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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
  • 2014 Street Glide
  • 1992 Heritage Softail
  • 1999 Honda Shadow
  • Riding
  • 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
Grips and Floorboards on the Dyna Wide Glide
1999 Dyna Wide Glide 

Grips and Floorboards on the Dyna Wide Glide

September 2, 2022 by Hersey

I know, I know it has been a good long while… sue me. Been a busy almost year with work and grandkids and riding and just stuff. I’ll try to do better, but I ain’t making any promises. I have had the…

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HogWorkz Street Glide Lower Fairings…
2014 Street Glide vlog 

HogWorkz Street Glide Lower Fairings…

August 28, 2022 by Hersey

I did a video on the YouTube channel a long time back but for some reason this post has been setting in my drafts folder… dummy. I picked up a set of HogWorkz lower fairings for the Street Glide a while ago….

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It’s Been a Minute…
Other Stuff Tools 

It’s Been a Minute…

November 9, 2021 by Hersey

I know it has been a bit since my last post. Still here, just been really busy with work and family stuff. Biketoberfest was a blast and I posted a couple of videos to the SportsterProject.com YouTube Channel. One from Willie’s Chopper…

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Rabbit Ear Handlebars…
88 Swedish Style Sportster vlog 

Rabbit Ear Handlebars…

September 21, 2021 by Hersey

The 88 “Swedish Style” Sportster project is getting a set of rabbit ear bars. The current bars on the Sportster are OK, they were just some I had but I don’t really like the pull back on them. I got a good…

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New Battery in the New (to me) Bike…
1999 Dyna Wide Glide vlog 

New Battery in the New (to me) Bike…

September 14, 2021 by Hersey

I picked up this 1999 Harley Davidson Dyna Wide Glide (FXDWG) a few weeks ago. Very nice bike. The bike was very well kept by the previous owner but it had been sitting for awhile so the battery was dead and would…

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Shadow Fuel Pump Delete
1999 Honda Shadow vlog 

Shadow Fuel Pump Delete

September 7, 2021 by Hersey

Removing the fuel pump to simplify the fuel delivery system on a my wife’s 1999 Honda Shadow VT750 ACE. The new TJ Brutal Customs peanut gas tank raises the fuel petcock well above the carburetors which will allow fuel to be gravity…

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Registering an Antique Motorcycle
1988 Sportster 1990 Sportster 1992 Heritage Softail 88 Swedish Style Sportster vlog 

Registering an Antique Motorcycle

August 30, 2021 by Hersey

I own several motorcycle registered as antique vehicles. What makes a motorcycle an antique? In Virginia if the model year of the motorcycle is more than 25 years old prior to January 1st of the current year, and you are not using…

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90 Sportster Leaky Fork Seal…
1990 Sportster vlog 

90 Sportster Leaky Fork Seal…

August 25, 2021 by Hersey

Getting close to getting the 90 Sportster back on the road. While it is on the lift being put back together I noticed a leak in one of the fork seals. When I put this bike together originally I did not mess…

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Rebuilding the carb for the 90 Sportster…
1990 Sportster vlog 

Rebuilding the carb for the 90 Sportster…

August 16, 2021 by Hersey

In my last post I disassembled the new to me CV carburetor which will replace the carburetor I took off the 90 Sportster to use on the 88 Sportster. The carburetor has been in the ultrasonic cleaner, then rinsed with hot water….

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Cleaning the carb for the 90 Sportster…
1990 Sportster vlog 

Cleaning the carb for the 90 Sportster…

August 14, 2021 by Hersey

I pillaged some parts and pieces from the 1990 Sportster to get the 1988 Swedish Style Sportster running. Mainly the from the intake, including the manifold, the CV carburetor, and the carburetor support bracket. I picked up a used intake manifold and…

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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

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