• 5:25

    Sportster Cafe Racer Wrap-up

    That’s a wrap! Our 2000 Sportster has been transformed into our modern, alternative version of a Cafe Racer. A lot of time was put into this project. Beginning with the time spent planning, scheduling, and budgeting. We started with a concept and an idea of what year and model Sportsters we could use for the…

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  • 44:30

    Cafe Racer Gas Tank Install and Start

    Before we put on the Cafe Racer gas tank we take a look at our build. Our Sportster now Harley Cafe Racer has come a long way since Tommy first rolled it into the shop. Not only has it gone through a drastic physical transformation, but it has also gained some serious performance upgrades. You’ve…

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  • 11:18

    Harley Cafe Racer Build Introduction

    Welcome to our Harley Cafe Racer Build. The MoCo, mothership Harley-Davidson, is working to get more people on 2 wheels and obviously a Harley. They have a 10-year plan to bring in 2 million riders. The Motorcycle Industry Council (MIC) has also joined in the rally to bring more riders on board, no matter which…

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  • 15:00

    Cafe Racer Parts and Plan

    The fun part: Cafe Racer parts and, of course, a plan. Whether you are planning a mild customization, a radical customization, or a full restoration of your Harley Davidson; it is of utmost importance that you start off by creating a plan. For most of us, the first step is to determine your budget. If…

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  • 29:03

    Harley Shop Essentials

    Tommy is gearing up for a big tear down and customization of our 2000 XL to a Harley Cafe Racer. In preparation, Tommy reviews Harley shop essentials, tools and materials that will be needed along the way. Safety is of utmost importance in your Harley shop. Eye and face protection, respirators, gloves, and appropriate clothing…

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  • 49:38

    Sportster Handlebars, Seat, Battery, Tank Removal

    Tommy is eager to take off the Sportster handlebars, seat, tank and more. Before picking up any tools, it is important to begin with a service manual and a plan. Don’t just start off by tearing down areas at random. Develop a plan of action. Make lists of parts that will be needed, parts that…

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  • 14:53

    Harley Carb and Exhaust Removal

    We are still working in the early, disassembly stages of our Sportster Harley Cafe Racer project. Next in line, Tommy removes the Screamin’ Eagle air cleaner assembly and the stock Harley carb or CV carburetor in anticipation of a new S&S carburetor assembly. The stock intake manifold will also be removed. Harley carb removal is…

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  • 24:19

    Sportster Forward Controls and Covers Removal

    Before we remove the Sportster forward controls, it is always important to block or seal off any openings in the engine, transmission, or primary drive compartments. Even if for only a short period of time. Debris, dust, or moisture can be damaging or even catastrophic depending on the circumstances. Tommy reminds us of this and,…

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  • 34:07

    Sportster Front End Removal

    Tommy is ready to fully disassemble the Sportster front end. He begins today with the final removal of the front brake line and clutch cable. Once the last retaining clamps are removed, both of these cables are free from the motorcycle and set aside. Next up on the Sportster front end, the handlebar top clamp…

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