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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 1988 Sportster. I also post information on other DIY projects I tinker on.




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  • 1988 Sportster
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  • 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
  • 1988 Sportster Project - Almost Ready to Ride
    1988 Sportster

    Almost there…

    April 16, 2020November 12, 2020 by herseyc
  • Sportster Tank and Front Fender Painted Satin Black
    1988 Sportster

    Little bit of black paint…

    April 13, 2020November 12, 2020 by herseyc
  • Sportster forward controls shift linkage
    1988 Sportster

    Shift linkage…

    March 30, 2020 by herseyc
  • Sportster Air Cleaner
    1988 Sportster

    DIY Sportster carburetor air cleaner…

    March 13, 2020 by herseyc

Tag: heads

Sportster Tinkering, Heads and Cylinders…
1988 Sportster 

Sportster Tinkering, Heads and Cylinders…

August 29, 2019 by herseyc

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 herseyc

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 herseyc

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, 2018December 20, 2018 by herseyc

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, 2018December 10, 2018 by herseyc

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 herseyc

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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Tags

bars Biketoberfest black brakes carburetor chain Clutch coil cut cylinder DIY engine exhaust fender frame garage gaskets gas tank Harley Davidson headlight heads ignition iron butt leak mount oil lines oil pump oil tank paint parts piston Primary project pushrods rear ride rocker box Sportster start Street Glide tank tappet weld wheels wiring




Links and Resources

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

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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