From: jeff@MicroUnity.com (Jeff 'Giga-hurts' Kaskey)
Subject: Re: Sportster Crotch Rocket??!!
Organization: MicroUnity Systems Engineering, Inc., Sunnyvale, CA, USA
Date: Wed, 30 Sep 1992 03:31:58 GMT

In article <1992Sep29.023741.1@kean.ucs.mun.ca>, afinlayson@kean.ucs.mun.ca writes:
|> Heh, I'm new to the group and [...] But my question
|> is: do any of you lot have any interest/experience with modifying
|> Sportsers into satisfying corner carvers?  Not GSXR or Ninja beaters,
|> neccessarily, but just something better than, say, a stock BMW or
|> Triumph. Cheers! Chris Finlayson

and then:

From: tim@intrepid.gsfc.nasa.gov (Tim Seiss)
Subject: Sportster Hop-up & Winter Storage

[...] Anyway, I've told him about rec.motorcycles.harley, and
he asked me to find out about 2 things:

 1) Recommendations on getting better performance from his
    bike.  He has drag pipes on it, and is thinking about 
    doing some more modifications to it.  Any suggestions
    as to what would be the next step, such as a jet kit,
    or new carb, cam, ignition, along with specific aftermarket
    suppliers would be appreciated.  Also, if someone would
    care to comment on the best "performance increase/dollar"
    and/or the best order in which to do specific hop-ups
    would also be appreciated.

Well, I'm learning that there aren't a lot of us who have the urge to 
have the ultimate Squidly Sporty (tm) but I've run across a few others.
There area bunch of ways to go at the problem, but in general, they 
fall into engine, suspension, frame and brakes.

The engine is easy enough that these days it's almost cookbook.  If 
starting with an 883, go to 1200. (your BIL is already there, so...) 
The next step is the "cash infusion" step, where you add a pipe 
(SuperTrapp 2:1 is most popular in this application for power and 
ground clearance), a set of cams (Andrews V2 is a mild boost, V4 
is a bit wilder but needs non-stock springs, there are others, too), 
carb (S&S super E or Mikuni HD or just bore out the stocker if it 
isn't a CV, or go all the way with one of the available fuel injection
systems), and hotter ignition module.  If you are still with me, you
have just dropped about a kilobuck, and gained 20 to 40 horses. By
the way, you're dropping some serious change, so be sure that your
parts house cuts you a 10-20% deal.  Oh, get an O-ring chain.

Suspension starts with Progressive Suspension springs up front and
Koni's in the rear (though I still use stock).  For personal suspension
go for a better seat. Harley makes a "pillow-look" Sporty seat, or 
spend a bit more for a Corbin.  A fork brace helps a bit too.  Tires
are important too.  I've had good luck with a Laser up front and an
ME88 in the rear, though Avon and Dunlop both make good rear tires.

There's only one frame mod that I know of, done by a member of the 
Harley mail list (whose name escapes me now).  He chopped the rake
back a few degrees (to 28, I think) for quicker steering, but 
hasn't reported back yet with lots of miles, so stay tuned.
Personally, I like the steering on my Sport as is, but I spend
enough time on twisty rough roads that I prefer stability over
absolute flickability.  YMMV.

There are a few approaches to brakes besides just adding a 
braided stainless line.  Performance machine makes a caliper
that replaces the stock unit and uses the stock disk.  You 
can instead convert to dual front disks using the fork leg
from an FXR to get the brake mounts (if you have spokes, you
must also replace the hub or go to a mag wheel). JayBrake also
makes a replacement caliper.  Of course, for more bucks you could
use the aftermarket calipers and go dual disk...  Don't overlook
good pads, and if you still have spare cash, a cast iron disk.

Over the years there have been some good articles on hopping up
Sportys (and Evos, much of which transfers) by Joe Minton and
others.  If you aren't on the mail list, Graeme just listed two
Sportster sources, the National Assoc. of Sportster Enthusiasts
(508)- 378-2233, and The Harley Davidson Sportster Performance
Handbook by Buzz Buzzeli (who was/is? a press writer at HD) for
18.95 1-800-826-6600.  Oops, I see that it won`t be available
until December.  Start dropping hints to Santa!

What is "best" depends on how you ride and what you expect.  No
one change will work miracles, they tend to work best in harmony,
though if pushed I`d recommend the pipe and high-flow (S&S) air 
cleaner first, followed by the front springs and a cam.  The whole
shit-load I've listed above will run under $2 Grand if you do the
installation yourself, though I'm not counting the frame mod or
the 1200 bore job.  Get a bigger gas tank - you won't want to stop
for a LONG time :-) And don't act too surprised when you catch up
with those GSXRs and Ninjas on any road with a few twists in it.

tfk  "Sportster from Heck"
Newsgroups: rec.motorcycles.harley