Bob and Mark remove a stock Harley-Davidson headlight and passing lamp set-up to install a custom set. Bob notes this is the time to switch out the headlight bulb if need be and keep all your stock wiring intact, don’t just cut it out. From there we go to the bench to wire the custom passing lamps set-up. Mark helps strip, cut, solder and shrink wrap the new wire connections. They install the new setup making sure all connectors work and that the hardware is tight. Nacelle installed and all parts cleaned they show us how the new set-up looks and operates.
In order to service the fuel filter on your Sportster, you’ll need to drain the fuel tank. Bob demonstrates the best way to do this using a MityVac and a gasoline can. Once you follow his instructions and drain the fuel tank filter, cleaning any dirty parts and tightening any loose bolts, you can refill the tank with fuel and your bike should be good to go.Watch Now >>
Bob and Mark put an older Sportster up on the lift to show you how to service the front and rear brake calipers. They teach you which parts to remove, clean and replace, and discuss the components of the single piston-style caliper assembly and how they work.Watch Now >>
Bob and Mark demonstrate the best way to empty Harley fork oil from your Sportster’s front fork sliders and replace it with new oil. It can be a two-man job, so try to complete the service with a friend. Newer bikes mostly use 39-millimeter forks, but most bikes are preset with varying levels of spring in the sliders, so consult your manual before you begin this service. Like any other service, you should clean all of the parts that you remove with parts cleaner to ensure that your bike operates smoothly between services.Watch Now >>
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.Watch Now >>