Harley-Davidson has discontinued the Evolution Sportster, but it’s going to be a very long time before the venerable V-twin fades into the rearview. Secondhand Sportsters are easy enough to find, work on, source parts for, and modify in every way imaginable. That’s why the Sporty has been a darling of the custom scene for as far back as we can remember, and why it’ll surely maintain that status far into the future.
David Zemla is not only a big fan of the Harley-Davidson Sportster, but he knows more about modifying it than most. That’s because he’s spent eight years working at S&S Cycle—the go-to manufacturer of performance Harley-Davidson parts.
“I love Sportsters in an unnatural sort of way,” says David. “In my eyes, they may be the perfect motorcycle—dirt cheap, un-killable, and can be anything you wish.”
“Chopper? Yeah, that’s been done since the 60s. Bobber? Easy and they look great. Scrambler? Sure, take a look at the white bike I built a few years back. Flat tracker? Come on, Sportster-based trackers ruled the roost of the turn-left kingdom for decades, and they still make a fine street tracker.”
This 1993 Harley XLH 883 had been around the block more than a few times before it ended up in David’s hands. Even though time had not been kind to the metal finishes, the 30-year-old Sporty was still plodding along happily. But very little of the original bike remains.
With a bored-out motor, new bodywork, new wheels, and a full complement of Öhlins suspension parts, the bike isn’t even recognizable as a 93 883 anymore. “It’s probably blasphemous to build a Sportster to this level,” David quips. “I mean, the fork legs alone are worth more than the donor bike; no sane person would do this.”
In a way, the high-end suspension is what catalyzed the rest of the build. David loves old bikes and old cars in equal measure, and almost every vehicle he’s owned has had its suspension altered or upgraded in some way. (He even built his air bag suspension system once.)
“Once I went down the Öhlins path the build took on a new light,” he explains. “Naturally it would need high-zoot wheels and brakes, and, of course, a truckload of S&S engine mods.”
The Öhlins piggyback shocks and upside-down forks are joined by a set of billet aluminum yokes from Brocks Performance, and an exceedingly classy set of Lyndall wheels. Measuring 19” up front and 16” at the back, and shod with Kenda tires, they work with the suspension to radically alter the Sporty’s stance.
Lyndall brake discs and high-powered Performance Machine radial-mount four-piston calipers handle stopping duties.
Naturally, the 883’s humble V-twin engine was treated to a smorgasbord of S&S Cycle go-fast parts. David rebuilt the motor with a 1,200 cc S&S big-bore kit and oversized cams, then hooked it up to the company’s popular Super E carb. The blocky vintage-style air cleaner is another S&S part.
David pieced the custom exhaust system from some S&S and Vance and Hines parts that he had lying around, then finished it all in black. A chain conversion with a Lyndall rear sprocket gets power to the wheel.
As the build started coming together, David looked to the brat style Sportsters of Japan, as popularized by the work of Go Takamine, for stylistic inspiration. With this in mind, he sourced a Honda-esque aftermarket fuel tank, then heavily modified it to fit the Sportster. Next, he fabricated a new seat pan, and then had it upholstered by Saddlemen in California.
A ribbed fender from Lowbrow customs sits at the back, tucked up against the Sportster’s new subframe loop. Up top, a small tool roll finishes off the tail perfectly.
At the opposite end of the bike, you’ll find ODI handlebars and risers, Biltwell Inc. grips, adjustable Oberon levers, and Motogadget mirrors. “I wanted a really aggressive cockpit with wide bars, and I love the look and function of the Motogadget mirrors,” says David.
The rest of the parts spec features a digital speedo and LED lighting from Alchemy Parts in the UK, late model Harley-Davidson controls, and aggressive foot pegs from Death Metal Racing.
David has probably spent more time and money on this humble 883 Sportster than any sane person would, but it’s hard to quibble with the results. Besides, we happen to like his particular brand of insanity.
David Zemla Instagram | Images by Cody Allen
