Hey everyone,

So My Sportster is 20 years old but has low miles (8k). It also has a TON of oil leeks in both cylinders, and I can't get myself to get rid of the bike, so I want to rebuild the engine.

I also want to add a screaming eagle kit, and convert it to a bobber while I'm doing it.
Does anyone have a good website i can reference? I don't even know where to start with rebuilding this bike. I don't know what parts i need or what to do. (I rebuilt a Nissan 240sx, and a honda accord, but i haven't ever even touched a harley's engine) Can someone help? What do i do first? What parts do i need? How do i do it? Does anyone have a reference guide of sorts?
Any help is appreciated, i want to start some time next week. Thanks!

Ben

 

Before I would do anything, get the bike in shape, fix the engine. No need to put time and money on an old leaky bike

 

Okay, what do I do? Replace all the gaskets and just clean it up?

 

Ben our reference guide is the factory service manual, which you can buy at any H-D dealer, or some on-line dealers. It will tell you most of what you need when stripping the engine down the the crankcases, to replace gaskets and cure those leaks. As franktko says, go one step at a time! Get the engine running right, then you can move onto your other ambitions, knowing that you will be able to ride it at any stage.

 

1994 is a great year. Clean it up, post some pictures of where the oil is leaking. I would definitely keep her. I'm up in Carlsbad if you need any help. There are other alternatives to the SE kit (if you mean pipes and aircleaner) for better prices.

John

 

I agree with the other posts. Get yourself a service manual and a gasket kit. Once you've got her tuned up and leak free you can start all the other stuff. I bobbed mine in a weekend ran wires through the handle bars and a ton of other things. If you want any help, info anything at all send me a message i have pictures, plans and bunch of busted knuckle experiences on Sportster's.

 

John, I might take you up on that.
Where can I find the service Manual? I will go ahead and take care of the leaks.
Will the Service Manual have a list of what I need to replace?
I took it to Harley in Temecula and they quoted me upward of 3 grand to fix the bike.
I'm Hoping I can knock this out in a weekend if I play my cards right and get all the right parts/tools

 

Any dealer can supply a factory service manual or get you one if they don't have it in stock. Alternatively try one of the on-line cut-price dealers.

 

Ben
I can believe 3K, my gal got a 93 with a bandit kit. And it leaked a ton.

Took me 2 days stripping all the old oil lines and fittings cleaned up the over spray and fittings and replaced all oil lines, brake cleaner was my best friend to get all the crap clean!

Good luck

Now on to the top end leaks.

 

Now the top end, had base gasket and rocker box leaks. We ended up replacing the base gasket and boring 10 over new pistons and head work, all new valves seals etc.

All this is done at my local dealer since it's winter 1/2 price labor time.

But just the lower oil line leaks would of had taken if THEY did it, a whole day. That's 8 hrs at 99 per hour. So at least get that part done your self. Took me 2 days because it was the 1st time working on a sporty , do get the shop manual! It helped me a ton!



My gal is gonna be so happy with her Xmas gift, bigger JUGGS . LMAO

Good luck on your Build!