Harley Davidson Sportster Primary Oil Change

How To Change Primary Oil in a Harley Davidson Sportster 1200!! Subscribe and Share! It truly helps the channel so much! ** https://goo.gl/Pjnknj **

I followed my Harley Davidson Sportster Service Manual to do my Sportster Primary Oil Change. I suggest you do the same, buuuuut. If you still want to do this, I recommend iFixit.com. Very good pics and instructions. If you prefer to follow me and read instructions, I'll copy/paste here.

**Credit to Brett Hartt on iFixit**
iFixit Article - https://goo.gl/yYVp8f

Step 1 — Workplace Preparation
For the best access to the transmission drain plug, optimal draining, and accurate re-filling, we recommend working with the bike secured in an upright position.

Step 2 — Removing the Primary Chain Inspection Cover
Using a 5/32 Hex or Allen screwdriver, unscrew the two screws from the primary chain inspection cover.

Remove the primary chain inspection cover from the transmission housing.

Step 3 — Draining the Transmission Oil
The transmission drain plug is located on the underside of the transmission on the left side of the bike, near the kickstand bumper.
Place a drain pan underneath the drain plug.

Using a wrench, unscrew the transmission drain plug and remove it.
Your drain plug may be 5/8" or 3/4" depending on the year.

Allow all the oil to drain out of the transmission. It should take about five minutes.

Step 4 -- While the oil is draining from the transmission, clean the transmission drain plug.

Using a spare rag or paper towel, clean the drain plug, removing excess oil and metal shavings.

There is a magnet on the end of the drain plug to capture any ferrous metal residue.

Step 5 — Removing the the Clutch Inspection Cover

Using a T27 screwdriver bit, remove the four screws holding the clutch inspection cover in place.

Step 6 -- Insert a heavy duty spudger or similar prying tool into the gap between the clutch inspection cover and the transmission housing near where clutch cable enters the housing.

Gently pry the clutch inspection cover away from the transmission housing.

The clutch cover spring may fall out. Be sure to keep track of this and re-install it before replacing the clutch inspection cover.

Step 7 — Installing the Transmission Drain Plug
Re-insert the transmission drain plug into the transmission housing and hand tighten.

Using a 3/4" wrench, tighten down the transmission drain plug.

It is important to not over-tighten the drain plug. Tightening the plug too much can strip the threads on the aluminum housing. The plug should be tight, but not too tight. The correct torque specification is 14 - 21 ft-lbs (168 - 252 in-lbs).

Step 8 — Adding New Oil
Insert the nozzle of a funnel into the primary chain inspection hole.

Pouring slowly, pour approximately 1 qt of oil into the transmission.

As you pour, watch the clutch inspection hole. Make sure that the oil level stays below the edge of the clutch inspection hole.
This may require less than the entire quart of oil.

Step 9 — Re-assembly
Before re-installing the primary chain inspection cover, make sure the rubber O-ring on the inside of the primary chain inspection hole is clean and properly seated.

Also make sure that the rubber o-rings are clean and in proper condition before replacing the screws in the primary chain inspection cover.

Using a 5/32" Hex or Allen screw head, re-install the primary chain inspection cover.

Step 10 - Using a T27 Screwdriver head, reinstall the clutch inspection cover. Install the screws in the following order:

Top
Bottom
Left
Right

Once all of the screws have been lightly hand-tightened, use a torque wrench to tighten them to their proper specification of 7 - 12 ft-lbs (84 - 108 in-lbs). Tighten the screws in the same order as before.

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