How anyone could thumbs down this is beyond me!! Dude, you’ve been a life saver on my first build of a 99 sportster hugger. Been such a pain finding vids on these older models! Thank you for being so thorough!!!
Just getting ready to do same thing, changing out main shaft for a kicker kit. This is the best info out here about pulling this apart. Completely real, no bullshitt camera poses and distracting music/noise. Thanks for doing this. Cheers. Ride safe. Guy Speight
This is an excellent video. All how to mechanics videos should be like this. He gets in there right to it doesn't talk a lot beating around the bush and shows every part taking out every bolt doesn't skip parts awesome man thanxx.
Just got a damaged 4th gear on my 2003 Sportster on the weekend and wasn't sure if I can fix it by my own. But after seeing this I'm keen to do it. Thanks for the vid!!!
Dan is the Man. Awesome to deal with and a great person to walk you through your job. My 90 Sportster was a dog until Dan did the heads and 1250 kit, spec'd the cams and ignition as well. Has been running flawlessly for years now.
I also have a 90 with a 1275 kit and it rips, magnets failed in the rotor, can’t find aftermarket parts. Local Harley don’t work on stuff older then 2000. Where do I get the sealed parts the faster upgraded stuff. If I gotta spend money I wanna go faster at least look cooler. Nothin beats crack in the throttle and all the guys in the big bikes look over with that look of bewilderment.
All I was going to do was change out the primary case from aluminum to chrome and even though this is more than I needed, this video is amazing and I watched the whole thing. Also saved this for the future. Thank you guys for making something that is detailed, simple, smart, and well thought out. My Sportster will live forever thanks to you.
i just don't understand what is there to dislike in this video???? if you people have better ways let's see ..... show your own video! meanwhile I do appreciate this video and the time you spent to make it. thank you
So I'm sat today absolutely gutted after my clutch basket killed itself and your video saved my sanity. Can't thank you enough!!!! Thank you! And good to know the clutch nut is righty loosy!!!
This is a very good, straight forward video. This helped quite a bit in the disassembly of my M2 Cyclone and in the diagnosis of a shift problem. Many thinks.
Great video Dan just like all your other videos too. Would be nice if you could make one on changing the shifting forks too. Since I may need to replace my second gear one, it's starting to slip out once in a while and I think its starting to go. But I may not need it either since I am fairly mechanical. I already put on your 120hp kit and its running very good. I still have some fine tuning to do though since I didn't get it dyno tested yet. Thanks for all your help and advice that you have given me. Have a blessed day.
When I have had a torx screw 'round out' as they sometimes do, I find that a hex socket driver (or Allen driver) can be gently tapped into the screw head and enable it to be removed - it pays to have both imperial and metric sized drivers available. A cheap multi bit set (such as from Harbour Freight or similar) will be very helpful for this as the bits have a hexagon shaft and can be used with a good quality battery drill set up in screw mode. Torx head screws were developed so machines can assemble things and are not made with the thought of disassembly in mind.... the guy who invented cross-head screws should also have been shot at birth !
Excellent quality answered every question I had I've never worked on a road bike just dirt but that case gasket gave on me mid mild road trip and soaked the back tire and I was done lol had it trailered home gaskets just got home about to service my grandpa's ol faithful thanks man I appreciate this video
This video helped me a lot I was putting back this back together because I got a crack in the outer shell to fix it and this guided me back to putting it back together
I was impressed at how those Sportsters come assembled..I would also like to add, that someone that is not making a video, should take lots of photos, at each step, so the details of assembly will be easy to access.
Hammer Dan I agree ☝️ with you on those torx they suck! Thx for the video I’m ready to do my energy one clutch from you guys as soon as it gets here. ~ Xena from the XL forum :-)
And a magnet on a stick. And c clamp pliers. And some other things. From what ive seen so far he's a damn good mechanic. He must of been in a hirry and didn't take time to go grab tools for this. Like he jist wanted to bang out a video real quick.
Wise are those who install a pushbutton solenoid end cover (I lube the O-rings with a little silicone dielectric grease). They bypass all external wiring and the solenoid windings making them outstanding backup (or a main method for chopper owners).
Love this video and all of them. I cant wait to get a 1275 kit. Will be soon for my Iron 1200. I was hoping for a reasonably video. I have to do just this to change my primary chain and would love to see a reassembly just in general but also to know how much to torque both the main nuts and also if you use red lock tight when reassembling Qu
enjoying the vid. Still learning on the Sportster, but I know when doing this job on a big twin, the engine sprocket nut should not be done with impact as the jarring can knock the magnets loose and break your alternator (working on one now like that)
Sitting here at 1 am tripping out (not on drugs goober) because I have a headset on and around 3:50 you can here the low rumble of a vehicle moving in the background and I thought it was happening outside my house...carry on good sir!
On that little C-clip you could take a basic wrench, like 3/8, place the two prongs of the open end against the clip's open end and a light tap with a mallet will take it off no problem... many many ways really but that one is something most DIY mechanics should be capable of.
Very good video sir I would like to have a better look at that main shaft gear that drives the belt. Harley wants $2,500 just to replace the bearings in that transmission you should totally do a bearing video particularly on a 2001 Sportster 883
also after i purchased my 2007 xlc 1200 sporty the dealership informed me it had a cobra tuner installed they suposedly didnt know about...is that an issue? id prefer to just put it back stock...probly cant now. suggestions? im lost what to do. thx for vids, excellent info
I didn’t realize that the transmission came out of the case as a whole unit. Since it’s that easy, is there a way to change gears for the 5 gear so that it’s not sounding like it’s on the high end of the rpm range?
Dan, I have a question about the lubrication of the Gear Box Case on the Sportsters, in my understand the Gear Box is sealed on the newer motors and are reached by a trap door on the older motors, therefore the Motor Oil lubricates the Gear Box Case on the Sportster, the Oil in the Primary is only to lubricate the clutch and chain set, right? Otherwise, howcame they make an open primary kit for Sportster? Or, how can only 1 quart of Oil in the Primary lubricates also the Gear Box if it is sealed from the chain case? The reason that I ask that is because I see lots of people saing that the Oil in the Primary on Sportster also lubricates the Gear Box, and I do not agree with that. Could you clarify please? Thanks and Congrats for the greats videos roling!
No, in all sportsters the primary and transmission are lubricated by the primary fluid. even though there is no trap door on the 2004+ models, there is still open passages to circulate the fluid to lubricate the transmission.
Great video. I have a question. How do you remove the clutch basket nut without the rear wheel spinning when trying to turn the nut? Is it in gear or something?
Thank you. I got to get the bottom end of my 883 Sportster in shape so I can turn it into a 1200. I do have an interesting question will 5 speed transmission fit in a four-speed case?
So my sportster was dropped and now won’t shift , I’ve drained the primary and inspected the clutch and sprockets but I can’t figure it out , any tip or ideas?
No, this is a Buell Thunderstorm engine. They made quite a bit more power than a 1200S motor due to better heads and hotter cams, and the factory air cleaner and exhaust were substantially better as well. A typical stock 1200S would make on the order of 65hp, where a stock Thunderstorm equipped Buell S1W, X1, or S3 would put down around 85hp.
great video hopefully i dont need to go there yet , i have 95 sportster n order for me to change/repair my starter - i need to take off the primary cover off ?
Hi Dan, I have a Buell just like this one and the bearing around my clutch adjustment screw just cracked in half. Would it be possible to remove that adjustment assembly as you did in the video, BUT without taking off the primary cover? Thanks for your help
I was able to get it off with the help of some looong nose ring clip pliers! Didn’t need to take off the cover. Thanks to your great video, I knew what I was doing!
Excellent video, though I would be hard pressed to get all the little parts back in the proper order....camera phone might be the answer. Question, my 2005 sporty 1200 can run up to 4-5 grand in neutral. When I put it in gear and pull away, it sounds like an irregular hammer hitting the inside of the motor. Any ideas what might have broken loose ?
Sounds like it's pinging. Run better gas. You might also try the 10R12X Gold plugs, they're a colder plug and will resist detonation and pinging better.
@@HAMMERPERFORMANCE thanks for the reply, always run 91 octane, just put in new plugs. I know it's hard to diagnose a text ;》 this is more like an irregular BANG metal on metal. I'm thinking I should pull the primary and check for broken parts. does the sporty have a compensator ?
when putting it all back together is there a certain way to put back on the clutch basket and motor sprocket assembly? or just side them back on, however?
Dear Hammer, my clutch hub is tighten but it has very very little movement side wise. I noticed when I wanted to check how starter engages the starter gear and notices that basked was reacting and moved just a slightly side wise. I mean I can move it a bit and its not rock solid on main shaft on gearbox. is it ok like that?
I wonder what the oil is for in the primary. Is it for the chain, the clutches? It seems like oil would interfere with stator. Would you need oil if you was not using the transmission? I’m doing a project that only needs the engine not the transmission.
How anyone could thumbs down this is beyond me!! Dude, you’ve been a life saver on my first build of a 99 sportster hugger. Been such a pain finding vids on these older models! Thank you for being so thorough!!!
I appreciate that!
Helpful video for me too !!
Thank you!
Excellent video. High quality resolution and lighting, straight to the point, no nonsense. Thanks for the quality tutorial!
Just getting ready to do same thing, changing out main shaft for a kicker kit. This is the best info out here about pulling this apart. Completely real, no bullshitt camera poses and distracting music/noise. Thanks for doing this. Cheers. Ride safe. Guy Speight
This is an excellent video. All how to mechanics videos should be like this. He gets in there right to it doesn't talk a lot beating around the bush and shows every part taking out every bolt doesn't skip parts awesome man thanxx.
Just got a damaged 4th gear on my 2003 Sportster on the weekend and wasn't sure if I can fix it by my own. But after seeing this I'm keen to do it. Thanks for the vid!!!
Good video Man no music no nonsense right to point beutiful thank u
Dan is the Man. Awesome to deal with and a great person to walk you through your job. My 90 Sportster was a dog until Dan did the heads and 1250 kit, spec'd the cams and ignition as well. Has been running flawlessly for years now.
I also have a 90 with a 1275 kit and it rips, magnets failed in the rotor, can’t find aftermarket parts. Local Harley don’t work on stuff older then 2000. Where do I get the sealed parts the faster upgraded stuff. If I gotta spend money I wanna go faster at least look cooler. Nothin beats crack in the throttle and all the guys in the big bikes look over with that look of bewilderment.
Thank you for doing a great job on helping us to learn how to work on our own bikes...👍🤝💯⚡🏁🇺🇲
All I was going to do was change out the primary case from aluminum to chrome and even though this is more than I needed, this video is amazing and I watched the whole thing. Also saved this for the future. Thank you guys for making something that is detailed, simple, smart, and well thought out. My Sportster will live forever thanks to you.
i just don't understand what is there to dislike in this video???? if you people have better ways let's see ..... show your own video!
meanwhile I do appreciate this video and the time you spent to make it.
thank you
So I'm sat today absolutely gutted after my clutch basket killed itself and your video saved my sanity. Can't thank you enough!!!! Thank you! And good to know the clutch nut is righty loosy!!!
This is a very good, straight forward video. This helped quite a bit in the disassembly of my M2 Cyclone and in the diagnosis of a shift problem. Many thinks.
This was great.. thank you... these videos make the service manual actually make sense to me!
this is the best video on this job by far. cheers guys, great work.
Thank you for the video, I'm interested in swap 34 to 38 tooth sprocket, and the video helps me a lot of before done the work. Regards from Spain.
Y’all are awesome. Dan, thank you for all the knowledge that you’ve shared with the rest of us.
This helped allot, thanks. Just opened primary and found broken detent clip rolling around in there.
Cheers
Thanks guys for those priceless videos. Learning so much from them. This is IMMENSE !!!!!
Great video. And a great mechanic. I hope you make lots of money. I have the factory shop manual but I'd rather watch it on video. Thanks a million.
Great video Dan just like all your other videos too. Would be nice if you could make one on changing the shifting forks too. Since I may need to replace my second gear one, it's starting to slip out once in a while and I think its starting to go. But I may not need it either since I am fairly mechanical. I already put on your 120hp kit and its running very good. I still have some fine tuning to do though since I didn't get it dyno tested yet. Thanks for all your help and advice that you have given me. Have a blessed day.
Thank you so much !! Nice video. You made it look so easy as an expert usually does !! Great
awesome videos, love to see how things are built and i dont even have a motorcycle(yet)
a transmission rebuild video would be great to see too.
thanks and keep it up.
we'll see what we can do. :-)
Thank you!!! Great detail and visuals.
Made the job a world easier..... plus now my harley repair manual actually makes sense...lol ..
Great video, I broke my cluch basket with the spring compressor (so much for saving money) so I had to figure out how to remove it. Thanks!
When I have had a torx screw 'round out' as they sometimes do, I find that a hex socket driver (or Allen driver) can be gently tapped into the screw head and enable it to be removed - it pays to have both imperial and metric sized drivers available.
A cheap multi bit set (such as from Harbour Freight or similar) will be very helpful for this as the bits have a hexagon shaft and can be used with a good quality battery drill set up in screw mode.
Torx head screws were developed so machines can assemble things and are not made with the thought of disassembly in mind.... the guy who invented cross-head screws should also have been shot at birth !
Great how to video for a DYIer. I am in the process of doing the same work on my 96 sportie 883. This lets me know I am on the right track. Thanks
Great Video just stumbled across Hammer Performance...and unlike some how to videos how great that u get the tools needed as well
Very informative and down to earth!! Excellent job thank you!
Great video.. thank you for posting!
Thanks man, I just read the manual and you made it easier to understand it
Great video man, thanks a lot. Very clear and well explained!
Excellent quality answered every question I had I've never worked on a road bike just dirt but that case gasket gave on me mid mild road trip and soaked the back tire and I was done lol had it trailered home gaskets just got home about to service my grandpa's ol faithful thanks man I appreciate this video
This video helped me a lot I was putting back this back together because I got a crack in the outer shell to fix it and this guided me back to putting it back together
I was impressed at how those Sportsters come assembled..I would also like to add, that someone that is not making a video, should take lots of photos, at each step, so the details of assembly will be easy to access.
Super video. Now I'm ready to put the Baker six speed into my Buell M2. Thank you a lot.
great video thanks for sharing your knowledge !!!
I'm going to.buy Hammer parts just because of the great videos you make! Thanks for these!
Excellent content and produced quite well. Thank you much!
Hammer Dan I agree ☝️ with you on those torx they suck! Thx for the video I’m ready to do my energy one clutch from you guys as soon as it gets here. ~ Xena from the XL forum :-)
A drill with a square drive adapter works wonders for speeding up the process.
I use a speed wrench, just as fast and no batteries to charge. 😁 Actually, I'm surprised he doesn't have one.
And a magnet on a stick. And c clamp pliers. And some other things. From what ive seen so far he's a damn good mechanic. He must of been in a hirry and didn't take time to go grab tools for this. Like he jist wanted to bang out a video real quick.
Jeez man solid work No messing around and well explained sir
Such a helpfull video ! Thank you so much !
I watched this cus I'm going to change the stator. It helped me a lot for this my first time on my sportster. Thank you very much.
I've got the same job ahead of me.
Wise are those who install a pushbutton solenoid end cover (I lube the O-rings with a little silicone dielectric grease). They bypass all external wiring and the solenoid windings making them outstanding backup (or a main method for chopper owners).
Great video, ive subscribed, cheers from Steve uk 🇬🇧
Great job mate thank you.
Love this video and all of them. I cant wait to get a 1275 kit. Will be soon for my Iron 1200. I was hoping for a reasonably video. I have to do just this to change my primary chain and would love to see a reassembly just in general but also to know how much to torque both the main nuts and also if you use red lock tight when reassembling
Qu
enjoying the vid. Still learning on the Sportster, but I know when doing this job on a big twin, the engine sprocket nut should not be done with impact as the jarring can knock the magnets loose and break your alternator (working on one now like that)
Bad ass! Thank you guys for the video!
Sitting here at 1 am tripping out (not on drugs goober) because I have a headset on and around 3:50 you can here the low rumble of a vehicle moving in the background and I thought it was happening outside my house...carry on good sir!
love these vids man they help a lot
can you do one on disassembling the transmission
Awesome VIdeo. Just made everything easy.
Brilliant video I've learned a lot by watching the video thank you
some of the bolts are different sizes....so be sure to remember what sizes came from where you took them out.
Yes that's exactly my issue right now!!
On that little C-clip you could take a basic wrench, like 3/8, place the two prongs of the open end against the clip's open end and a light tap with a mallet will take it off no problem... many many ways really but that one is something most DIY mechanics should be capable of.
Very good video sir I would like to have a better look at that main shaft gear that drives the belt. Harley wants $2,500 just to replace the bearings in that transmission you should totally do a bearing video particularly on a 2001 Sportster 883
we'll see what we can do.
This is why i love sportster. So easy to wrench in when you race your shit and it breaks.
Another Great Video... Thank You for posting this...
Good stuff buddy....
also after i purchased my 2007 xlc 1200 sporty the dealership informed me it had a cobra tuner installed they suposedly didnt know about...is that an issue? id prefer to just put it back stock...probly cant now. suggestions? im lost what to do. thx for vids, excellent info
Great video . thank's men
Excellent video man
I have buell x1 needing full rebuild and thinking of doing myself
I built Myself a standard pliers that has a key-way welded to one jaw just for taking off that darn c-clip.
This video was super helpful, Taking apart a Buell blast (Yeah it's different but very similar to this process)
great and helpful video thanks
That "C" clip looked like the hardest part, LOL
Good video!
I didn’t realize that the transmission came out of the case as a whole unit. Since it’s that easy, is there a way to change gears for the 5 gear so that it’s not sounding like it’s on the high end of the rpm range?
Definitely want to keep all primary cover bolts in the order they came out, each bolt goes back to the same hole it came from
I noticed they're different sizes while removing, so I kept them in the same order, glad I did!
excellent video cheers
Quick work and thanks for video. I can't get gears 1,3,4,5 just 2 and neutral.
Silly question. Are the 2 sprockets timed? Or can I just remove the chain and refit however it goes? Great video, really helpful
Not a silly question at all. They are NOT timed, so you don't need to worry about that. Be sure you torque things accurately during reassembly.
thanks ^ ^
Not enough thanks!. Liked and subscribed 👍
Do you still need to loosen the slack in the clutch cable if you are just taking off the circular cover and putting a new one on?
Dan, I have a question about the lubrication of the Gear Box Case on the Sportsters, in my understand the Gear Box is sealed on the newer motors and are reached by a trap door on the older motors, therefore the Motor Oil lubricates the Gear Box Case on the Sportster, the Oil in the Primary is only to lubricate the clutch and chain set, right?
Otherwise, howcame they make an open primary kit for Sportster? Or, how can only 1 quart of Oil in the Primary lubricates also the Gear Box if it is sealed from the chain case?
The reason that I ask that is because I see lots of people saing that the Oil in the Primary on Sportster also lubricates the Gear Box, and I do not agree with that. Could you clarify please?
Thanks and Congrats for the greats videos roling!
No, in all sportsters the primary and transmission are lubricated by the primary fluid. even though there is no trap door on the 2004+ models, there is still open passages to circulate the fluid to lubricate the transmission.
Great video. I have a question. How do you remove the clutch basket nut without the rear wheel spinning when trying to turn the nut? Is it in gear or something?
i took the clutch pack out and hit it with an impact driver, just came loose didnt need to lock anything
Getting close to 1000 subs. I’m sure you will be there within a couple more months.
Thank you very much.
Thank you. I got to get the bottom end of my 883 Sportster in shape so I can turn it into a 1200. I do have an interesting question will 5 speed transmission fit in a four-speed case?
No I'm sorry it sure won't.
Great video
Thank you ! ! !
So my sportster was dropped and now won’t shift , I’ve drained the primary and inspected the clutch and sprockets but I can’t figure it out , any tip or ideas?
Hey Dan did you guys ever do a video on put a close ratio gear swap?
Thanks, great video very informative, is that the same engine that they put in the 03 Sportster 1200S?
No, this is a Buell Thunderstorm engine. They made quite a bit more power than a 1200S motor due to better heads and hotter cams, and the factory air cleaner and exhaust were substantially better as well. A typical stock 1200S would make on the order of 65hp, where a stock Thunderstorm equipped Buell S1W, X1, or S3 would put down around 85hp.
great video hopefully i dont need to go there yet , i have 95 sportster n order for me to change/repair my starter - i need to take off the primary cover off ?
Yes, that's right, the bolts that hold the starter to the case are only accessible from inside the primary.
Hi Dan, I have a Buell just like this one and the bearing around my clutch adjustment screw just cracked in half. Would it be possible to remove that adjustment assembly as you did in the video, BUT without taking off the primary cover? Thanks for your help
thats a good question, I'm not sure. Haven't been in that situation.
I was able to get it off with the help of some looong nose ring clip pliers! Didn’t need to take off the cover. Thanks to your great video, I knew what I was doing!
Excellent video, though I would be hard pressed to get all the little parts back in the proper order....camera phone might be the answer. Question, my 2005 sporty 1200 can run up to 4-5 grand in neutral. When I put it in gear and pull away, it sounds like an irregular hammer hitting the inside of the motor. Any ideas what might have broken loose ?
Sounds like it's pinging. Run better gas. You might also try the 10R12X Gold plugs, they're a colder plug and will resist detonation and pinging better.
@@HAMMERPERFORMANCE thanks for the reply, always run 91 octane, just put in new plugs. I know it's hard to diagnose a text ;》 this is more like an irregular BANG metal on metal. I'm thinking I should pull the primary and check for broken parts. does the sporty have a compensator ?
Awesome vid, car guy learning bikes. What's the round cylinder at the front of the motor?
Oil filter
Thanks!! Good info and video work! (How is so dumb to dislike this video and why??)
I’m struggling to put back the primary cover. Any tips on what I can do ?
For a 2017 sportster is there a need to put in specific transmission oil?
when putting it all back together is there a certain way to put back on the clutch basket and motor sprocket assembly? or just side them back on, however?
no good way, but you do have to put them both on together with the chain. Just slide the whole assembly on.
@@HAMMERPERFORMANCE thank you much help
Anti-seize on the inspection cover screws (which tend to stick due to corrosion) makes life easier the next time one does maintenance.
21:23 You do not have to take out the transmission to remove the starter. Just remove the primary cover and you have access to the bolts.
Is the shifter shaft suppose to kinda pop in and out and wiggle up and down?
Dear Hammer, my clutch hub is tighten but it has very very little movement side wise. I noticed when I wanted to check how starter engages the starter gear and notices that basked was reacting and moved just a slightly side wise. I mean I can move it a bit and its not rock solid on main shaft on gearbox. is it ok like that?
So if I wanted to swap to 8bolt from 4 is it just a normal swap or is it harder than that ?
I wonder what the oil is for in the primary. Is it for the chain, the clutches? It seems like oil would interfere with stator. Would you need oil if you was not using the transmission? I’m doing a project that only needs the engine not the transmission.