20 Most Recent 2003 Harley Davidson XL 1200 S Sportster Sport Questions & Answers

Must have hit more than the foot peg. Is this mid or forward controls bike??

You will need to loosen the cable adjustment off all the way. Then you will need to remove the snap ring and pull the pin out and then pull the handle off and remove the nylon pin to release the cable from the handle and do not drop any of these parts and then put the new lever on, reinstall the parts in the reverse order and adjust the cable so there is 1/16 to 1/8 inch freeplay at the cable and perch area.

How do you know the clutch is blue unless you have had it apart. If it is blue it is overheated and you need to change the parts out for new ones. It is likely slipping if blued. Make sure it gets done right and adjusted properly when you rebuild it. Can be just as cheap to just buy the whole clutch as an assembly.

Depends what it needs, what problems it has. If no problems oil change for engine and trans primary, oil filter, air filter and spark plugs are likely all you would need. Depending on mileage you could/should find out what inspection is due, if any and do what is on the inspection sheets. If you have laced wheels check the spoke tension and drive belt and primary chain tension/deflection/ check the brake pads, rotors for wear etc and if the brake fluid has not been changed for some time you may want to flush the systems even though it is DOT 5 fluid which is not hygroscopic. Check air pressures, lights, horn etc etc

You were supposed to put 4 ounces into the filter before installation to prime the system.

best bet is to go to the dealer and get correct screws that way you are certian of getting the right length and thread size then use thread seal to stop vibrating loose again . cheers

You may have a broken shifter pawl. It is located behind the clutch assembly in the primary. You'll have to remove the outer primary cover and the primary drive that includes the engine sprocket, primary chain, and clutch assembly. The shifter pawl is located behind the clutch. I would suggest that if you're going to fix the bike yourself that you purchase a service manual. In this particular case, there are a few settings that have to be made. It is difficult to explain how to make these adjustments using this form of communication. A picture is worth a thousand words in this case. Besides, if you repair the bike yourself, the money you save will more than pay for the book. Try this site for a manual. http://www.diyrepairmanuals.com/products.asp?cat=14286

Good Luck
Steve

There is a torque sequence and pattern to bolting the Evolution Sportster heads on. Contact me directly and send you the information you need which requires a drawing to show you the sequence. You know the saying "A picture is worth a thousand words". Well, that is certainly true in this case. Contact me at [email protected] and I'll send you a JPG and the torque specs.

Steve

Have you checked you fuel petcock in the tank. These things are vacuum operated and are notorious for giving problems.

if your hearing a noise like a herd of locus in your front wheel*slight brake drag sound) then that is normal, sadly yes I said that is normal.

Ok, I'm going to assume that you're trying to remove the primary cover on the left side of the bike. You've got the bolts out but the cover will not come off, right? You must remove the bolts that hold the plate on the side of the over where the clutch release mechanism is located. Remove the spring and the "lock nut". Then turn the slotted screw clockwise to get the cover off. Good Luck, Steve