• 29:03

    Tommy is gearing up for a big tear down and customization of our 2000 XL to a Harley Cafe Racer. In preparation, Tommy reviews Harley shop essentials, tools and materials that will be needed along the way. Safety is of utmost importance in your Harley shop. Eye and face protection, respirators, gloves, and appropriate clothing…

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  • 49:38

    Tommy is eager to take off the Sportster handlebars, seat, tank and more. Before picking up any tools, it is important to begin with a service manual and a plan. Don’t just start off by tearing down areas at random. Develop a plan of action. Make lists of parts that will be needed, parts that…

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  • 14:53

    We are still working in the early, disassembly stages of our Sportster Harley Cafe Racer project. Next in line, Tommy removes the Screamin’ Eagle air cleaner assembly and the stock Harley carb or CV carburetor in anticipation of a new S&S carburetor assembly. The stock intake manifold will also be removed. Harley carb removal is…

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  • 24:19

    Before we remove the Sportster forward controls, it is always important to block or seal off any openings in the engine, transmission, or primary drive compartments. Even if for only a short period of time. Debris, dust, or moisture can be damaging or even catastrophic depending on the circumstances. Tommy reminds us of this and,…

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  • 34:07

    Tommy is ready to fully disassemble the Sportster front end. He begins today with the final removal of the front brake line and clutch cable. Once the last retaining clamps are removed, both of these cables are free from the motorcycle and set aside. Next up on the Sportster front end, the handlebar top clamp…

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  • 30:47

    Our Sportster rear fender removal will keep us moving right along with the disassembly and planning of our cafe racer. Tommy gets right to work by removing the sissy bar and luggage rack assembly. The rear strut and Sportster rear fender hardware can be difficult to access so Tommy takes a few extra minutes to…

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  • 14:50

    All of our powder coated parts orders have been received back from our powder coater. We are anxious to begin the assembly process on our XL, Cafe Racer Project. You’ll notice we have powder coated parts that are black at 60% and a wrinkle black. We have a few reasons we powder coated some of…

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  • 30:16

    We removed the outer Sportster primary drive cover to have it powered coated. Before reinstalling the Sportster primary drive, we couldn’t help ourselves. We had to install another Barnett Scorpion clutch assembly and Barnett clutch cable. Please watch our 90 Minute Barnett Scorpion Clutch, step-by-step, 5-part install series before you attempt to install your own.…

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  • 47:41

    Tommy is ready to begin assembly of the Sportster front end on our Harley Cafe Racer project. The stock, Sportster front end, lower sliders have been powder coated and the fork tube assemblies have been completely rebuilt with new upper and lower bushings and fork seals. A Burly lowering kit is installed to lower our…

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