• 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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  • 7:44

    Mike has completed a check of the motorcycle’s lights & indicators. The painted surfaces are safely covered. Now, the electrical system’s main fuse can be removed. To do so, use a 5/32″ Allen bit to remove the left side cover. Pull the fuse caddy from its mount and remove the plastic cover to expose the…

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  • 4:05

    Although checking Softail tire pressure and tire/wheel inspection is very easy to do, it is by far the most commonly overlooked pre-ride inspection. Tire pressure should always be checked cold, and while tire manufacturers do label every tire with a maximum pressure specification, we suggest following the factory service manual recommendations for front and rear…

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  • 3:21

    If your Harley Davidson has spoke rims, it is extremely important to inspect the spokes for proper tightness at regular maintenance intervals. If Harley spoke wheels become and remain loose from neglect, it can not only be very damaging to the wheel, but riding conditions will become extremely dangerous. If you have never experienced riding…

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  • 12:46

    The master cylinder reservoir top cap should be removed at every service interval for fluid inspection and fluid level inspection. Between services, you can simply make a quick inspection through the sight glass of the master cylinder to verify correct Harley brake fluid level. Most importantly, the Harley brake fluid flush must be completely done…

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