Harley Sportster, Clutch Cable and Primary Case Removal !

[@LS-uv9gg]

I really love the whole "need a tool, make a tool" philosophy, regardless of how cheap or expensive buying one is. Foot pegs or Kick stands attached to the engine via side cases or engine blocks, utterly terrify me lol.

[@rickrogers2649]

This series is pure gold Del. So many great tips like the cardboard templates where you arrange the bolts and the orderly way you lay out the parts as you disassemble them. This is a perfect text book for any one thinking of doing a job like this. Looking forward to the custom tool you will be making. Best wishes to you and Penny and thank you for another great post.

[@Moonfleet41]

Many thanks indeed Rick for such a wonderful message... we really appreciate your kind words of encouragement, a lot goes in to making the videos, so it's much great to know they're enjoyed, have a great week there and 'see ya Friday'! D&Px

[@grosbeakmc]

Hey Del and Penny, beautifully made video as always. Content, format, information, editing - all second to none, and I have an inkling of how much work you put into that. And while I do miss Springy and The Blokes now and then, the sound of fasteners cracking loose, oil splashing into a pan and vinyl gloves squeaking on a hex key is the most beautiful of music. Thanks for everything you do! P.S. Always nice to see a bolt map in use - I'm a big fan!

[@Moonfleet41]

Thank you so much for those kind words my friend, it's so good to know that you enjoy it so much.. bolt maps are great as you not only remember which ones go where.. but you don;t lose any under the bench either.. Take care and keep safe buddy.. and stay in touch.. D&Pxx

[@clark7169]

Hi Del & Penny This episode was a timely reminder to keep on top of maintaining the clutch cable. I know you mentioned in the past using zip ties around each end of the rubber boot. Top tip! The cable looked nice and fresh in the casing but I guess it will being splashed around with oil. I bet it's a different story further up the cable. I know you mentioned replacing it. Cycle manufacturers produce teflon lined cables which last way longer and work much smoother than steel lined cables. Not sure if you can get aftermarket teflon lined cables for motorcycles. Another fantastic episode Del in every way. Have a good rest of the week both! 🇸🇪🇬🇧👋🏻😊

[@Moonfleet41]

Hi Paul, im not sure what the new OEM cable will be, but what ever it is it'll be better than the old one aye.!! Thank you for your kind support as always buddy, it's always good to hear from you.. D&Pxx

[@lukeb4582]

Last 3 videos have been amazing Del! Very informative, such beautiful editing! The videos flow so well, I watch all your videos on tv hence not always commenting, Project is very exciting, I bet your mind is in overdrive with the ‘look’ of the bike once the mechanicals have been done, I’m excited for you when you receive all the parts from HD! As always, have a lovely blessed rest of your week both of you! Cherish one another, smile, have fun, laugh, and ride if you can, ain’t that weather got nippy today though 😬 haha, Much love, Luke x

[@Moonfleet41]

Hi there Luke.. Sir, Thank you so much for those kind and generous words, it makes all the time and effort worth while when it is appreciated. You are right too, im buzzing with the possibilities, these bikes lend themselves to all the genres, Chopper, Bobber, Tracker, Stunter.. it's all possible, i just have to bring it all in under the budget.. and at the moment, the motor is beating my up with the cost of parts.. but its ok, the heart or any bike is it's engine, so that has to be right first.. i have the gaskets in now, but the piston kit and carb kit is held up in customs, no sign of when ill see them yet.. but i have lots to be getting on with. Thank you as always for your wonderful support Luke.. stay safe and keep in touch.. D&Pxx

[@CalmCobra75]

Amazing video!!! Lots of great info. The ideal motorcycle workshop and the best techniques on display. Nothing even comes close to this.

[@Moonfleet41]

Wow, thanks Arul for your kind words, we both truly appreciate them!

[@ACoustaDC]

Your filming has gotten so much better over the years.

[@Moonfleet41]

Thank you for your kind words..

[@jasonshortphd]

When you did this series I watched and learned a lot. Now, two years later, I have a 92 Sportster and am doing a lot of the same stuff you did here! Once again you have a video for something before I even needed it. I will say your engine looks a LOT better than mine with 45k miles. I am thinking about a 1200 kit as well now.

[@Moonfleet41]

Great to hear that sir.. you'll have lot's of fun with that, it's a simple swap and really enjoyable to do.. We're so glad the content can help, obviously always ask if you need anything we can help with..D&Px

[@tinks43]

I do like a bit of disassembly. Well done peeps. Look forward to the tool making 👍🏻

[@Moonfleet41]

Thanks buddy.. got to save money where i can, See you soon aye.. D&Px

[@TroubadourJuggernaut]

Incredibly clear, tidy, thorough with masterful editing (as usual)

[@Moonfleet41]

Thank you most kindly sir.. Glad you think so!

[@kwiebje24]

Another great video! Today, I used your “paper” trick to unbolt a bumper from my girlfriends car. She was impressed! It saves a lot of memory 💪👍👍 I like your structured way of working👌

[@Moonfleet41]

Thanks for the cool feedback mate.. Glad it helped!

[@garymccaughey691]

As all ways loving the videos and more so your back with an HD. But, what I'm really glad to see is you got a pick set again and broke that habit of pulling orings with a flat head. 😉😂 Gonna be glued to this build!

[@Moonfleet41]

Thank you for your kind words Gary, glad you're enjoying it, it's a fun project!

[@elirawlins8932]

@@Moonfleet41 what should I do if the center adjusting screw is flush with the nut beneath it? I’ve snapped the tips off of 2 flatheads so far and it hasn’t budged the slightest?

[@TheWibbo]

Nice to see you are back to wrenching on a sportster again. Started watching your vids when i bought an XR12 about the same time you did videos on yours (too bad it gave you some grief). I still have mine and enjoy it tremendously.

[@Moonfleet41]

Thanks mate, i realise now what a great bike the XR1200 was, and i only sold it at the time because we had a business and needed the money for various things.. the luxuries always go first aye.. Glad to hear you still have yours, they're a great investment now and really hold their money.

[@alexphillips8387]

Really excited to see the mpg figures on this baby when it’s done.

[@Moonfleet41]

I told you, 55 mate! ... lol

[@TechnMoto]

Brining back memories of when I did my primary seals etc. look forward to seeing that tool being built. 👍 keep on brother

[@Moonfleet41]

Thank you so much for your kind words Mike, great to hear from you always, hope life is good and you're keeping safe!

[@wobblysauce]

The way they hold the clutch cable is great.

[@softailfun]

Nicely done fella. “Need a tool, make a tool” always love it!👍🏻. Seems to be coming along nicely, nothing breaking, slipping, snapping etc. still gritting my teeth every time you crack a fastener! Be safe.

[@Moonfleet41]

Ha ha, you and me both mate, it's often a nail biting journey, but that makes it all the more fun aye. Keep safe and chat soon, been flat out today, ill drop you a line on the lathe shortly bruv.. ..

[@softailfun]

@@Moonfleet41 Whenever you can brother. No problem.

[@notsoprettyasyou]

Thank you for the clear instructions - the torx 27 of the clutch-cover are much easier to remove, if you give them a ligth kick with the hammer before moving....

[@garya3056]

Phenomenal vid, Del! You sure know your way around the guts of the HD primary! BTW -Aren’t prices going through the roof these days? And heavens knows there’s still the massive delays! This weekend is service time for the wife’s big Vespa, so lots of good greasy fun in the garage for me. Hope you both are feeling well and staying safe- 🏍👍🏍

[@Moonfleet41]

Thanks Gary, and yeah i guess so, been inside a few over the years and there isn't much to them really. Prices of everything are just chronic right now, fuel is ridiculous now at about £1.90 a liter ($7 for a US gallon), and the piston kit is delayed in customs along with the carb jet kit.. pretty much anything coming in from Europe is at a stand still.. but i still have a fair bit to do before i need it so it'll be fine. Good luck with the Vespa, have fun with it and enjoy the journey.. Take care and keep safe both of you.. D&Pxx

[@garya3056]

@@Moonfleet41 stuff is crazy, my friend! Thanks and take care. 😎

[@SpookyHaunted]

Wow, man! This is a super helpful video! New subscriber! Just watched your video on adjusting the clutch cable, and seems to be an easy task. I enjoy how in depth you go but not to the point of being confusing. Really helpful for us beginners! Do you happen to have a complete handlebar swap video? I'm searching but so far haven't found one haha! Cheers from the U.S.A!

[@Moonfleet41]

Thanks buddy, and welcome aboard.. have a look at this video, done a few bar swaps over the years on various bikes, this one's quite old but pretty detailed so should help you out.. Good luck with it.. kzbin.info/www/bejne/m3SZmZSubLetrdE

[@SpookyHaunted]

@@Moonfleet41 Thank you! I appreciate it!

[@mikeopenshaw9128]

Well I think Luke B said it all - very well put - so you can have a bit of a lazy "ditto" from me! 😉 Eagerly awaiting the next instalment - many thanks guys!

[@Moonfleet41]

Why thank you most kindly Sir.. Glad you're enjoying the action.. it's a great fun project already.

[@rsbharley4766]

Excellent video Del & Penny. Looks nice and clean inside mate, looking forward to the making of the clutch spring tool. Penny and you have a great week. Take care, Cheers

[@Moonfleet41]

Thanks mate👍, glad you're enjoying the project. we really appreciate your constant loyal support, it's always good top hear from you.. Have a great week too.. D&Pxx

[@raydouglas5896]

Great work again Del. Brings back a lot of memories when I was doing this, picking up some tips still too.

[@nickmitton7350]

Nice video again sir!! Can't beat a bit of Blue Peter , here's one I made earlier!!!

[@Moonfleet41]

Damn it, you've shown your age there buddy! Join us next week for some sticky back plastic action lol

[@renzovc]

Another great video brother! super informative ! it makes sense on making your own tool and saving money specially since you are barely going to use it 👍 can't wait for the next video brother!!! keep up the great work ! stay safe guys cheers from new york 🍺🍺🍺🍺🍷🍷🍷🍷

[@Moonfleet41]

Yes indeed brother, some of the specialist tools are very expensive, which is fine if you use them enough, or if there's no other way round it, but think you'll enjoy the next video! Have a great week both, be safe and always good to hear from you, D&Px

[@rolandschleicher7458]

"the spring will disapear into another dimension" best line ever.

[@MrBradfordchild]

G'day Delboy, your videos are fantastic! Thanks very much for the time and effort you put into making them, and no music or radio blaring away in the background. As a muso, this makes me very happy! Thanks, form Australia.

[@PatriotNC1]

Again, a very informative video. You thoroughly explain each step you take, which is great for those who haven't dug that deep into their Sportsters. I look forward to your future videos, really enjoying them.

[@Moonfleet41]

Glad it was helpful!

[@enriquecorona3184]

Hey.. good to come across ur work on Harleys.. it seems that u have been on the Road eh..! Ur accent sound scottish to me, right..?

[@christophermcreynolds6001]

You obviously love working on Harley’s, and it great for me to enjoy the process. Thanks mate 👍👍👍👍

[@Moonfleet41]

You bet mate.. it's always fun.

[@grzechorachon]

Many thanks for another great video 👍👍

[@nicholasbishop3300]

Great step by step tutorial Del Nick Australia

[@Moonfleet41]

Thanks Nick, glad you're enjoying it mate!

[@darinski68]

Neat & tidy work with pride & precision as usual Del, always a pleasure to watch you get the job done. 🙏

[@Moonfleet41]

Thanks Darren👍 Much appreciated mate.

[@springy-2112]

Coming along Del . Its fun making tools , mine normally look like scrapheap challenge but do the job . Peace and love brother 👍🏻☮❤

[@Moonfleet41]

Hey as long as it does the job, there's no marks for making it posh! Keep safe and stay in touch brother, D&Px

[@ScottForrest420]

This REALLY REALLY helped me with my 95 XL1200 Sporty. Much appreciated.

[@jose44552]

Great video very helpful. Thank you.

[@enduromotorradtouren]

Some neglect by previous owner makes cleaning and tidying necessary. But that's the fun part, isn't it, Del? Cheers, Günter from Nürnberg/Germany

[@shaunglendinning]

Great advice Del! Appreciated.

[@EvoKnievel-bh4rr]

What year is this sportster? Looks identical to my 95. Was wondering if you knew the size or part number of the o ring (clutch cable to transmission). Google hasn’t been my friend here and the service manual doesn’t mention it for my year. I’m coming up with 11179 but getting mixed fitment details for my year. Also, thanks for all your videos I’ve done the top end and several other projects all thanks to you.

[@Moonfleet41]

Thanks buddy, glad the videos can help.. i wouldn't know the o ring size, i don;t bother looking.. just mach it to a fresh one from stock... Treat yourself to one of these, you'll never have this problem again... www.spanner-monkey.co.uk/rubber-o-ring-assortment-407pc-imperial-113280?search=BOR407&description=true

[@wb1956]

Really good. Thank you

[@markwitham6784]

Good video that 1 mate. Very informative.👍 Thanks

[@andrew1977au]

Replace the damper mid pack with a plate and steel, they fail and take out the basket.

[@richardwhittle2302]

Fascinating and very slick video Del 👍

[@Moonfleet41]

Thanks Richard👍

[@harveysmale8538]

Do you have to take the chain tensioner out?

[@beans4491]

Wow, i wondered what was lurking inside that cover…looks like a flux capacitor to me?😂 Great video mate, just gonna watch the next one with my dinner on a tray on my lap!…perfect! Actually!…..how do you know all this stuff?

[@Moonfleet41]

Hey buddy, thank you for your support, a lifetime on the spanners and I guess you cover everything at some point... plus a good service manual for the data and specs! Enjoy your weekend mate and keep safe.

[@beans4491]

You are always the gentleman mate, stay safe too.

[@nickhellen6303]

Great “How to do it” video. Anybody wanting to remove a Sporty’s primary cover would find it impossible to do incorrectly after watching that. Love the cardboard template for the bolts. Whenever I’ve had to remove the primary on my Softail, that’s exactly what I do. Keep it going Mate.

[@Moonfleet41]

Thanks Nick, I love to keep fasteners in order when they're different sizes, and it helps to keep them altogether as well... with an engine in bits, it's easy to lose small parts and fasteners kicking around the bench! Thanks for watching, have a great week!

[@goldilocks913]

Informative and empowering as ever! 👍

[@Moonfleet41]

Good to hear you enjoy!

[@loddude5706]

Some say, this type of clutch is a Welsh invention; courtesy of Mr. & Mrs. Aphragm's little boy Dai, often known as the dish faced Prince of Boing - generally 'short & stocky', but what they lack in height they make up for in toe curling power : )xx

[@Moonfleet41]

Hang on, that's a sheep joke, but I like it!

[@Jay0346]

I really enjoy this build!

[@FelicianoTech]

Hi. I get why you label the container you put the oil in as used oil. Why do you mark the oil weight on it though? Great video as usual. Thank you.

[@Njsl-u7o]

If I just want to change the clutch cable do I really need to release the tension on the adjuster or just follow the procedure until that step ?🤔 thx

[@alexmade8434]

Great Vid, really good to hear you explaining as your doing.

[@th3v1k1ngW4rri0r]

what a pavlova! lol (cant spell palaver lmao) but Kudos on need a tool make a tool. I made a tool to take the blue star.. out of yamaha blue star/blue spot calipers. Now have 2x xj900s diversions with blue spots on them. 1x is still my military nato green bike The other 1x standard old school 1996 colour scheme, with a matching bagster tank cover. ( really really wanna army rat that one.. lol.. BUT I wont... Going to finish the mods on it, then re-sell it.. maybe)

[@Moonfleet41]

Gotta love an army style bike, so much scope and really easy to look after too.. send us a few pictures when yer done buddy, id love to see it.

[@ObsessiveCarDetailer]

What a top video, thoroughly enjoyed that👍

[@Moonfleet41]

Glad you enjoyed it buddy!

[@josephmaistre8570]

Much better with the commentary

[@motordown7664]

Great video Del. I too enjoy making DIY tools and saving money. This is a great HD project series to follow. Your editing is spot on as usual.

[@Moonfleet41]

Thanks mate. Glad you enjoyed it!

[@paullane8586]

I made one for my sporty. Easy pessy. Good vid. I watch in antici pation.

[@MegaBruceC]

I bought the tool before I opened my primary, only to find that I have a Barnett Scorpion clutch inside... Thank goodness I have a Buell as well!!!

[@Moonfleet41]

If that's a 6 spring outer plate... then a seriously heavy investment for someone in the past..! Good find, great when it goes like that aye !

[@GrandpaFumblefingers]

I have no idea what you are planning for the Sportster, but I sure would like to see, 19" wheels fore & aft, peanut tank, solo seat and a P Pad. Make it into a real Street Tracker. Grandpa Fumblefingers

[@Moonfleet41]

Hey buddy.. 19" rear would be great for "flat track purity", but there is almost NO tyre choice for "rear" on 110/90/19.... they'd be "front" tyres, and you'd have to mount them backwards if they're directional or choose crappy non directional commuter tyres.. it'd be better to go 18" on the rear, then i could fit a 130/70/18 which has a huge amount of tyre choice on the market and a lot safer on wet roads.. also it'd look pretty much the same and still give a lot more of a 'tracker look' than the dumpy 16" it has now..!

[@GrandpaFumblefingers]

@@Moonfleet41 Guys here are using Maxxis DT tires. What are the guys with Vintage Brit bikes running, Most of them had 19" fore& aft

[@stevenharris7788]

Thanks for your videos brilliant and I enjoy them hope your well

[@Goldwing1500rider]

Super video !! Some things I never knew… incredible how engineering makes those parts, make them work. So often, making own tools much better than what China makes. Can’t wait your next video.

[@Moonfleet41]

Thank you very much Sir, hope you enjoy the next video too! Have a great week.

[@tomtilley3162]

love this channel every episode i learn stuff .you have a methodical method that makes everything much simpler well for me anyway lol

[@Moonfleet41]

Thanks Tom, im glad to help and really appreciate your feedback.

[@richardwhittle2302]

Clever Stuff 👍

[@MintyGusto]

Nice and simple easy to follow instructions as always Del! Interesting to see how much oil was left in there after the drain too!

[@Moonfleet41]

Exactly mate, which is why when you fill the casing with oil, you must check the level and not just dump a quart in as specified.. you never know how much of the old stuff is left behind.

[@FourIntoOne]

As I have always said: if a jobs worth doing its worth doing cheaply!

[@myz06rocks]

thanks for the video in which you accomplished something worthwhile. I needed it! Feeling pretty discouraged myself. Got everything on the ST reassembled and the damn thing doesn't start. so back at disassembly and trouble shooting. Just spins over. ARGH Ah well, all part of the experience :) At least thats what i'm telling myself!

[@Moonfleet41]

No way.. sorry to heat that buddy.. it can drive you mad aye.. specially after all the hard work to get it back together.. im sure it's something simple.. Good luck with it, take a step back, make a brew, and it'll all look different in the morning.. Take care and keep safe aye.. D&Pxx

[@JardineTTV]

My clutch adjustment screw does not turn clockwise or counterclockwise and I don’t understand why

[@chadkegley9458]

Reminds me of Gordon Ramsey but motorbikes instead of food lol

[@jmead6121]

Great Thanks but the de-compression tool you only use every 5 years .if you invested in one ..but a question - is it because you do hardly no Bike Clutches or is this Problem unique to Sportster Only ..Thanks

[@LucioLarangeiraFilmes]

That was amazing. thanks!!! specially because I will be doing it soon. helped a whole lot. loving the project and waiting anciously for every installment.

[@Moonfleet41]

Best of luck of your project, thanks for your support!

[@johnmccallum8487]

This is very useful as I’m about to fit a Rekluse Exp auto clutch in my Sportster , was looking daunting but following your vid makes it a lot easier cheers.

[@Moonfleet41]

Glad to hear that it can help you out John, ill be uploading a full video of reassembly, including installing the new clutch, once ive made the tool to take it apart. Good luck with yours, hope it all goes well for you mate.

[@jedi_duck5170]

Quick question, how do you dispose of you oils after you’ve drained them?

[@Moonfleet41]

Once i have a fair quantity, i take it all to the local recycling tip, they have a huge tank for it and it gets recycled into heating oil by the local council for schools etc.. You empty all the bottles and cans into the tank, then put the plastic bottles in the plastic recycle skip..!

[@REKLESSWOLVES1]

😮 OMG Del, no stickers ????? If ide spent £ 260 beer tokens on bike parts ide expect at least one kickass free sticker, LOL. 😜

[@Moonfleet41]

Oh i'll get stickers when the parts arrive.. that was just the oil, filters and new clutch.. most of the stuff is still to arrive buddy.!

[@geovanniperez9663]

Que tal amigo muy bien explicando no hablo inglés pero si entiendo

[@Moonfleet41]

¡Buenas noticias, le agradecemos que lo vea!

[@mguilbert143]

Nice one mate really looking forward to this one. Hope you and Penny are doing ok.

[@Moonfleet41]

Thanks mate, we're fine, and enjoying the project too.

[@wademccomas4004]

Is there a torque spec for the 2 foot peg bolts that attach to the primary case? I'm having an oil leak coming from there and the manual I found online doesn't mention a spec.

[@Moonfleet41]

If you have a primary joint leak, then tightening those two bolts will not stop it... remember the other bolts around the casing will seal it, even without the footpeg bolts connected... it's more likely you have a gasket breach, which is common if somebody has removed it in the past and re-used the old gasket... so I would, maybe consider, buy yourself a new one, whip the case off and replace it... and there will be a torque setting for those bolts, it'll be in your manual.

[@wademccomas4004]

@@Moonfleet41 I've cleaned the area around it and it appears that the oil is specifically coming from the footpeg location. I tightened them up when all was cold and it did help, but still had a small leak. So I've tightened them more whilst the oil was still warm. Hoping it completely eliminates the leak this time.. Thanks for the advice though! I plan to do a rebuild of the motor in the future and am super thankful I'll have your videos as a guide!

[@Moonfleet41]

@@wademccomas4004 Most welcome.. good luck with it Wade.!

[@danparsonage3884]

Love a bit of strippage haha

[@Rocky19011]

Hi Del, what gloves are you using? I would like to order some. Cheers!

[@Moonfleet41]

Here you go George, black are out of stock at the moment, so this is all that's currently available, few issues with supply right now, but this is where I get mine: www.spanner-monkey.co.uk/index.php?route=product/search&search=nitrile%20gloves&description=true

[@Rocky19011]

@Delboy's Garage @Delboy's Garage Thank you very much Del, much appreciated. I've struggled to find decent gloves, so going to give these a go. They look quite durable from your videos.

[@TheSweetasanut]

Great as always del

[@Moonfleet41]

Thanks 👍

[@jamesmich4973]

Yourr left handed???

[@TheSweetasanut]

Where did you get that rubber ring set del

[@Moonfleet41]

Here you go Martin.. ! www.spanner-monkey.co.uk/rubber-o-ring-assortment-407pc-imperial-113280?search=BOR407&description=true

[@TheSweetasanut]

Thank you del

[@filipd.3613]

hello wanted to ask which gear oil you could recommend (2001 Sportster 883)

[@Moonfleet41]

Do you mean Primary oil?

[@Moonfleet41]

@@filipd.3613 Only two oils on a Sportster Filip, Engine oil, and Primary Oil.! separate gear oil is only on the Big Twins !

[@filipd.3613]

@@Moonfleet41 it's the primary oil. Which brand would you recommend and which type?

[@filipd.3613]

@@Moonfleet41 yes the primary oil

[@Moonfleet41]

@@filipd.3613 Ive used everything from Screaming Eagle Syn3, to Amsoil, to even plain Dextron ATF.. it's just a splash oil to lubricate the chain and keep the clutch cool.. it's not under any pressure.. so just regular HD Primary fluid from your dealer is fine, treat it to something more extravagant if you like.. it's not critical !

[@alfonsofalcon621]

Hello!! Hi from Mexico, I want to share with you that I have been following the channel for a few years and you are a great inspiration to me, it has been 1 month since I opened my own workshop and I would like to show you what I do!! Could you send me an email or address to send you some stickers and things I have for you? I am very grateful to have found your channel!!

[@Moonfleet41]

Hi Alfonso, how good to hear from you all the way from Mexico! We'd love to hear what you've been up to, so you can email us at: [e-mail] ! Thank You