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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
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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

Author: Hersey Cartwright

Hersey Cartwright

New Bars

New Bars

April 19, 2018 by Hersey Cartwright

Got the new bars, risers, and grips this week. Got them all fitted up. Still waiting on the switch covers and front master cylinder from eBay, should have them sometime next week. I think the new bars look fantastic, little different look…

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She’s Alive! She’s Alive!

She’s Alive! She’s Alive!

April 14, 2018 by Hersey Cartwright

She started!!! I replaced the ignition system with a new module, sensor, rotor, and coil. Prior to replacing the ignition system I was getting a spark on both plugs but based on some youtube research; we had a spark, just not enough….

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Exhaust Wrap

Exhaust Wrap

April 9, 2018 by Hersey Cartwright

Looks like the reason we are not able to get the Sporty to start is the ignition module. So replacing it with a Compu-Fire HDE-1 Digital Electronic Ignition which I ordered and is on the way. Since I am waiting on parts…

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Compression Test

Compression Test

April 7, 2018 by Hersey Cartwright

Still having issues getting the Sporty to start. She turns over, sounds like she wants to go… but nope. Have tried a fresh battery and some starter fluid with no luck. Couple of buddies on Facebook said I may not have good…

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So Close…

So Close…

April 2, 2018 by Hersey Cartwright

Sandy and I did some work on the Sporty over the weekend. Primary is all put together. Carburetor and such is mounted. When we hit the button she turns over, even fires a few times, but will not start. Couple of times…

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Preparing to Start…

Preparing to Start…

March 29, 2018 by Hersey Cartwright

Just a quick checklist of things I need to finish up to try and get the Sporty started, maybe this weekend.

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Replacing the Exhaust Studs

Replacing the Exhaust Studs

March 28, 2018 by Hersey Cartwright

Did some tinkering on the bike this evening after work. When I tore things down and I pulled the exhaust off two of the four studs, one in the front and one in the rear, came out with the nut so I…

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Signs of Life

Signs of Life

March 26, 2018 by Hersey Cartwright

Just a bit of tinker on the Sporty this weekend. Nothing major done, but checked a couple of small things off the list. Every little thing gets me that much closer to making it go (and be bad ass while going).

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New Oil Tank

New Oil Tank

March 21, 2018 by Hersey Cartwright

Had the day off today and the new oil tank showed up. After a trip to the dealership to pick up the isolation mounts I got it fitted. Not completely done yet, I have a couple other things to do first, but…

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Frame Freshening Up – 10 Foot Fix

Frame Freshening Up – 10 Foot Fix

March 19, 2018 by Hersey Cartwright

Took a wire brush to a couple of rust spots where the seat hits the frame. Cleaned them up real good, hit them with some etching primer and then some black engine paint.

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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

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