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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

Month: December 2018

I see you…
1990 Sportster 

I see you…

December 27, 2018 by Hersey

Picked up a mirror for the Sporty. Looking good if I do say so myself, and so does the mirror. This will probably be the last post in 2018, so have a HAPPY NEW YEAR!!! Looking back at the things I have…

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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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Pistons, Rings and Cylinders…
1992 EVO Big Twin Tools 

Pistons, Rings and Cylinders…

December 17, 2018 by Hersey

Making progress on the 1992 Evolution motor. Got the pistons installed and the wrist pins in. Installed the rings on the pistons and the cylinders installed. Starting to look like a motor again, instead of just a bunch of parts scattered about…

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Cylinder Honing…
1992 EVO Big Twin Tools 

Cylinder Honing…

December 15, 2018 by Hersey

The pistons seem to still be in good shape and I am replacing the rings. I measured the cylinders and pistons to make sure everything was still in specs defined in the service manual. The cylinder walls are nearly smooth. I needed…

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1992 EVO Project Budget
1992 EVO Big Twin 

1992 EVO Project Budget

December 14, 2018 by Hersey Cartwright

I put this budget together before I started working on the project and created a Google Sheet to track what I am spending on the 1992 EVO Project.

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Cam Gear, Tappet Guides, Oil pump…
1992 EVO Big Twin Tools 

Cam Gear, Tappet Guides, Oil pump…

December 13, 2018 by Hersey

Did some tinkering on the EVO Motor in the evenings this week. Over a couple of chilly evenings in the garage I got the cam gears, tappet guides, and oil pump installed.

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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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Parts is parts…
1992 EVO Big Twin 

Parts is parts…

December 7, 2018 by Hersey

Everything has been cleaned up and ready to start putting things back together. Ordered some of the parts I need to get started with the assembly. Some of them will be here this weekend so I may get a chance to get…

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Honda Shadow Carb…
1999 Honda Shadow 

Honda Shadow Carb…

December 3, 2018 by Hersey

Had to do a little work on the wife’s 1999 Honda Shadow. It has been setting awhile. Thanksgiving weekend the weather was great and she wanted to take it out for a ride, it started and idled just fine but would not…

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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

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

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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