Speed Style 5 Ways To Modify Your Harley Davidson Sportster Engine

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From coveted Knuckleheads to iconic Pans and Shovels, the history of Harley-Davidson has, and will always, be a tale of storied engines. All lore aside, it’s the middle-age Evolution engine that’s credited with saving the brand, and while the Evo’s time has come and gone, there’s no denying that it continues to be a staple of the custom scene, especially in the Sportster platform.

The Evolution built on the best bits of the outgoing, unit-construction Ironhead, and addressed performance and reliability concerns associated with the heavy cast-iron cylinders and heads. The 45-degree, air-cooled V-twin displaced 833, 1,100, and 1,200 cc across 30-plus years in production, and as a testament to the design, running examples of the Evo Sporter can be found everywhere these days for dirt cheap.

Whether you’re building a chopper, tracker, café racer, or stock cruiser, the Evolution Sportster has become an ideal candidate for customization with nearly endless aftermarket support for whatever wild concepts you can dream up.
To get your wheels spinning on the possibilities, we compiled five of our favorite ways to modify the Sporty V-twin.

1. Prism Supply Bristol Breather
Sometimes simple satisfaction goes a long way, and if you’re looking for a little something to shake up the look and feel of your custom Sporty, look no further than the Prism Supply Bristol Breather carburetor screen. The Bristol Breather is a sleek aluminum bezel with a stainless-steel screen, designed to replace bulky air filters. A huge upgrade over the XL Sportster’s massive air cleaner housing, the Bristol breather frees up leg room in the saddle and may even facilitate more seat-of-the-pants power.

Made in the U.S.A. and designed to fit S&S Super E/G, CV, and Linkert carburetors, the Bristol Breather is available in both tumbled and polished finishes. It’s worth noting that you may need to use an aftermarket carb support bracket and breather bolts for proper installation, and its open mesh screen design, may not be the move for dusty environments. [Prism]

2. EMD Ribster Primary Cover and Cam Cover
The EMD Ribster Primary Cover and Cam Cover are stylish, bolt-on upgrades for Evolution XL models, offering a blend of vintage flavor and rugged construction. Made from cast aluminum in the South of France by Esteves Motorcycles Design (EMD), these covers feature bold ribbed styling that adds a raw, classic look to the bike. Available in four finish options, the Ribster covers are a quick way to give your Sportster a unique custom edge without diving into engine internals.

Installation is straightforward and well within reach for most home mechanics. Ribster covers are direct replacements for OEM primary and cam covers, making the swap easy with basic tools. It’s recommended to drain your primary fluid before installation and use new gaskets for a proper seal.
Whether you’re going for a retro look or an easy way to set your engine apart from the crowd, EMD’s Ribster series delivers standout style with proven fit and durability. [EMD]

3. S&S 1,250 cc Hooligan Kit
The S&S 1,250 cc Hooligan Kit is a performance-focused upgrade for 2000 to 2018 Harley-Davidson Sportster XL models originally equipped with 883 cc or 1,200 cc engines. If you’re freshening up a stock Sporty, it won’t hurt to go big, and these big-bore kits provide up to 85 hp with minimal supporting mods. This results in faster acceleration and higher top speeds, while also enabling the bike to maintain highway cruising speeds with less strain—ideal for touring or aggressive riding. Despite the jump in performance, the kit adds minimal weight, preserving the Sportster’s nimble handling.

While marketed as a bolt-on upgrade with no machining or rebalancing required, installation involves disassembling your engine’s top end, which may be best handled by a professional mechanic. The kit includes S&S cams with .482″ lift and durations of 240° (intake) and 234° (exhaust), along with premium tappets. With a compression ratio of 11.2:1, the kit delivers strong throttle response and top-end pull while retaining compatibility with stock 1,200 cc heads, pushrods, and fuel system for a streamlined install. [S&S]

4. Barnett Kevlar Extra Plate Clutch Kit
All the power in the world won’t do you any good if you can’t put it to the pavement, and as such, your performance Sporty build isn’t complete without addressing those worn-out clutch discs. The Barnett Kevlar Extra Plate Clutch Kit includes nine Kevlar friction plates and eight steel plates, increasing surface area for better grip, reduced slippage, and more efficient power transfer.
One of the key benefits of this Barnett kit is the elimination of the stock riveted spring plate, a well-known weak point in the Sportster’s stock clutch. By removing it, the kit boosts durability and reliability, especially under stress. Kevlar friction material is proven to provide smoother engagement, longer service life, and greater resistance to heat and wear.
While installation isn’t overly complex, it does require some specialized tools and mechanical know-how, making it a solid DIY project for experienced home mechanics or a smart job to hand off to a trusted shop. [Barnett]

5. Prism Supply Quick Stick Start Lever
The Prism Supply Quick Stick Start Lever is a clean and novel solution for riders looking to simplify their handlebars by eliminating the bulky factory starter button and associated wiring. Designed to mount directly to the starter solenoid using only three screws, this lever allows you to engage the starter mechanically, and will certainly turn heads at any function. Made of durable stainless steel and crafted in the U.S.A., it fits 1991 and up Harley-Davidson Sportsters as well as 1989 and newer Big Twins.

In addition to its minimalist function, the Quick Stick Start Lever adds a custom touch with a replaceable knob that’s compatible with any of Prism’s shift knobs. Installation is straightforward for most home mechanics using basic tools. In some setups, the exhaust may need to be temporarily removed to complete the installation, and care should be taken to ensure the lever is compatible with aftermarket exhausts. [Prism]

With its long production run, rock-solid reliability, and unparalleled aftermarket support, the Harley-Davidson Evolution Sportster remains one of the most customizable motorcycle platforms in the V-twin world. Whether you’re chasing performance gains, vintage aesthetics, or just a stripped-down, no-nonsense ride, there’s no shortage of upgrades to help bring your vision to life.
The Evo Sportster has proven time and again that it’s far more than just an entry-level Harley—it’s a blank canvas for personal expression and mechanical creativity.


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