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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 1999 Honda Shadow ACE. I also post information on other DIY projects I tinker on.




  • Home
  • eBay
  • Tools
  • OEM
  • 1988 Sportster
  • 1990 Sportster
  • 1992 EVO Big Twin
  • 2014 Street Glide
  • 1992 Heritage Softail
  • 1999 Honda Shadow
  • Riding
  • Other Stuff
  • Sportster 2:1 Mini-Speedometer
    1988 Sportster

    How Fast is Fast…

    April 12, 2021April 13, 2021 by herseyc
  • Garage built sissy bar
    1988 Sportster

    Garage Built Sissy Bar – Part II

    April 8, 2021 by herseyc
  • Brake Crafters
    1988 Sportster / 1999 Honda Shadow

    Brake parts and rebuild kits…

    March 29, 2021April 3, 2021 by herseyc
  • How to Build a Custom Motorcycle
    1988 Sportster / 1990 Sportster / 1992 EVO Big Twin / 1992 Heritage Softail / 1999 Honda Shadow / Other Stuff / Tools

    How to Build a Motorcycle…

    February 23, 2021March 19, 2021 by herseyc
  • 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

Category: Tools

The right tool for the right job, sometimes the wrong tool for the right job.

Measure RPM with an Inductive Tachometer
Tools 

Measure RPM with an Inductive Tachometer

March 15, 2021 by herseyc

An Inductive Tachometer is a handy little tool to have in the toolbox if you are working on something which does not have a tach. Knowing the engine RPMs helps with setting the idle engine speed and tuning. Some folks are really…

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Dual Carb Sync…
1999 Honda Shadow Tools 

Dual Carb Sync…

March 5, 2021March 6, 2021 by herseyc

The Honda Shadow has about 45k miles on it. Since I have had the carburetors in and out of it a bunch of times I figured it would probably be worth checking, and adjusting if needed, the synchronization of the carburetors.

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How to Build a Motorcycle…
1988 Sportster 1990 Sportster 1992 EVO Big Twin 1992 Heritage Softail 1999 Honda Shadow Other Stuff Tools 

How to Build a Motorcycle…

February 23, 2021March 19, 2021 by herseyc

Saw this on my instagram feed (can’t remember who shared it). I decided to pick up a copy of How to Build a Motorcycle – A Nut and Bolt Guide to Customizing Your Bike by Gary Inman. Enjoyed the read so figured…

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Charge!!! Battery Charger Quick Connect…
1988 Sportster Tools 

Charge!!! Battery Charger Quick Connect…

August 9, 2020 by herseyc

Been a couple weeks since I fired up the 1988 Sportster. Went to fire her up to take her for a quick ride the other night and the battery was dead 🙁 Had to take the seat off to connect the charger…

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Extended Front Fork Tubes…
1988 Sportster Tools 

Extended Front Fork Tubes…

December 18, 2019November 12, 2020 by herseyc

TC Bros Choppers had a pretty decent “Black Friday” sale on the 6+ 39mm fork tube kit they carry. Was planning on getting one of these kits later on in the project but since the kit was on sale over the Thanksgiving…

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Sealing the tank…
1992 EVO Big Twin Tools 

Sealing the tank…

May 19, 2019 by herseyc

Sealed the tank for the 1992 Evo Project this weekend. The sealer helps protect the inside of the tank from rusting and seals up any pinholes there may be in the weld seams.

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Primary Motor Plate…
1992 EVO Big Twin Tools 

Primary Motor Plate…

March 16, 2019March 16, 2019 by herseyc

I have a 3″ belt drive primary drive on my 1992 Heritage. I really like the look of it and it has performed well for thousands of miles. For this project I chose the 2″ open belt primary kit from Ultima. I…

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Springer FTW…
1992 EVO Big Twin Tools 

Springer FTW…

February 11, 2019February 11, 2019 by herseyc

A little work on the 1992 EVO project over the weekend. Pressed the steering neck cups into the frame and mocked up the springer front end. Starting to look like a motorcycle now, and it looks pretty bad ass. Really like the…

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Welder…
Tools 

Welder…

February 4, 2019March 11, 2019 by herseyc

I have a cheap flux core welder I got from Harbor Freight some time ago. It served its purpose – mostly just to tack things in place, no real “welding”. It quit working so I decided to upgrade and plan to practice…

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Wheels, Tubes, and Tires…
1992 EVO Big Twin Tools 

Wheels, Tubes, and Tires…

January 20, 2019January 20, 2019 by herseyc

The rolling chassis kit I ordered from American Classic Motors was delivered last week. Everything has been unpacked and checked out. I had some time over the weekend so I mounted tires on the rims. The front and rear wheels for the…

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Links and Resources

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

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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