Dual Sportster build

[fabiodriven]

Hey guys. This is something I've really wanted to do for a couple years now. I picked up a nice Sportster about three weeks ago in the thoughts that this would be just a fork and shock swap, but it's turned into an all out custom build. Even though I have owned a Buell for quite a few years now, Harley Davidson motorcycles are brand new to me.

Building this bike is not like building a Japanese bike at all. I spent three days on the phone with Sprocket Specialists just for a sprocket, I have parts on order that take weeks to arrive because they have to be built, and I'm fairly positive I've spent more on parts then I paid for the bike. When I'm building Japanese stuff, if I need a part I just open my phone and jump on eBay or Partzilla and the parts are on their way. This isn't like that.

It's an 89 Sportster which was sold to me as a 1200. Unfortunately, I found out yesterday it's an 883. It was an honest mistake from the seller and I didn't know enough to check. The price was right, it's super low miles, and it's in really nice shape. He actually lost money on the deal so I decided to just keep it. Plus it's in a million pieces right now anyways so... It is what it is. A lot of people have a lot worse things going on in their lives right now so I'll be fine.

So the basic lift is an XL600R front end which has the same diameter 39mm forks as the Sportster. Easy enough. The rear uses 15" shocks, which wasn't enough for me, so I ordered a set of lift blocks as well. I had to beg for those. They were sold out but the guy dug up a set somewhere for me. I'm very grateful to him for doing that. That was Hugh's Hand Built.

The 21" Honda XL front wheel is much larger than what comes on the Sportster. Ideally I'd like a fatter front tire and bigger forks, but this will get me on two wheels for now. The rear was a 16" wheel on my bike, but it's been swapped out for an 18" wheel. This was literally the only rear wheel of the correct size I could find in the country. I saw one company that sold the size I need new, but it's backordered and it's chrome. No thanks. Instead I paid almost $400 for a 40+ year old rim that didn't even come with spacers. It looks like it spent a long time outside lol. It's super heavy unfortunately but it should look good, and again, it will get me on two wheels. Using that wheel required a spacer for the sprocket and I have to cut my own axle spacers.

I painted the tanks myself with Krylon and Rustoleum. The fenders are universal dual sport plastic fenders and the handlebars are from (I'll add this later) and are 1" for the Sportster. All the factory handlebar controls will remain. I didn't cheap out on lighting, got some good stuff. Seat is universal but custom in regards to the stitch color and pattern. Exhaust is hand built in Mexico, I'm one of very few people in this country with this man's exhaust. It's sectional with raw tig welds. The rearset lowset pegs are key to this build and that guy hasn't even been able to start making those yet.

Building a custom Harley tailored to just you is a very interesting experience. I get frustrated sometimes but it's also a lot of fun. I got the rear halfway lifted tonight, waiting on the lift brackets for the full rear lift. Once I get it lifted and get the rear tire mounted, I feel like that's a decent milestone. Where the bike turned a corner and started to become something completely different. It was super gay when I got it so the contrast upon completion will be stark.

I should have opened with this, but you either love this idea or strongly oppose it. A LOT of people dislike this idea, which makes me like it even more. I've even had people try to talk me out of it. I feel like most people I know seriously think I'm weird or off for moving forward with this build. It's like everyone is going by "If you don't have anything nice to say", so people just aren't saying anything lol.

It's likely going to be called the "Corona Bike" even though I'm not crazy about that name. I think it's kind of unavoidable at this point.

So these two pictures ARE NOT my bike. These are examples of what my final product will be like.





This is my bike.

[schlepp29]

This is gonna be an interesting build. A long time ago I kinda wanted to build a flat track bike but I lost interest.

[Shep1970]

Nice, I really like the looks of the top (example) pic orange bike, I’m not sold on the headlight though. The bike you’ve got looks really clean. Good luck

Shep

[ATC King]

Good choice!

For gravel road riding, it can be much more practical that many would think. It's easy on fuel, and has a large oil supply with a dry sump system. More oil helps keep it cool, and the dry sump means a more compact crankcase, which increases ground clearance.

Loads of aftermarket support for the bike, low purchase price, low insurance cost, simple and low tech, reliable, and sounds better than most everything else you'll encounter off pavement.

Bottom end torque is easier to get traction with in slick conditions than top end power. There are quite a few parallel twin engines in new adventure style bikes, but most tend to put peak power above tractability, partly because higher HP numbers on paper, help sell bikes.

Triumph recently redesigned their Tiger engine and call it a T-plane configuration. The crank pins are spaced at 180-90-180, which would cause something like a short pause in the power pulses, to aid in traction.

With all the tech being thrown into top tier adventure bikes, the basic engine mechanicals still have to be designed with useable power in mind. Your Sportster choice has that, and a narrower profile than a parallel or horizontally opposed twin.

Good bikes. We've had a few around here. I ordered a XL1200S the first year they came out, '98 I think. That was the fastest stock bike Harley had at the time. It would leave my buddy's 1200 Custom in the dust.



I almost forgot why I posted. If you want to do the most you can with the XL600R forks, Racetech has Emulators that will fit them. They aren't listed in a search for that bike. They are Gold Valves: FEGV 3801 and need the adapters to work which are AD3802 P Adapters, pair for 3801 Emulators. They'll recommend different sprigs and oil weight based on your needs, so you'd want to contact them for that.

[coolpool]

This is going to a sweet build! Most folks didn't know Harley ventured into the dirt bike market (70's AMF time?) many moons ago but never got into the endure scene; that's where this comes in. You're a pioneer! Have you thought about making it road legal at the same time or was that always the plan?

[schlepp29]

Yeah this is gonna be a killer gravel road bike for sure. I never thought about all the stuff atc king said. Be alot better than the xr650l .

[ATC King]

Be alot better than the xr650l .

Oh dang!


Maybe you mean his XR650L trike though.


My XR650L is in SUMO mode right now, and has some nearly treadless street tires that are sketchy on wet pavement, even worse on the gravel roads they love to put SB2 about five-seven inches deep on, in this state. Absolute pucker mode when it's smooth sailing, then all of a sudden that mess, especially in a turn, which is exactly where they like to put it.

Nearly as bad as being caught off-guard by a field of babyheads.

[fabiodriven]

Good choice!

For gravel road riding, it can be much more practical that many would think. It's easy on fuel, and has a large oil supply with a dry sump system. More oil helps keep it cool, and the dry sump means a more compact crankcase, which increases ground clearance.

Loads of aftermarket support for the bike, low purchase price, low insurance cost, simple and low tech, reliable, and sounds better than most everything else you'll encounter off pavement.

Bottom end torque is easier to get traction with in slick conditions than top end power. There are quite a few parallel twin engines in new adventure style bikes, but most tend to put peak power above tractability, partly because higher HP numbers on paper, help sell bikes.

Triumph recently redesigned their Tiger engine and call it a T-plane configuration. The crank pins are spaced at 180-90-180, which would cause something like a short pause in the power pulses, to aid in traction.

With all the tech being thrown into top tier adventure bikes, the basic engine mechanicals still have to be designed with useable power in mind. Your Sportster choice has that, and a narrower profile than a parallel or horizontally opposed twin.

Good bikes. We've had a few around here. I ordered a XL1200S the first year they came out, '98 I think. That was the fastest stock bike Harley had at the time. It would leave my buddy's 1200 Custom in the dust.



I almost forgot why I posted. If you want to do the most you can with the XL600R forks, Racetech has Emulators that will fit them. They aren't listed in a search for that bike. They are Gold Valves: FEGV 3801 and need the adapters to work which are AD3802 P Adapters, pair for 3801 Emulators. They'll recommend different sprigs and oil weight based on your needs, so you'd want to contact them for that.

You make a lot of very good points there sir! And yes, gravel roads are more what I intend to attack as opposed to deep woods. I feel this bike is going to shine at what I want it for. Funny you mention the emulators, as I just watched a video on those a couple of weeks ago. They seem like a fantastic idea to me. I added an oil cooler even though it has the reservoir. It's probably not necessary but I like oil coolers, lol.

Thank you very much for such an insightful and informative post!

[fabiodriven]

This is going to a sweet build! Most folks didn't know Harley ventured into the dirt bike market (70's AMF time?) many moons ago but never got into the endure scene; that's where this comes in. You're a pioneer! Have you thought about making it road legal at the same time or was that always the plan?

I always wanted this bike to be road legal Pete. Strictly as a dirt bike I'm thinking they're probably less than ideal.

[fabiodriven]

Yeah this is gonna be a killer gravel road bike for sure. I never thought about all the stuff atc king said. Be alot better than the xr650l .

So the bike I was going to buy was an XR650R, not XR650L, but I agree with what you're saying. Either of those Hondas would do better in the woods than the Harley by far, but I think the HD would have the advantage on gravel.

[schlepp29]

Before I bought my xr650l I really wanted the xr650r, and go figure I was looking for one for awhile then I decided to buy the 650l after having no luck and it was a week or 2 later one popped up. I think the Harley could be doable if setup right. But I don't even like mine in woods. Probably cause I'm too short lol.

[ATC King]

Oh yeah, it's going to be a great gravel road bike.

They're not any heavier than the liter sized adventure bikes being bought by discerning Starbucks drinkers today.


An oil cooler is nice addition regardless. Just want to make sure the oil doesn't stay too cool if riding during cold temps. There are manual and automatic bypass valves that can be installed between the lines to prevent that. Got to keep that oil temp up at least enough to get rid of water condensation. The temperature dipsticks for those oil tanks work good, and they're simple.

https://jagg.com/collections/by-pass-valves






Having a more powerful bike, you may be tempted to eek a little more from the 883, but I'd be hesitant to with the small fuel tank. The Keihin CV40 carbs are really good. You could add something like the Yost Power Tube, but it'll probably increase fuel consumption, and I know they may say it doesn't on their website. Experiences will differ, some better MPG, some worse.

Ditching that stock exhaust will lighten the bike up, but that crossover tube does work. A 2-1 system would be ideal. Too large of an exhaust pipe diameter will kill the bottom end power on an 883. I mean make it totally gutless. Some torque cones are probably going to bee needed with any aftermarket exhaust you use. They'll help keep the exhaust velocity up and prevent reversion.

https://cv-performance.com/exhaust-torque-cones




I don't know what brake fluid that year uses. HD likes to use DOT5 anymore, because it won't destroy paint, but some people find it makes the brakes feel a little less responsive. It's completely incompatible with DOT3,4, & 5.1 though, and is not hygroscopic either (which means moisture will settle in the low spots instead of being suspended in the fluid). I'm mentioning this because you may be running a different brake up front with the different forks and having to use a different fluid for the front and rear would be a little bit of a PITA. If the Sportster doesn't use DOT5, it won't matter.


You having a Buell already, I don't want to sound like I'm preaching to the choir on some American V-Twin stuff. Just throwing some ideas and products out there that maybe you haven't heard about.

[oldskool83]

nead idea...id hate to lay that over at a raised center of gravity

[fabiodriven]

nead idea...id hate to lay that over at a raised center of gravity

Thanks oldskool! Yeah it wasn't intended to be a dirt bike from the factory, so it's not ideal. It's just ideal for me lol!

[fabiodriven]

Before I bought my xr650l I really wanted the xr650r, and go figure I was looking for one for awhile then I decided to buy the 650l after having no luck and it was a week or 2 later one popped up. I think the Harley could be doable if setup right. But I don't even like mine in woods. Probably cause I'm too short lol.

Yes the 650's are really tall! The Harley is definitely not going to be that tall.