Hello, I have been active on the EVO Classic page for the past 5 years or so since I bought a 1997 Electra Glide Classic. Been wanting to do a bike project so I am starting a Sportster Scrambler build that I thought I would share with you guys. I picked up a 19,000 mile non-running 1997 XL883 Sportster with plans to turn it into a Scrambler. The couple bikes that Burly Brand built are my inspiration. This white one is my favorite.


Here is the bike I am starting with after cleaning the gas tank and carburetor, along with a new fuel petcock and some new fuel and vacuum lines plus engine oil and filter change. The bike had not run in 5 plus years as I was told by the PO. After going thru it, the bike fired right up and seems to run good.


After a short test ride to check out the bikes transmission, brakes, light, etc, I started to tear it down. Everything seemed to worked as it should.



I know the white Burly Brand bike is running a 19" wheel in the front and 17" wheel in the rear. Not sure what width rims or what size Continental TKC 80 tires it is running. Finding a blog post on this bikes build, I know that it is using 15" Burly Stiletto rear shocks and a 2" drop Burly Progressive fork spring kit. Using the 15" version of the Stiletto shocks, a belt idler wheel needed to be made to keep the belt off of the rear master cylinder I think?

I wanted the look of a taller and narrow rear wheel so this is what I have ordered and plan to run on my bike.

Front wheel: 19" x 2.5" stock Sportster
Rear wheel: 18" x 2.5" V-Twin Steel Drop Center Rim, Buchanan Stainless steel spokes and nipples, Stock Sportster aluminum hub
Front Tire: Shinko E804 100/90-19
Rear Tire: Shinko E805 120/90-18
Rear Shocks: Burly Stiletto 13" shocks
Fork: Stock Sportster with Burly 2" Drop Progressive Spring Kit

I am hoping running the 18" wheel will give me the look I am going for and using the 13" rear shocks will keep me from having to make a belt idler. I don't plan on taking the Sporty off road too much. Mostly plan to bomb up and down all the damn dirt roads I live near in Michigan so I don't feel I need the 15" shocks.

Like the white Burly bike, I ordered a beaded rear 5" wide fender and 1" Dime City Cycle rear seat frame loop. The first step will be cutting off the Harley fender supports and welding on the rear frame loop. I will post some pictures when I get the parts in and take on this fab work.

G.B.

 

Its going to be a fun build. I built mine over this past winter.

 

I went with the 15 inch shocks, raised the front 4 inch's, 19×2.5 front rjm, 18×3.5 rear. I made a belt tensioner using a automotive sepintine belt tensioner. Very easy and cost maybe $30 in parts.

 

Thanks whylee. I had seen your bike and threads and think it looks sweet! I wanted to go with a narrower rear wheel and tire and have been finding this to be a PIA. I have tried to buy (2) 18" x 2.5" rims only to find out that the first one was listed wrong on eBay and was a 2.15" wide rim and not 2.5". And then the second one is a V-Twin Manufacturing rim that is backorder some 6 weeks. I thought I found one last night and ordered it on line. Well this morning I get an email from the internet store telling me that they don't have a rim and it is backordered.

I ordered spokes for the 18" x 2" rim, I have 120 mm wide rear tire for this rim and I have a 5" wide fender all set up for the 18" x 2.5" rim. I am going to start fab work on the rear frame section and install the progressive spring kit in the fork and hope the rim comes in soon. The only other 18" x 2.5" rims I have found that I can get my hands on now are aluminum. Nothing against the aluminum rim. its just that I would want to replace the front rim as well so they match and that is more money that I didn't want to spend????? G.B.

 

I went with the aluminum for weight reduction only.

 

Also check out Tracker Die, they have alot of knowledge and parts. I had alot of grief dealing with Burley.

 

Gone Blue
I like the white bike, except, the front end is too low, in my opinion. I mean first off the bottom of the frame is not level, as it should be, and second, a scrambler NEEDS suspension travel. Why lower a scrambler front end? That seems counter intuitive to me.

I am only 5'7" with a 29" inseam and I would go 15" shocks in the rear and at least the Sportster "R" dampers to lift the front, giving you about 5 1/2" travel. Or as Whylee did and get more. Install a nice soft set of progressive springs and let them easily soak up those off road bumps.

You guys are making me jealous.

 

Where did you purchase those rims?

 

I bought the hubs new off ebay and sent them to Bucannons and bought the wheels from them and had them lace them.
I powdercoated the hubs OD green myself before sending them.

 

Whylee, great looking bike! I like it fae better than the white one. How did you get another 4" out of the front?