…

October 8, 2018 by Hersey Cartwright

Installed a cheap tachometer on the 1990 Sportster. I’ll upgrade it to something nicer one day, or not. Really only installed it cause the wiring was already there and it was cheap.

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Antique Plates…

Antique Plates…

September 30, 2018 by Hersey Cartwright

The Sportster is a 1990, the same year I graduated from High School, which makes it well over 25 years old. In Virginia, since the bike is over 25 years old, it qualifies for antique license plates.

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Oil Pump Problems…

Oil Pump Problems…

September 23, 2018 by Hersey Cartwright

Had some issues with a lifter not lifting (another post on that later) and discovered the Cam gears were not timed correctly.  Got everything fixed and put back together.  She fired right up and was running great… then the oil light came…

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Rear Rocker Box…

Rear Rocker Box…

August 11, 2018 by Hersey Cartwright

Got a chance to open up the rear rocker box to replace the tappet guide and pushrod cover o-rings, adjust the pushrods, and replace the rocker box gaskets. Second verse same as the first (or front in this case).

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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

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

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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