Okay, folks, let me walk you through this “harley 800” thing I got myself into recently. It wasn’t exactly a walk in the park, but hey, that’s how you learn, right?
Getting Started
So, this project landed in my lap, basically an old Sportster, think it was an 883 technically, but everyone just kinda calls ’em 800s sometimes, or maybe that was just what the owner called this particular job. Anyway, it looked pretty tired. Sat for a while, needed some serious love. The goal wasn’t anything crazy, just get it running solid again, maybe a little cleaner.
The Teardown Phase
First things first, had to take it apart. Man, pulling apart an old bike… always surprises you. Started with the easy stuff: seat, tank, fenders off. Then dug into the guts. Took loads of pictures with my phone, threw bolts and bits into labeled bags. You think you’ll remember where everything goes, but trust me, you won’t. Found some crusty wiring under the seat, typical stuff. The frame needed a good scrub too.
- Pulled the wheels off to check bearings and give ’em a clean.
- Drained all the old fluids. Smelled nasty.
- Got the engine covers off, peeked inside. Looked okay, but definitely needed attention.
Engine Work – The Core Job
This was the main part, getting that V-twin heart beating right. Didn’t go for a big engine rebuild or anything fancy like a 1200 conversion this time. Just wanted the stock 883 (or “800” as we were calling it) to be reliable.
Pulled the top end – heads and cylinders. Took a look at the pistons and rings. Cleaned up a lot of carbon buildup. Honed the cylinders lightly just to get a fresh surface for the rings. Put in new gaskets all around, that’s a must. Checked the valves, they seemed okay, just gave them a quick lap for good measure. Putting those heads back on and torquing everything down right… gotta be careful there.
Putting It All Back Together
Reassembly is always slower than taking it apart. Fought with a few things. Getting the engine back in the frame without scratching the new paint I put on a few bits was a pain. Then the wiring… ugh. Had to fix some bad connections, replace a few frayed wires. Took my time, double-checked the manual (when I could find the right page!).
Cleaned the carb thoroughly. Those little jets get clogged easy. Bolted the exhaust back on, put the tank and seat back. Slowly, it started looking like a motorcycle again.
The Moment of Truth
Filled it up with fresh oil and gas. Hooked up the battery. Took a deep breath and hit the starter. Coughed a bit, sputtered… then BAM! It fired up! Rough at first, needed some idle adjustment and played with the mixture screw on the carb a bit. Let it warm up, listened for any weird noises. Sounded pretty good, actually. That rumble is always satisfying.
Wrapping Up
Took it for a short test ride around the block. Felt okay! Shifted smooth, pulled decent enough for an 883. Still gotta put some proper miles on it to be sure, but the main job was done. It’s alive again. Wasn’t the hardest project, but every bike has its own quirks. Definitely got my hands dirty, learned a couple of new swear words, but seeing it roll out under its own power? Yeah, that felt good. That’s the story of the harley 800 job. Simple, but a good bit of work.
