2003 Sportster Customized, Bobber, Board Track, Cafe on 2040-motos

This Sportster was bone stock at 11,000 miles, at which point it was completely customized.  The bike now has 11,325 miles.  I built the bike because I love to build bikes and hot rods.  I have decades of experience as a fabricator and welder.  I just don’t get enough opportunities to ride this bike and I’m on to a new hot rod project.  It is a blast to ride and it always attracts attention whenever I take it out.  It needs nothing but someone to ride it.  It has a clear California title in my name and is currently registered.  Don’t hesitate to ask questions or for additional photos.  The bike is available for inspection near Redding CA by appointment.

Build Details:

Sheet Metal

The gas tank is a Cole Foster design with a pop-up cap.  The oil tank is custom fabricated with rubber mounts.  The rear fender is steel for a 21â€� wheel modified to fit.  There is NO BONDO on any sheet metal parts.  All the steel was metal finished, blued using a chemical process to produce the color as seen in the photos, and then clear coated with automotive clear coat.  You will not see this finish on any other bike.  All the welds are visible through the clear coat.  Different steels take the coloring differently so there is some color variation.  In my opinion, it adds to the apparent patina.  There are a few minor imperfections in the clear coat, but no major issues.

Frame

The frame is unmodified except the tail end.  The cast fender/shock mounts were cut off and a new tubing structure created.  All tabs and extra brackets were cut off and the frame smoothed and painted gloss black.  The upper motor mount is modified to hold the coil and it is blued along with the motor mount plates and hardware.  The VIN number is  easily readable.

Wheels/Tires

Custom HD wheels, 21â€� front and rear.  Stainless spokes.  There is only single flange in rear for sprocket brake.  New Avon AM20 90/90 tires front and rear.

Suspension

The fork sliders were given a brushed finish and the fender mounts were shaved.  Arlen Ness 2â€� lower dampers were installed with the stock springs.  The stock triple trees were smoothed and given a brushed finish.  A Klock Werkes flush axle was used.  The swing arm is stock length and was smoothed and pocketed to clear the sprocket brake caliper.  The rear axle and swing arm pivot shafts were blued.  Custom Hagon rear shocks provide a much more comfortable ride than a rigid.  The leather saddle is mounted to the frame with compact rubber isolators.

Electrical

The original wiring harness was re-used, with extra circuits removed.  All wiring is double-jacketed and run through the frame and handlebars.  The voltage regulator is below the seat with the fuses.  The key (ignition and start) switch is above the oil tank and is automotive style.  The tip-over safety switch was maintained and mounted in the correct orientation so it operates correctly.  It is mounted to the custom stainless battery mount beneath the swing arm that holds a new Interstate battery.  Since the original wiring harness was used, all of the color coding is correct and any Harley manual can be used to decipher.  No horn is installed.

Lights

The headlight is an aftermarket bucket with bosses for the LED turn signals welded on.  It has been blued and clear coated.  Only the low beam is on – if high beam is desired a switch will have to be added.  A Penta Star lighting controller is mounted in the headlight bucket and provides auto-canceling turn signals.  The rear LED lights are very bright and frenched into the frame tube ends.  These lights are dual intensity and work as running / stop / turn lights.  The license plate mount is custom with a frame has built in LED lighting with the wiring run through the swing arm.

Hand / Foot Controls

The stainless bars were custom fabricated.  The throttle is an internal ball bearing unit by LA County Chop Rods.  The front brake master cylinder, clutch lever, turn switches and bar end mirror are from Joker Machine.  All handlebar wiring is internal.  The shifter is stock and blued.  The rear brake lever is custom fabricated and blued.  The speedometer is the stock Harley gauge mounted in a custom mount to the upper triple tree, blued to match.  It is the original speedometer to the bike and the mileage is correct.  The speedometer mount also has neutral and oil warning lights.  The chain drive final gear ratio was kept the same as the original belt drive so the speedometer reads correctly.

Brakes

The front rotor and caliper are from Exile Cycles plumbed with a DOT brake line.  The rear sprocket brake is also from Exile Cycles and is operated using the original master cylinder with the cover blued.  The rear brake line is run through the swing arm.  The rear brake has a pressure switch for the brake light.  The front switch is built into the Joker hand control.  The chain conversion was completed with a Zippers Performance transmission sprocket.

Engine

This is an un-molested 883.  All internals are stock including the ignition and cams.  All the aluminum was given a brushed finish and the fasteners were blued.  The Arlen Ness air cleaner cover was blued and clear coated.  Since the photos, the original ignition cover (says “5 speedâ€�) was replaced with a fabricated and blued cover to match the rest of the bike.   The stainless exhaust was custom fabricated.  All the tubing joints were TIG welded and blended.  No poor craftsmanship is hidden beneath heat wrap.  There are 2 “super bikeâ€� mufflers with internal “drag pipeâ€� baffles added.  The muffler assembly is mounted to the original front muffler mount on the engine.  The front and rear “tail pipesâ€� are blended together.  The pipes separate into 3 pieces for service – front pipe, back pipe, and muffler assembly.  You will not find another exhaust like this one.  The bike has a very unique sound and is not overly loud – only a little louder than stock.  The baffles could be removed to make it louder.  The carb was re-jetted with a CV-Performance N65 needle and correct main and pilot jets.  This EVO has been completely reliable with plenty of power for the weight of the bike and tens of thousands of miles of typical life remaining.