How To Install S&S Cycles 1200cc Hooligan kit 883cc Harley-Davidson Sportsters Part 1 - Disassembly

This Video is brought to you by Lowbrow Customs www.lowbrowcus...
Part 1 - Disassembly - In this How to video, Todd walks you through the disassembly of a 2003 Harley-Davidson Sportster 883cc engine in preparation for installing a S&S Cycles Hooligan 1200cc conversion kit with oversized cams. These kits work on 2000-2018 Harley-Davidson Sportsters and can be installed on your motor with in a day spent in the garage. So, break out the tool box and follow along. See how "There's no big mystery going on in there!" This step by step and does not skip anything, and will help you understand how easy it is to break down your motor and add some real horsepower to it.
Part 2: • How To Install S&S Cyc...
Part 3: • How To Install S&S Cyc...
You can purchase the S&S Cycles Hooligan Here:
Sliver: www.lowbrowcus...
Black: www.lowbrowcus...
00:01 - Intro
01:12 - What you may need to get started.
02:44 - Make sure your Gas tank, exhaust, carb, and coil is removed from the bike so you have clear access to the engine. Drain your oil Tank.
04:01 - Start by removing the 8 bolts on the top of the rocker boxes.
06:41 - Break the rocker boxes free with a dead blow and remove them from the engine. Do not use a screw driver to pry. This can be a pain but they will separate.
07:49 - Keeping a clear work bench separate front and rear parts keeping them separate and in order will help keep the job going smoothly.
08:16 - Remove the spark plugs so that you can rotate the engine. This will allow for you to get the pushrods down to their lowest point and relieve pressure.
08:40 - Jack up the rear wheel and put it in gear to rotate the engine. Watch the rockers on the rear rocker box and stop when they are at their lowest point.
09:20 - Remove the 9 bolts from the rear rocker box.
09:45 - Gone Fishing!
14:47 - Pull the pushrods out before removing the rest of the rear rocker box, it will make it easier to remove.
15:36 - Review of what bolts you need to remove from the inside rocker box.
15:53 - Start on the front one, repeat the process you just did on the rear.
16:55 - Doh! Don't pull a todd and forget to rotate the engine.
19:50 - Remove the rocker box.
20:09 - Remove the pushrods, Note: pink colored band is exhaust, Brown colored band is intake.
20:26 - Its now time to remove the cylinder heads!
22:29 - Don't Forget to remove your intake manifold before removing the cylinders. We have a special wrench available on the website to help with this job.
24:25: See why your intake manifold only needs to remove 2 bolts.
24:48 - Remove all 8 cylinder head bolts.
26:35 - Remove rear cylinder head.
27:00 - If you have a head stay still on your front cylinder be sure to remove it.
27:53 - Remove the front cylinder head.
28:07 - Now we are down to the cylinders, remove both cylinders.
29:27 - Stuff each cylinder hole with blue shop rags so no bolts, circlips, or anything else falls down in your crank case!
29:43 - Remove the circlips from the piston pins.
30:10 - Remove the pins from the pistons. Push the pin from the opposite side of the removed circlip.
30:32 - Remove the push rod tube holders. Even if you are not replacing the liters and cams you need to do this step to replace the lower push rod tube seals.
32:28 - Time to remove the lifters, you must first remove he 4 locking pin bolts.
33:07 - How the lifter locking pin looks and works.
34:43 - Using a magnet, stick it down the lifter holes and pull up the lifters. If you are reusing the same lifters, be sure to pay attention and mark which holes each one comes out of.
35:23 - Remove the front drive pulley cover.
36:24 - Remove the ignition module. Scribe or mark your timing for was of use getting it back timed.
77:11 - Find your ignition pick up plug and unplug it from the wiring harness under the frame.
38:02 - Remove the timing cup.
39:02 - Now it's time to remove the cam cover! Woooo!
39:14 - Tips and tricks on how to keep track of the different sized bolts that belong to the cam cover.
40:55 - Demo of the best trick to keep track of your bolts and where they go on the cam cover.
41:35 - Cam cover off... yeah right that Mother F*cker is on there! DOHHHHH! Do not pry with screwdriver!
42:02 - Make sure to have some kind of oil pan under your cam area because if you haven't drained your oil it will all come out of your oil pump.
42:12 - Once cam cover is free pull off and unhook the breather oil line located on the left of the cover.
43:35 - Would ya look at that cam chest!
43:50 - Remove the old Cams.
44:28 - To be continued...
Music:
Licensed acquired by: Artlist.io
"Coming Home"
"Now is the Moment"
Composed by: Geva Alon
"Great Pretender"
Composed by: Tony Petersen

[@evanjennings5827]

The Bob Ross of motorcycle mechanics. Just going to loosen these happy little bolts.

[@dawidos117]

Evan Jennings and also Pacific Mike 👍🏻

[@thecentralscrutinizer5105]

...and dangitt, I thought it was Jeff "Skunk" Baxter of the infamous _"Doobie Brothers"_

[@Carreidas]

I can't believe I watched all of this. I don't own a Harley. 😂😂 Thank you for sharing your knowledge and experience with gen pop. Much appreciated.

[@glenncampbell9126]

I appreciate seeing a longer video, I learned alot. I don't know much about Sportsters. Thanks again.

[@RCXBuildsIt]

The quality of the editing and the content of this video series are just about all I needed for me to be convinced you guys are getting my business. Well done. This will be my "go to" step by step guide when I upgrade my bike. Subbed!

[@terrydavis7389]

i am a firm believer that 12pt sockets should only be used on 12pt fasteners, thanks for all the informational videos. these are very helpful for a new harley owner such as myself. Hope to see more vids soon.

[@ruben151988]

Hey man, sure it is more t’ha fun learning from you, I don’t even own a Harley (yet) and still watch all your videos beginning to end

[@renerodriguez6300]

Yes he's very detailed !

[@Max1dollar]

Im in the same boat as you haha hopefully a Harley is on my horizon sometime soon though!

[@gardnerwebb3749]

Get one!

[@mickey-eq5vw]

its not always so smooth you always run into unforseen problems when working on a harley one time it took me 5 hrs to change my bars 😂 shit happens with used bikes

[@Agraael]

I wish I had your calm when working on my Harley, man, you're awesome!

[@DTR4IN]

This dude is so awesome he teaches you but he is also hilarious without even trying I love it.

[@bryanbsa8927]

I find it therapeutic watching and listening to you. Just the right shade of Cool.... : ) Glad to see you back. I Have a 1964 650 BSA that I bought in 1973 from a dealer in Richmond, Illinois. I watched your whole Triumph series and the Electronic Ignition install. They were most help full as I just finished my rebuild. Thank you. ✌👍

[@Dingdongding-h2q]

Feel the same, especially when someone nonchalantly plops down disassembled bike parts right on the work bench

[@wrench7665]

This video (along with the Hammer videos if they ever figure out how to use a mic in the same room and not 3 blocks away from the person) is one of the best videos I've ever seen on YT. I do however feel like he will be showing up when I am doing this "easy" job and judging every damn mistake I make Gordon Ramsay style... (And he won't be wrong).

[@taterbites]

Built my first chopper when I was 14. It was a old 74 panhead. And I'm 70 years young now.

[@busy1702]

Alt Hough I know Nothing in motocycle mechanics, You are of Great help to me via your tutorial, and I Evolved in mechanics thanks to you thank you very much

[@BloodPlusPwn]

I am so glad you are doing this. A similar kit is definitely in my future, and such a great video means even a no-nothing like myself can just do this myself in my garage. Thanks!

[@willisluckey4328]

Thank you, Mr, Todd for a very excellent video 💯💯💯 and for showing us how to work on our own bikes ⚡⚡⚡have a great Harley Davidson day 🏁🏁🏁🏁🇺🇲🇺🇲🇺🇲

[@frankmc5112]

This is awesome! I looked at this kit a couple months ago and was like I don't know if I want to take the time to learn to to do this. This makes things so much easier.

[@jerryking1434]

Did you pull the trigger... Did you do this yourself ..???

[@jamesa6272]

You guys gave me the motivation to get my dads 78 triumph back on the road and it runs great. I may do this job to my 05 sportster 883. Great videos. Thank you!!

[@ka-bar5060]

Yet, another great video with Todd. Woo!!!

[@damnielm0]

I love how when the case was a little stuck the cuss words start flying. I knew something was missing from this video. Now I feel at home.

[@aphysique]

LMAO 😂 Exactly, wouldn't be human, right!

[@xcolemanx4]

Logged into my account after this video to just let you know your a badass and I appreciate the simplicity of this damn video you gave me all the confidence I needed. Thank yo hair

[@c00345]

Starting my build teardown today. Your video will be on replay on the shops tv

[@jefferybye2169]

Greetings Todd its Jeff from Pennsville NJ

[@bileeire195]

Just bought an 03' 883 smooth little bike . These videos are great ! Gonna give this a go !

[@branney1]

This was a great series and guide. I have an efi model so minimal differences, very helpful and used it kind of like a walkthrough with laptop next to bike as I disassembled and reassembled. Cam guide was helpful too!

[@lowbrowcustoms]

love to hear that it went well! hell yeah! thanks for the support!

[@Joeygonzales09]

Thanks,with recent events and Los Angeles on lock down,Have had time to watch everyone from Hammer Dan,Tattro, Zipper kits, NHRS,Short Block Charlie,The guy from S&S has some great videos on cams,the S&S 3 part cam video explained every thing from lift overlap duration,that's a great video series to watch and really breaks down cams,anyway great watch an see all you guys and how you guys are all great teachers an have a different style and are entertaining,thanks again.

[@milmex317th]

If I make it to next year. F 49hp. Thanks to this video Black Betty is getting bigger jugs.

[@TimothyRobnett]

Great video - I may have to do this to my 2001 Sporty. I was highly amused with your disdain at 42:30 for HD's use of Oetiker / ear-style clamps. Keep up the good work; excellent video and you did de-mystify a bunch of the inner workings to remove the worry factor. Cheers.

[@BearArms1972]

Diggin' the video. Breaking it down "Barney Style" for a beginner like me. looking forward to trying this on an 883. good project for me and my 14 year old son.

[@balmori.hangarage]

Hey Todd! of course I saw the last videos!! and besides all this jobs 02:55 don´t forget to say that you lubricate the floor, the lifter and your shirt as well jajaja

[@dirtyd1768]

I really appreciate your videos. It just so happens I am looking at putting this same 1200 kit on the same year of 883 for my wife. I will be ordering my parts from you guys. Thank you for the videos and keep up the good work.

[@shovelhead4558]

I used new bolts on my conversion as they looked stretched great work thanks.

[@erictaylor7996]

As you were taking the rockers off it made me think how I tore into my first bike (1200 sportster) over 20 years ago and I was thinking about how funny it smelled. Then you said something about the smell,😂

[@RyanMcPizza]

LOL man. One of my local harley dealers told me this was a 12 hour job @ $1700 (not including the price of the kit). I'll be doing this myself with a friend now. Thanks!

[@ElijahGoulding]

Just Bought The S&S 1200 kit for my 99 sporty off your website it arrives tomorrow ! wish my bike was compatible with the hooligan kit so I could upgrade my cams as well but hey one step at a time!

[@IntoTheWildernessBushcraft]

Awesome video! Me & my son are about to tear into a 1200 & this was amazing! Thank you! 👊🏼

[@stevetomkins2919]

Amazing video. You sir explain things so well, and in a calm relaxing manner. Thinking about getting a kit now. Thank you so much 👍👍

[@steveUSMCNOTOLERANCE]

When I did my 03, I got 93 hp out of it on dino. And put a Baker 6 speed trans. in to. The bike was a rocket

[@theaidenman]

Was that 6 speed a bitch to get done?

[@gnarlytothemax]

how does the S&S 1200 kit differ from a factory 1200?

[@steveUSMCNOTOLERANCE]

@@gnarlytothemax I don't know.

[@TailEndCustoms]

Ya’ll are stand up for makin this video for people. 🤙🏽🤙🏽🤙🏽

[@raydreamer7566]

Great video. I have a 1200 Sportster , got it that way. So I am here in the Philippines waiting in a lock down type environment and learning . All my experiences are with the 1000 cc Sportster. So I am learning . Big thanks.

[@HyprCHARged]

I had a few questions about specific things and I called lowbrow customs and Todd him self answer my questions

[@blackdraggn]

So glad I found this, I am getting ready to do a conversion on my 2003 883. These videos are going to come in clutch for me, thanks!

[@dieselrotor]

Great vid. I've done two of these. The first one went perfect, the second one I didn't realize I put the front cyl pushrod(s) in the wrong tube(s) (I got lucky on the first one and accidentally got it right not knowing one was longer). Getting ready to do My own 2005 883 so I thought I better watch. Thank You.

[@ericweber1969]

Fantastic video, I'll be bookmarking this one for future use! You guys are the best.

[@leechamberlain1273]

Well done Todd, really like these videos you make , so interesting.

[@harpo1965]

Man this was and awesome video, love the detail and your patience ,ill be doing this soon! well me and you will be doing this soon.

[@GBW175]

I’m really digging your videos. It’s been a minute or two since I’ve done most of this. It’s reminding me of some of the little things that makes your life easier. Example: I always kept 8 pieces of fuel line (approx 3-4” each) to put over the cylinder studs to prevent boogering up the threads by accident. I noticed you used some on the front two. One day, I’m going to visit LowBrows. Love my QuadCam & love y’all’s appreciation for XLs & such. The style of your bikes is right up my alley, unlike “bikers” like Arlen Ness & such 🤮

[@RufioMini]

Todd’s still the man, haha

[@THEBIGCHULETA]

This was an awesome explanation on how to do the disassembly. You helped me decide what my first full blown build will be. But the suspense is killing me. Where’s part 2?

[@lowbrowcustoms]

THEBIGCHULETA it’s live we are going to release part 3 and 4 the next following Monday’s

[@57Technoman]

I have an 03 883 Custom Screaming Eagle. This is going to be my next project.

[@TonysGarage]

Fantastic video! Well done

[@gunner9010]

Awesome series!!

[@trevellyanblack4101]

Very informative. Now I know what my Hugger looks like when stripped.

[@Chris-yy7qc]

Always good to know how she looks stripped!

[@bobkinney2430]

You make it look so easy. Lots of parts :)

[@thakery5720]

Always remember that when you remove the cam cover the oil in the oil tank will slowly run through the pump and drain out of the oil galley that allows it to get into the timing cover - resulting in a huge mess under the bike. Either drain the tank first or pinch off the feed tube from the tank to the pump with some vice grip pliers........

[@lowbrowcustoms]

Thank you... sound advice! We totally thought there was only a little left in there! Ahahha whoops

[@thakery5720]

@@lowbrowcustoms I recently forgot my own advice and had a big puddle under the bike after I stopped for lunch when changing cams.... Oh well, that piece of concrete will never go rusty !!

[@nizzamp]

How long have you been wrenching on bikes and what is a ballpark rate someone would expect to pay to have their 883 upgraded to 1200?

[@crspcritter]

😎👍🏻 doing 4” cyls on my 88” softail. Yes black cyls on silver engine .

[@tiedyedkarma]

Todd is a LEGEND!

[@kentonjoegibsonii2211]

Cool video man thanks for the vid tutorial

[@matevoros8924]

Good video! Bigup from Hungary /europe

[@Unmarked_1]

I dig your style man✌🧔👍

[@dormantsuperhero]

Thinking of doing this to mine, love the video, always good watching and learning, had to hit the subscribe button it's so good;)

[@gorillatactics7777]

I don’t own a motorcycle, great vid

[@evil_musclemuscled3814]

Thank you for your knowledge and time

[@ChadwickRider]

100% on the Clymer Manuals. Haines are good as well, but I've found Clymer to be the best as well.

[@craigpennington1251]

Very interested in how this goes. I hope that you video all of the process. Love the Sportster and the S&S engines are top notch material. If all goes well, it just might happen for me. The sporty always did need some extra go for the 2 lane blacktops that I ride on and some 4 lane divided. It would fit the bill for a short 250 mile trip in a few hours.

[@lowbrowcustoms]

Releasing part 2 next Monday and part 3 the following Monday. we go step by step. A lot of other videos skim through it, we want to make sure everyone is comfortable doing this from beginner to master

[@craigpennington1251]

@@lowbrowcustoms Works for me. Great video on this change over.

[@ericweber1969]

lowbrowcustoms ...and this is one of the many reasons why Lowbrow is AWESOME!!!

[@larrylucas5731]

Ever thought about using cordless tools? They work great for me...

[@cdsouthern]

I got carpal tunnel just from watching all that ratchet work. Electric impact is the way to go.

[@chrispetersen8637]

I didn't think anyone else used "whoa nelly"🤣😁

[@TheSevenboy127]

Hey brother in cali most aftermarket pipes dont meet cali specs can i still do all this work like big bore kit,air cleaner, and cams and tune but run my stock pipes will this work still

[@lowbrowcustoms]

Yes.

[@sylp2059]

This guy is awesome.

[@JoeCool455SD]

Very good video I like the laid back," see you can do this" approach. But seriously, a Fram oil filter?? 💩

[@lowbrowcustoms]

soon as we bought this bike we started tearing it apart. it will have a new filter and not a fram lol. thanks for the kind words on the vid

[@christopherdean1326]

I bought a '94 Sportster which I think has an S&S kit on it. Is there an easy way to be sure?

[@lowbrowcustoms]

It’ll say S&S on the jugs

[@christopherdean1326]

@@lowbrowcustoms Thanks. I'll look later, In UK where it is currently 10.15 pm and freezing cold!!!

[@matthewburns6843]

@@christopherdean1326 the engine is cast stamped on the aluminum at the bottom of the heads will say 883 or 1200!!

[@chrisaskme811]

I usually run without pushrod tubes as I prefer the open rod look

[@consul6262]

Like other I don't own a Harley, but do enjoy all these how to videos, definitely going to get one someday. One criticism of HD, but definitely not just them, it amazes me as pointed out in the video, how little thought goes into maintenance of their products, would it really have been that hard, to have some extra room to help with removal of that rear cover? I've just finished renewing a cam belt on my Ford, what a pain all for just a little bit more room. I worked in heavy engineering, and the same issues crop up time and time again, and you hear the same cry " what f**king clown designed this" When all that was needed was half an inch!

[@eskimoto4417]

i love your channel man how did you learn your craft was it all practice or did you study mechanics theory and more... ? is it true what they say is it 90% experience 10% book knowledge? I wish I had your hands man DAMN !!!

[@MrLordHamHam]

Hey around the 28 minute mark when you took the jugs off I noticed a large amount of sediment drop into the crank case.

[@raymondperry8816]

Just got my first harley 1972 sportster 1000 xlh sat for years i finnaly got her running i bearly but running so i have ordered new everything carb gene started solenoids chain etc etc im confident im aome of my abilities but i need to do rocker box gaskets an thet dont have james gaskets is there angthing i may need to know befor i attempt thia alone?

[@matthewburns6843]

Rtv red will do it for gaskets!!

[@charlesharper7292]

Pretty good, would you do something cool for us pre rubber mount XL1200s?

[@lowbrowcustoms]

we have 1200 kits for 86-19 sportsters. process is very similar. you just dont have the hopped up cams. gotta get those separately. www.lowbrowcustoms.com/collections/motorcycle-engine/products/s-and-s-cycle-harley-sportster-883-to-1200cc-1986-2019-silver-s-s-cycle-big-bore-kit-910-0688

[@guillaumedemeulle382]

Thanks for the video. I have a 90' sportster and want to put on the s&s conversion kit. But I am told that the lower engine can break. I need advice. do I or not?

[@lowbrowcustoms]

Break, how? As long as you do everything correctly, torque stuff properly, you have nothing to worry about. If you are unsure that you can properly install it on your own, reach out to a local shop and have them do it. Companies make these kits because they work, not because they break motors. They just need to be installed properly. Hope that helps.

[@ruthlesschoy]

If your just doing the jugs and pistons do you need to drain the oil?

[@lowbrowcustoms]

You could possibly not drain it but, you might have a mess on your hands, better to run fresh oil in her anyway with the new pistons.

[@ruthlesschoy]

@@lowbrowcustoms okay thanks. Just changed my oil and then decided to order big bore, was trying to be lazy but I'll drain it

[@NigelsModellingBench]

I don't have those lifter locking pins on my 2018 883 iron??

[@micc4044]

I wanna do the 1250 hooligan kit on my sporty 1200 in assume this is the same procedure

[@lowbrowcustoms]

only thing different is the jugs and piston size. all the procedures are the same. and if you aren't doing cams skip that vid.

[@micc4044]

@@lowbrowcustoms I want to get the ss kit with the cams and tappetts. A buddy told me get the kit without and go with Andrew's cams. What's your opinion. What Andrew cam would be best and would I need tappetts still? Thanks for your response

[@lowbrowcustoms]

@@micc4044 if you are chaining the cams get the Andrews lifters too. Change it all out new and fresh. Do you research and see if there is a certain set that works best with whatever cams you are buying.

[@micc4044]

@@lowbrowcustoms alright thanks. I need to figure out what Andrew's cams and tappetts go best with the 1250 kit on stock heads. I will call them hope they can help. Thx again.

[@geraldwest3428]

Killer video series! Where can I get rims like those? Thank you!

[@missingremote4388]

Amazing and cool

[@PkwyDrive13]

I have a 2017 iron 883.. What is the advantages to the hooligan kit with cams over just the big bore cylinder/pistons?

[@christophercummins4946]

I love watching your videos you really know what you're doing but I'd like to see how you do that on a 1990 engine because I have a 1990 Sportster

[@harpo1965]

i do have a needy question, would you by chance have a list A-Z on every tool needed for this?

[@lowbrowcustoms]

Sorry no we don’t.

[@reveng6705]

my 2005 sportster does not have that timing thing.. I removed that little cover and there's nothing. how is the ignition timing done on 2005 sporties?

[@lowbrowcustoms]

04-06 sportsters the ignition module is under the seat. they moved it out of the timing cover area. here is 32622-04 OEM number for ignition module you can google that number and can see its larger square box.

[@1381greg]

Great vid....

[@filmfreaken]

Thanks for this video, my 12 point head bolts could use a replacement, or a deep polish, same with the pushrod tube holders, would it be safe for me to remove one of them, and install it back in and torque it, without taking anyhting else apart, 1 by 1 exchange to new bolts, im fairly new to HD :)

[@Ask-me2]

Can you up the hp on a 1200 using the same kit? I want MORE POWER!

[@aphysique]

You should call YOURSELF, BADABING BADABOOM MECHANIC!! 🤘👌😆

[@greenempirelawncare3446]

I have a 2019, would this still work? If not what’s different?

[@michaelkelly146]

oops, forgot to say, loved the vid, watched all 3 parts just cuz. not planning a job like this, but enjoyed the whole thing. one question, couldn't you put the pistons in the barrels on the bench first? easier with only 2 hands? just a thort.

[@eskimoto4417]

The Roy Garber of mechanics ( Shipping wars )

[@freedommonger4512]

i have been using dewalt 1/4" drive impact 20v for tear down.

[@2022streetbobwheelies]

very intelligent. excellent video.

[@undone8103]

Thanks for sharing

[@thecentralscrutinizer5105]

_"That young man needs a well overdue haircut"_ -Todd's Mom

[@damiancobb8177]

Does anyone know if the wrist pins are the same as stock

[@theone9564]

Bro...Were u been?

[@aphysique]

BADA - BING / BADA - BOOM, LIKA A SEW.....🤘👌