Bob and Mark install a Power Commander to custom map this Harley after a custom exhaust and air intake. They remove the battery and remove the battery box to properly install the Power Commander. Take your time and only cut the tie wraps that you have to. They have to level the relay box to install this PC since this model has a custom rear fender, check your model and install instructions. Battery back in and they use a little dielectric grease to install the PC plug into the ECM and back to the factory harness. Once the PC is in place they download a map to it for the custom set up from the computer.
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2:47Harley Drive Belt Tension
Bob and Mark demonstrate the professional technique for finding the tight spot in a Sportster’s rear wheel belt. You should do this without a rider or passenger and with the bike in neutral. They teach you how to check for belt tension and deflection and how to retorque the axle so you can give your bike a smoother ride.
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12:07Harley Brake Caliper 2000 – 2003 Front & Rear Service
Bob demonstrates how to service the front and rear brake calipers on a Sportster. There are a few changes that Harley has made over the years, so you should be sure to pay attention to the differences; they could affect how you service your bike.
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4:14Harley Sportster Spark Plugs Replacement
Bob teaches you how to service the spark plugs on your Harley’s engine. Although you can clean and service your old spark plugs, Bob recommends just buying new ones because they are fairly inexpensive. You should purchase gapped, Harley-only spark plugs which usually come with a gap of 38-43,000th of an inch. After applying some anti-seize to the threads of the new plugs, you can thread them into the cylinder by hand and tighten them with a torque wrench and you’ll be good to go.
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9:32Motorcycle safety inspection after service
Now that you’ve fully serviced your Harley Sportster, you can take the opportunity to check all of the safety features on the bike. Make sure the lights are working properly, the horn makes noise, turn signals are operational, and all grommets are in place. Then you should check the throttle, add oil and fill the tires to the correct level. Once your finished with the service, get out and ride!
*****The service manual states you should follow your negation cable down from battery and remove nut that secures the connector to ground stud on the crankcase boss behind the starter motor assembly. You will need to do the reverse during installation.
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