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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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  • 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

Tag: heads

Sportster Tinkering, Heads and Cylinders…
1988 Sportster 

Sportster Tinkering, Heads and Cylinders…

August 29, 2019 by Hersey

Pretty much have the whole 1988 Sportster engine tore down and the first few layers of crude cleaned off everything. The James Complete Engine Gasket kit showed up so I start working on the cylinders and heads.

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Tearing things down and making a list…
1988 Sportster 

Tearing things down and making a list…

August 26, 2019 by Hersey

The weather was kind of crappy on Saturday so I started working through the 1988 Sportster engine I picked up. Not even close to an expert here, but IMHO it seems to be in fairly decent shape for an engine which hasn’t…

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Heads and Rocker Boxes…
1992 EVO Big Twin 

Heads and Rocker Boxes…

December 26, 2018 by Hersey

Had a great Christmas with a lot going on, but had some time in the garage to tinker on the 1992 Harley Davidson Evolution motor. Got the cylinder heads on, pushrods installed, and the rocker boxes all buttoned up. Looks great, manual…

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Valve Seals, Springs, and Keepers…
1992 EVO Big Twin Tools 

Valve Seals, Springs, and Keepers…

December 20, 2018 by Hersey

Cylinders have been honed, valves have been lapped, and the pistons and rings have been installed. Getting the valve oil seals and valves installed in the heads so I can get the 1992 Evolution motor top-end put back together.

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Lapping Valves…
1992 EVO Big Twin Tools 

Lapping Valves…

December 10, 2018 by Hersey

The weather sucked this weekend, but at least we did not get any snow. I did make some progress on the EVO motor. Got the heads cleaned up, as clean as I could get them, and the valves lapped.

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Valve Removal…
1992 EVO Big Twin Tools 

Valve Removal…

November 26, 2018 by Hersey

Removed the valves from the EVO motor heads. The valve springs are held with keepers on the valve stems. To remove the valves the springs need to be compressed to remove the keepers.

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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

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

Recent Comments

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Categories

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Most Viewed Posts

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