Bikervation - Part 6 - Harley Sportster XL 1200R Rocker & Head Gasket Replacement /oil leak fix.

[@trevorjameson3213]

This is the best video on how to properly assemble the top end by the book. Excellent lighting and sound quality also. I have an '01 Sportster 883 that I'm currently in the process of converting to a 1200. I've had the bike since new, so nearly 20 years, and over 80 thousand miles on it, so it was time for a top end rebuild. So far it's going well. I bought the shop manual back in '02 shortly after buying the bike, and I couldn't do this work without it. I'm looking forward to getting the bike back together and seeing how well it runs with the extra power of the 1200cc's. Should be a lot of fun. I sold my old Honda XR250R and bought a nice, clean XR400R to replace it. It's currently waiting for some parts that need replacing, and I have to finish the Sportster first before beginning work on the Honda. Both fun projects and great bikes.

[@Bikervation]

Thanks for the encouragement, it takes a lot of time lighting and moving the camera every time you take a different angle. I’m not so sure I would use Scotch Brite again as it must remove some aluminium and affect the surface flatness, I was aware of this and took it very carefully. If you subscribe :) and hit the bell it helps me and you get an update for Part 7, which I’ll be doing this week. Chris

[@petef.4688]

Great playlist man. I really really appreciate this.

[@Bikervation]

Thanks Pete, good luck with yours 😊.

[@springy-2112]

Hey Chris your videos are absolutely fine buddy ..compared to my shakey no plan off on a tangent efforts they are superb. The only person who moans about my awful videos is me !! so I've decided to stop apologising and keep doing my thing !! believe me brother yours are far superior and educational and entertaining. peace and love buddy 👍🏻❤☮

[@Bikervation]

Thanks for those positive words of encouragement Springy2112, I guess I’ll get belter with time. I think it’s best to be yourself and not copy others. Cheers, Chris

[@woodsrunner7102]

Thx for all these vids...ive got the same issue on my 07 xlc 1200...at least now i know what im in for...and that i can do it...screw the stealerships....rather do it myself

[@Bikervation]

Hi, Thanks for that, I was on the edge of my comfort zone but thought if I took it slow I could do it. For me it was taking the time to do it at a pace I could reflect upon and not rush to finish and making the videos helped as it slowed me down. Good luck with yours and thanks for watching. Chris

[@bernardlesperance742]

You needed a 1/4" torque wrench with swivel bit to get to the three 7/16 (silver) bolts and bolt down the rocker box. I'm guessing you were using a 3/8", which just won't get in there because of its size.

[@Bikervation]

Yea, I didn’t have one so used feel.🙂

[@ElFalsoKrew]

Good video ✅

[@Bikervation]

Thanks, and thanks for watching.

[@Jeff82556]

Please tell me at 22:52 when you insert those 4 bolts I noticed that 2 bolts are shorter than the other two. I'm not sure which side the shorter bolts go on. (clutch side or throttle side?) Thanks for your response!

[@Bikervation]

Hi and thanks for watching, this was 4 years ago so a bit hazy but I seem to remember the shorter bolts were the wrong ones! I noticed this at 23:44 and corrected it and as I recall the bolts were all the same (long ones) and the short ones were from the rocker cover. Shows how important it is to keep everything in order, I find using cardboard and put bolts through with labels on disassembly so I know where they go on reassembly helps - a lesson learnt after this mix up :)

[@Jeff82556]

@@BikervationYou must be talking about something else, some other bolts. Those bolts are NOT the same. (your arm blocked the view) As I said, at 22:52 there are 4 bolts, 2 of them are shorter. (1/2 inch) Where do the shorter ones go? (not talking about the 3 shorter 7/16" bolts) The answer from Haynes manual is: "The rocker arm cover bolt sizes are different. Install the longer bolts (A, Figure 41 ) on the right-hand side. So thanks anyway. I figured it out, thanks to Haynes.

[@Bikervation]

@@Jeff82556 It was some time ago, but great you managed to sort it, workshop manuals are a great tool. Ride safe

[@valcason100]

good morning thanks for your videos which I discovered recently but I think they are really useful, is it possible to know where to find the technical data sheets you consult in the video I have an HD 883 iron

[@Bikervation]

Hi, Thanks for watching and commenting, the sheets are from the HD service Manual for my bike, I’ve printed them out and encapsulated them against grubby hands.

[@valcason100]

thanks for the quick response... can I have a copy of the manual?@@Bikervation

[@Bikervation]

Sorry I can’t help - mine’s a hard copy bought from my local HD dealer but you could probably find the manual for your bike on-line, some of the Facebook groups have sections covering things like that and there are several Forums that have the same. Takes a bit of leg work but I’m sure you can find what you’re after.@@valcason100

[@valcason100]

thanks... I have to do the same thing to the head gaskets, could you please help me tighten the screws?.. thanks, I will continue to follow you

[@Bikervation]

Hi, If I’m not mistaken all my procedures are in the videos but that’s for my bike. The best thing you can do to help yourself is get hold of a workshop manual, either a Harley Davidson or Clymer should be sufficient for your needs. It’s all a learning curve, Good luck.@@valcason100

[@krtt750]

Angle torque? Why? Timing mark on flywheel for TDC?

[@Bikervation]

Because that’s what the workshop manual says to do.

[@ihateemael]

looking at all the carbon on the piston crown (earlier vid), your engine will benefit from redirecting the cylinder head breathers to an external catch can.

[@Bikervation]

Hi Richard, thanks for your comment. I don’t have a problem with a small amount of carbon build up on the pistons over a 13 years period. However I do understand what you are saying but would not know how to easily go about redirecting the breathers. Thanks watching, stay safe, Chris

[@austinleamer4541]

Could you give me the specs on that tool you made to rest the piston on allowing easier install of the jug?

[@Bikervation]

Hi, Thanks for watching, it’s made from 5mm aluminium 175mm x 70mm the slot is 17mm wide a goes 130mm along the length. Hope that helps, Chris

[@sacsoverlanding]

I've done this with a 2003 and 2013 sportster.... its a job for sure but MUUUCCCHHH cheaper

[@Bikervation]

Agreed, another benefit is the increased knowledge and confidence you get, thanks for watching. Chris