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Have a 2003 1200 Custom

How hard is to replace stock exhaust , aircleaner, rejet carb yourself ?


From those who have had it done

What is cost by HD (parts + labor) vs doing it yourself

Will it void warranty?

And finally any set up recommendations?

Thanks in advance for your help

Forum is great!!!!
 

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Not hard at all. Even the most two left thums mechs can do it.
The Sporty do well with the Dynojet kit, but there way over priced and you get near the same from simple re-jet. I say use the S/E air cleaner and pipes of your liking. Not even the sorriest of Harley dealers should void your warrenty if you do your stage 1 right.
 

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check out www.sportster.org it has a step by step. did mine in two parts
1. drill out baffles (7/8" hole saw w/ 12" extension)
bore 6 holes in air box backing plate ( same hole saw)
re- jet carb up i size on both jets

cost about $6.00/ took aout 15 minutes



2. added samson pipes
cost about $350/ took about 1 hour


good luck with whatever you do
 

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I just did the Stage 1 on my new XL 1200C. I went with the SE air cleaner, SE II slip ons, and Thunderslide kit. I had a hell of a time tuning the carb to get rid of the popping. Finally ended up with a 45 slow jet, stock 170 main, and moved the e-clip to slot 5 on the needle.
 
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