How To Adjust An Evolution Harley Davidson Sportster or Buell Motorcycle Primary Chain & Change Oil

Here's how to adjust an Evolution Harley Davidson Sportster motorcycle primary chain. www.hoohoohoblin.com is where you can see more about my Sportster-Engine bikes. Adjusting the primary chain tension and changing the fluid is really easy to do, and you can see everything involved in this video. If you have a 2002 or older tube-framed Buell motorcycle with the Harley Davidson Evolution Sportster Engine, this will work for you as well. Just open the inspection hole, measure the gap, crank the engine over 5 or 10 times and measure to see if there is less than 1/2 inch of play at the tightest point with the engine cold. It's really easy to do, and these chains don't stretch much, so most of the time you won't need to adjust it. To change the oil, drain it, and then dump in a quart. I show you how to check the Evolution Sportster primary fluid in this video, but if you're changing the oil you don't need to check it. Just put in a fresh quart of Harley-Davidson Sportster primary oil after you drain it. I hope this helps you learn to do this yourself. It's simple, and you'll save a lot of money on service.

[@DayDreamer0115]

Hey, you've probably heard it so often that you're getting tired of it, but thanks for the informative video. Well done! As a single female, I can use all the help I can get on maintaining my sporty.

[@PuppyPhoenix]

Thanks for your quick and timely response, man. Very kind of you. That rattling of the chain is getting on my last nerve. Also, thanks for giving me the courage to change my fluids. Didn't think I had it in me but thanks to you, I've successfully done it. Cheers.

[@2CabrasLocas]

Great video and THANKS for sharing your experience! On the Buell, use a grinder to trim 1/4" off the allen wrench and you should be all set.

[@moneymaker8461]

Hey man I am working on my Antique EVOLUTION 1340 80"....Long story short I have one of the first Evo motors to ever come out of the factory and when it did come out, it was 1984. That year was the year the EVOLUTION was born.

[@hoohoohoblin]

+Money Maker It's a really well-designed engine. Take care of it, and it will run forever.

[@DaveoCamaro]

The proper tool to avoid removing the muffler to adjust the primary chain tension is a ball end hex key allen wrench. Thanks for all the great videos!

[@papakernz]

I actually own a Buell just as you have shown, that is another reason it was so particularly helpful. You may also consider adding "Buell" in your video name for someone that wouldn't think to look here. Thanks again!

[@Mr05Tundra]

Hey, I'm a new Harley owner, I like my bike so far. I really enjoy your videos, they give me a lot of good information! Keep them coming!

[@anyak882]

Thank you, I am from Poland and few people can help me here, thanks to you I will do it myself, it was very helpful. The film is many years old and still useful.

[@hoohoohoblin]

You’re welcome. I’m glad I could help.

[@timbo21]

Keep making those videos your doing the buell community a world of good. Thanks.

[@midatlanticcycle]

great vid. i'm a buell owner and have been using 20-50 wt. castrol act-evo in the primary for years and clutch and trans work wonderfully.

[@ryno921]

Very helpful video. Thanks for taking the time to make it and share with us!

[@filmfreaken]

This video helped me find the courage and motivation to adjust my primary chain! - thank you!

[@hoohoohoblin]

You’re welcome.

[@eddyrawlings9556]

This was very helpful and simplified what appeared as pretty complicated, I do believe I can handle this now... Many Thanks!!!

[@papakernz]

Excellent video, good instructions, easy to understand. Thanks!

[@Blake4Truth]

Typically, a few ounces of transmission lube will remain trapped within the primary/transmission such that a full quart added will be too much and can cause the clutch to grab, especially when cold. Round about 28 to 30 ounces is ideal. Great video!

[@Sven136]

Wish I had known this sooner! I figured it out after being late to work 3 mornings in a row from stopping due to clutch issues, drained about 2.5oz and now it runs prime👌

[@sanderidzerda6636]

Man, exactly what i needed. Thanks!

[@hoohoohoblin]

You’re welcome

[@tshaffer90]

Hey im brand new to tbe harley world traded my crotch rocket for a 97 m2 cyclone Best thing ive ever done I will never have another rocket. Anyway and your videos have helped me so much thank you.

[@williamdavis7053]

Thanks for the video. I've always wrenched my own cars and trucks, my 96 sporty I inherited from my dad is the first bike I have to maintain. while the Clymer manual is a great help I learn better seeing it being done. Post more on the Evo..

[@hoohoohoblin]

You're welcome. It's a great, reliable machine that is easy to work on, and parts are cheap.

[@PowellRobertM]

Awesome video. Thanks for the detailed info

[@midlantic1]

Good job, Thanks. I'm very familiar with the big twin systems but had no clue about the sporty which my son just picked up. So thanks for the info

[@DustinBond007]

Thanks for the video man, this has helped me a lot! I ride a stroked 100hp sportster 1200s, ride safe brother!

[@hoohoohoblin]

You're welcome.

[@brewjitsu429]

Came to see primary chain adjustment, saw FXR. Nice! :)

[@hoohoohoblin]

Thanks. Here is a better look at it. kzbin.info/www/bejne/eJ-2e55riMpqrq8

[@PuppyPhoenix]

What size wrench are you using on the Lock Nut to adjust the chain? I can't seem to find any in my stash that fit it.

[@IIIsticksone]

Great vid. Thanks for posting.

[@llGoofsterll]

thanks for the vid man .. love the buell

[@alcrosbie7098]

Hey there, just wanna say thank you for the video it was really helpful for me tonight. Appreciated 🙏 and kindest regards, Allan ❤️☮️

[@hoohoohoblin]

You’re welcome

[@elgol71]

thanks , i found everything i need to know, im getting my sportster ready for the trail of tears ride ,from maddison alabama to waterloo al, gracias.....

[@3thedward]

Danke für die gutgemachten Videos, thanks for this real good videos, I like that you make perfect work, including to put some grease to the bolts when you put the things together Great Ed

[@garynumanfan]

thanks for this mate, I'll be checking mine. nice bikes : D

[@save4775]

Thank you for the video. Excellent and helpful!

[@hoohoohoblin]

You're welcome.

[@hammyhambone85]

Great video! Thanks. I've been using Castrol Power RS full synthetic for engine and primary oil on my Buell XB. Castrol specifically states that this oil is formulated for Transmissions and Primary chaincase (as well as motor). It is a 20W-50. What do you think?

[@Patiboke]

Video's 10y old but it helped me, thanks!

[@hoohoohoblin]

You’re welcome

[@hushjohnny9543]

Thanks man for this. I followed what you did on my 95' Sporty. All is good ! GREAT vid. \,,/

[@hoohoohoblin]

You’re welcome. I’m glad I could help.

[@GCANDY100]

Nice video:) wery good explaining step by step:)

[@vanportguy]

Thanks. Good info. I just got a 2003 harley 883. I just changed my oil and this will help me even further. I was wondering if you have any videos on carbs or carb maintenance. Kind regards

[@leestratton1]

lots of good info... thanks

[@jorgecastro5253]

very helpful, thanks!

[@tweettuwoo]

I'm going to impress my husband and do this to my bike all by myself. Thanks :)

[@hoohoohoblin]

You're welcome! You can do it!

[@MrTurtleneckbreath]

On the Buell muffler space cramping issue, just go buy a single Allen key to fit and with a 1mm cut off wheel shorten the working end to 1mm longer than the depth of the Allen stud socket. Dress the cut face a little with a file, sandpaper or even the 1mm cut off. Keep that dedicated little sucker in the on board toolkit. I have one for the intake manifold from when I had a leaky rear rubber seal. I find the long stem keys are best for those awkward spots.

[@maiden666guitar]

Hey dude, how often or after how many miles should I change the oil again? Also, I went to adjust my clutch and when I took of the clutch cover I found foam and small traces of water on the cover. Upon further insp. the oil on the chain and as far as I could see were ok. Is this normal, THX.

[@milwaukeecitizenpres]

Great video and diagram. Thanks much!

[@hoohoohoblin]

milwaukeecitizenpres You're welcome.

[@XenaS-np3cs]

Im finally able to do this on my X1 Buell, thank you so much for showing how its done.

[@hoohoohoblin]

Glad I could help!

[@mdniteflyer]

Very good video, thanks!

[@hoohoohoblin]

Michael Clark You're welcome.

[@warrenzvon9324]

i've had the bike a couple months and i'm new to hd and nervous because i have only had metric bikes. gonna give this a try. thanx.

[@rexwilson6598]

Great Video thank you!

[@hoohoohoblin]

+Rex Wilson You're welcome.

[@brandonhamil1534]

My adjuster bolt goes almost all of the way into the adjuster but before it starts to get tight. What could my problem be?

[@tulo66an]

Awesome and easy to understad

[@hoohoohoblin]

tulo66an Thanks.

[@NOT_EZ_NFL]

So i just bought a buell x1 lightning 1999, a few weeks back The bike just became very hard to shift and i can't figure out what i should do i pulled the inspection cover off and checked the chain like you did and looks great, however when i pulled the off the clutch cover oil literally poured out, Im assuming since this didn't happen on yours this is very bad could maybe the previous owner just of filled it to much? what should i do from here

[@hoohoohoblin]

Maybe they did put too much oil in there. Try riding it with the proper amount of oil in it and see if it works right. If not, then make sure the clutch cable is adjusted right, so it fully disengages when you pull in the clutch all the way. If that is adjusted right, then it is possible that something is wrong with one of the clutch plates. I had a 1996 Sportster, which had a spring plate between the clutch plates, which was riveted together. Its purpose was to make the clutch quiet enough to pass noise emissions. The rivets came loose, and the result was that sometimes the clutch didn't disengage properly when I pulled the lever in, even though the lever was adjusted properly, and it felt like it was working. The spring plate loose rivets were jamming up the clutch mechanism, stopping it from fully disengaging. On that bike I bought a Kevlar extra plate clutch kit and replaced all the metal and friction plates, and replaced the spring plate with an extra friction and metal plate. I don't know if the Buell has a spring plate, but if it does, this could be the problem .

[@ellendowning3162]

wow thanks so very much just bought a 1999 1200 love her but she needs her chain adjusted i will take your video in the garage so i won't screw it up lol thanks again

[@kalogirouax]

Nice video! Do you think some difficulty downshifting on a 2002 sporty could be due to low level oil? or clutch? the problem is only during downshifting...

[@hoohoohoblin]

+Chilly AK It is probably something mechanical, like a shifter return spring.

[@kalogirouax]

thank you, I will take it apart today and have a look!

[@dirrka69]

hi there, how do i check and top up my 02 M2 transmission oil? regards, craig NZ

[@conorbauer5574]

Thanks for the video! I have a 88 sporty 1200. Have some noise when I'm in third gear. Hopefully this is the issue! Haha. Question for you- what gear oil and weight do you reccomend to use? I need to pick some up.

[@hoohoohoblin]

I use Harley oil now, but on my old Sportster I used Valvoline 85w-90 gear oil for 43,000 miles and it worked fine.

[@MrBoabiegringo]

Tough to get Harley oil in Ireland without getting royally screwed what do you think about Motul 3000 20W50 for the primary? Great video! I've had my Sporty 2 odd years & loving it more all the time!

[@hoohoohoblin]

I put 75w-90 weight Valvoline gear oil in my 1996 Sportster primary and it ran fine for 43,000 miles, and then I sold it. I think you want to use gear oil instead of motor oil, but I am not sure if newer Harley's are different.

[@astifcaulkinyeras]

How does the Buell get way more HP than my Sportster with the same engine?

[@gregorymcfadden6940]

my clutch is making noise and it's only when it is engaged(lever released right?) that it makes the noise n the best way I can describe is it sounds kinda like a turkey and will do this thru each gear and occasionally would stop now kinda all the time I e done some researching and have the primary cover off noticed that the adjustment screw has a lot of play could this be the throw out bearing if not have you ever heard of it making this kinda of noise I mean it seems to me to be like a bad bearing noise

[@hoohoohoblin]

+Gregory McFadden I haven't heard that sound before. It may be the throwout bearing. Some of these Harley clutches also have a spring plate in them, which can break in half and cause problems. It might be that. That happened to my sportster, but it didn't make any funny noises. It just sometimes wouldn't disengage.

[@gregorymcfadden6940]

hoohoohoblin hey thanx for the advice I guess I'm just gona have to dig deeper I it a 96 and I seen in another comment you mentioned about the clutch I'm at 40,000 so might be time be time for a upgrade

[@jcmac1313]

good video just rember intead of turning over the enigne. turn the tire by hand. Measure in 6 diferent places and adjust at tightest spot in the primary chain or you could over or under tighten

[@dirrka69]

thanks mate

[@tonyross9669]

how do you get the primary chain and clutch pack out of a 88 sportster?

[@hoohoohoblin]

I've done it before on a 96 Sportster. It's pretty easy to do. I installed a Barnett extra plate clutch kit, which gives you one more plate. You need a special tool to pull the clutch pack. If the engine is close to stock, don't use a higher-pressure spring. A regular spring will work fine and will be easier on your hand when you use the clutch. I didn't make a video of it, so I cant show you, but I did the job on my Royal Enfield Bullet, which is a very similar design. It looked like this: kzbin.info/www/bejne/mJq9hJ-KoLWmptE

[@HDSportsterguy]

great info! :-)

[@miniskullzz23]

Do you have any videos on how to adjust the clutch?

[@XenaTheQuadCamBikah]

Check hammer performance KZbin page they have a great tutorial for it.

[@MrSlowestD16]

What did the sportsters use after '03? Thought they still use the evo engines currently?

[@hoohoohoblin]

They made some changes in 2004, but they do still call it an Evolution engine. Not sure if the chain adjustment procedure is the same or not.

[@MrSlowestD16]

***** Yeah, I have a '13, looked at the factory service manual, looks exactly as you described.

[@twistedtaipan3862]

2004 was the first year the bikes were rubber mounted instead of solid mounted. 2007 was the first year of fuel injection. I have a 2002 883 and my owners manual also discusses the same procedure. Dumb question but how did you bump the starter without starting the bike? Did you have to remove the plugs or anything? Could I roll the bike in neutral instead?

[@Blake4Truth]

@hoohoohoblin Those chain tensioners are trouble. Many have suffered problems because of them. They don't maintain enough pressure on the chain, then when they break, parts flying around, getting into clutch, not good. Come say hello at my Buell Forum, BadWeatherBikers.

[@darrdarr3321]

Ummm... if you put the allen wrench in the bolt and hold it in place while you're loosening and tightening the locknut, the adjustment won't change.

[@ziiofswe]

There's always a little play in the thread itself. When you tighten the nut, the bolt will get pushed downwards in the thread. Not by much, but... a little. Matters less in this case, but it's a real pain in the ass when you're adjusting the valve play on an older engine without hydraulic lifters... like the old Volvo B18/B20's. Measure > adjust > measure > tighten > measure again > loosen > readjust > tighten > measure again > gaaaah! > loosen > readjust > tighten > measure AGAIN > finally! Only seven to go.

[@ManuelGarcia-yi8qc]

Thank you

[@hoohoohoblin]

You’re welcome

[@AionBully]

Suggestion! YOu can just cut your allen wrench a bit and it will fit perfectly!

[@teche883]

Hey, firtsly, sorry about my english. You need to lift the bike and put 5º gear, move the wheel until you have the tightstest point in the primary chain. In this point you adjust the chain, not in wherever point. And always with the bike lifted. In other case you´re adjusting wrongly...

[@belair55zz56]

@TonyShelton54 Youve got a Sport Model, the fastest air cooled sportster.

[@crucialmatt]

They do make a center stand for sportster I have one it’s made by venom

[@hoohoohoblin]

That’s good to know. Thanks.

[@750tblack]

nice fxr

[@Simonomon2]

I think my primary chain is loose because there is a persistent rattling noise coming from the left side of my engine. My friend who is experienced with motorcycles examined it with a little stethiscope and said my cylinders are fine and the engine is solid.. but he doesn't know waht it is. I think my primary chain is loose. The engine performs just the same as it did before the rattling.

[@newjargon1697]

Take the allen wrench to the bench grinder and shorten er up.

[@808pathfinder]

if you don't have a 1 you can use a allen key just grind a 1/2 of n inch off n ur done

[@SlingBlade79]

Evo was built from 1984 1/2 to 2003.

[@rustykeller8264]

SlingBlade79 Yep, 1984 first year of the Evo engine, and the last year of the Shovel.

[@RayfordRaySiegel]

Can you tell me why it's called an "Evo" (Evolution) Sportster?

[@hoohoohoblin]

That’s a marketing term Harley Davidson came up with. Their engines evolve slowly, rather than them making radical brand new designs every year.

[@Nibrud6969]

Your statement that the years on the bike are wrong, the case on the video is nothing like the case on a 87 to 91 evo 1200 case. most everything else is accurate except for the overflow screw on the 87 to 91 case , you can not see the level on that case you must rely on the let run out the screw hole method.. enjoy the videos keep up the great job.. SportyRiderinOhio.. butch aka Poppa Smurf

[@sn0fx]

muffler is a center lift point.

[@shannonstiles8751]

🇺🇸

[@user-vo5ee1bc6i]

Ok

[@bikelover5157]

i cant unscrew the inspection cover, its so freaking hard

[@hoohoohoblin]

+bike lover Yes. Sometimes they are really hard to get out if they were overtightened. I had to drill one out on one of my old bikes.

[@bikelover5157]

+hoohoohoblin okay so i finally took both nuts off the primary chain. can i pour both transmission and primary oil in that hole? bc one of the screw wont come off

[@brianlamberts756]

I had to cut a slot in one of mine to get it out with a big screwdriver. Buggered up the inspection cover with the cutoff tool, fortunately I had an extra one. Nice video--simplifies the process. Thanks!

[@chopperking007]

Got a 2016 roadster with the same evo...that's a 30 year run lol

[@hoohoohoblin]

Yeah. I don’t know what the product development people at Harley Davidson do other than change the color of the paint.

[@chopperking007]

@@hoohoohoblin but I luv the motor as there's no tappet adjustment making it cheap too service or do it yourself....$2000 to service my ducati and $200 for the evo

[@ACoustaDC]

Please don't remove the derby cover on the side stand or you will end up cleaning oil off your floor for 2 hours..... please don't ask me how I know, but exp[erience is the best teacher LOL

[@philtownsend6058]

Don't look nothing like my bike where can I find a video on how to replace the tensioner on a 86 flh this is so aggravating Harley says it is to old won't work on it don't work on there own product wtf

[@ruger45hollowpoint]

those rubber washers, in my hood are known as "o-rings"......duh......

[@Blake4Truth]

Looser is better on the primary chain adjustment, especially for a Buell. When the engine and transmission get hot, the chain actually tightens since the aluminum engine/transmission cases expand with temperature at twice the rate of the steel chain. The Buells being higher performance and typically being ridden more aggressively, often run hotter than their H-D cousins, thus causing the chain to become tighter at temperature. Use a wax pencil to mark each spot you check.

[@DRSmith-wq4td]

Thats too much play.....

[@69GTOby1]

Cover the muffler with oil to keep it from getting oily? Lol or just drain it and spray it off with Brakleen. Or just drain it and it'll burn off in a couple minutes. No big deal.

[@hoohoohoblin]

Yeah. Either way it's ok.

[@QuincyRobinson_prime]

rub it in like lotion!