Softail 6 Speed Transmission Instruction Sheet - Harley
Contents
1. Part No 35058 03 35059 03 35080 03 35083 03 35104 03 35131 03 35134 03 35135 03 35136 03 35137 03 35138 03 35158 03 35140 03 34088 87A 35143 03 35144 03 35145 03 8876A i06797 Description Qty Door Retaining Ring 2 Trapdoor Bearing 2 Mainshaft Countershaft Locknut 2 Top Lid Vent Hose Clutch Release Cover Lower Screw 4 Mainshaft Countershaft Retaining Ring 8 MainshaftThrust Washer 2 Sprocket Spacer Mainshaft Race Main Case Seal Quad Seal Top Lid Vent Fitting Mainshaft 5th Gear Shifter Seal Washer Speed Sensor Plate Gasket Neutral Switch Top Lid Chrome Door Roll Pin Part No 35087 99A 8992A 35078 79 42533 91A 4718A 11067 6003 33344 94 34091 85A 12067B 11165 62375 57A 35237 03 6497HW 35152 03 33904 00A 34541 00 634 3 of 6 SMOTORZ e Service Parts Part No 33044 03A Date 10 2005 Softail 6 Speed Transmission Silver and Chrome Item 37 39 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Description Qty Main Case Bearing Trapdoor Gasket Clutch Release Cover Gasket Top Lid Gasket Shifter Seal Shifter Retaining Ring Trapdoor Upper Screw 2 Pillow Block Screw 4 Shifter Centering Screw Chrome Dipstick Dipstick O Ring Countershaft Bearing Top Lid Screw 4 Clutch Release2. Upper Screw 3 Transmission Pulley Mega Nut Mega Nut Screw 2 Shift Drum Assembly J03479 Part No 8996A 35147 03 35148 03 34904 86D 12045 11150 4814A 3909 34978 00A 37075 87 11132 8977 4740A 4717A 40250 94C 35236 03 Not sold 35142 03 Item 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 Description Qty Left Pillow Block Assembly Shift Drum Retainer Shifter Lever Shifter Lever Screw Plug Shifter Fork Shaft Set Screw Lower Trapdoor Screw 4 Speed Sensor Plate Speed Sensor Plate Screw Countershaft 5th Gear Speedo Sensor O Ring Detent Arm Spring Right Pillow Block Detent Arm Screw Detent Sleeve Detent Follower Shifter Shaft Assembly Case Bearing Retaining Ring Trapdoor Plug Transmission Case Black Part No 33301 00A 11342 33849 97 856A 3784 3249 35153 03 4705 Not sold 11289A 33374 00 33304 00 33376 00 33375 00A 33364 00A 35146 03 11161 45830 48 Not sold 6 of 6
3. Cover and Top Lid Upper Screw 3 Transmission Pulley Mega Nut Mega Nut Screw 2 Shift Drum Assembly J03479 Part No 8996A 35147 03 35148 03 34904 86D 12045 11150 4814A 3909 34978 00A 37075 87 11132 8977 4740A 4717A 40250 94C Not sold 4069A 35142 03 Item 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 Description Qty Left Pillow Block Assembly Shift Drum Retainer Shifter Lever Shifter Lever Screw Plug Shifter Fork Shaft Set Screw Lower Trapdoor Screw 4 Speed Sensor Plate Speed Sensor Plate Screw Countershaft 5th Gear Speedo Sensor O Ring Detent Arm Spring Right Pillow Block Detent Arm Screw Detent Sleeve Detent Follower Shifter Shaft Assembly Case Bearing Retaining Ring Trapdoor Plug Transmission Case Silver Part No 33301 00A 11342 33849 97 856A 3784 3249 35153 03 4705 Not sold 11289A 33374 00 33304 00 33376 00 33375 00A 33364 00A 35146 03 11161 45830 48 Not sold 4 of 6 Part No 33045 03A Date 10 2005 MOTOR e Service Parts Softail 6 Speed Transmission Black and Chrome i06783 24 242418 18 Description Qty Part No Description Qty Part No Mainshaft 35058 03 Door Retaining Ring 2 35087 99 Countershaft 35059 03 Trapdoor Bearing 2 8992A Countersha
4. REMOVAL in the Service Manual and follow the instruction given to remove the pivot shaft freeing the transmission 17 Remove the four bolts and washers connecting the trans mission to the engine 18 The transmission is now loose from the frame and engine and resting on a support Tip up and slide the transmis sion toward the rear of the bike to clear the dowel pins and out the right side of the motorcycle Installation of New Transmission 1 Refer to your Service Manual and install the new transmission into the motorcycle 2 Slide the transmission from the right and align the four bolt holes on the transmission with the four holes on the engine i06179 Dowel pins Figure 1 Transmission Housing to Crankcase Torque Sequence 3 Install the four bolts and washers removed in step 17 4 See Figure 1 Tighten the four transmission mounting bolts in a cross pattern sequence as follows a First tighten all four bolts finger tight b Torque all four bolts in turn to 15 ft lbs 20 3 Nm c Then torque all four bolts in turn to 30 35 ft lbs 40 7 47 5 Nm NOTE Proper pivot shaft tightening is important to maintain rear fork alignment 5 Refer to REAR FORK installation and slide the fork assembly into position aligning with mounting boss of transmission case and install the pivot shaft J03479 Apply LOCTITE ANTI S
5. EIZE to pivot shaft From the right side install pivot shaft and two spacers with spacer collars facing transmission case c Apply LOCTITE THREADLOCKER 262 red to the threads of the pivot shaft nut d Tighten pivot shaft nut to 90 110 ft lbs 122 149 1 Nm 6 Install belt over rear wheel sprocket and transmission sprocket Refer to REAR BELT DEFLECTION in the Service Manual and follow the instructions given to cor rectly install the belt to the proper deflection 7 Refer to the PRIMARY CHAINCASE HOUSING in the Service Manual to install the chaincase housing 8 Refer to NEUTRAL SWITCH in the Service Manual and follow the instructions giver to install these connections 9 Refer to VEHICLE SPEED SENSOR in the Service Manual and follow the instruction given to install the speedometer speed sensor and use the new o ring 64 provided in the kit 10 Refer to the STARTER INSTALLATION in the Service Manual and follow instruction to install starter from the right side Oo D 11 Refer to the DRIVE COMPONENTS in the Service Manual and install the clutch assembly primary chain and compensating sprocket as a single assembly NOTE Do not install the Derby Cover until the Side Cover Release Kit is installed 12 Refer to PRIMARY CHAINCASE INSTALLATION in the Service Manual and follow the instructions given to install the primary chaincase cover 13 Refer to PRIMARY CHAINCASE INSTALLATION in the Service Manual and follo
6. MOTOR HARLEY DAVIDSON WY J03479 INSTRUCTIONS REV 10 13 2005 Kit Numbers 33044 03A 33045 03A SOFTAIL 6 SPEED TRANSMISSION COMPLETE General These kits fit 2000 and later carbureted and 2001 and later EFI Softail model motorcycles Requires separate purchase of cable Sidecover Release Kit or Hydraulic Sidecover Release Kit See retail catalog for parts numbers Refer to Instructions included in Sidecover Release Kits to complete installation of Screamin Eagle 6 Speed Transmission or Gearset Kits Kit number 33044 03 is a complete 6 Speed Silver and Chrome transmission Kit number 33045 03 is a complete 6 Speed Black and Chrome transmission STOCK 5 SPEED SE 6 SPEED Transmission Ratio Comparison WARNING The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00308a NOTE A Service Manual for your model motorcycle is available from any Harley Davidson dealer NOTE Prior to starting this installation it is recommended that the output shaft be rotated by hand and that the transmission be Shifted through all six gears to verify proper operation Input shaft may need to be rocked back and forth to get all gears to shift Removal of Original Transmissi
7. ft 1st Gear 35080 03 Mainshaft Countershaft Mainshaft 3rd Gear Locknut 2 35078 79 Countershaft 2nd Gear 2 35083 03 Top Lid Vent Hose 42533 91A Mainshaft 4th Gear 35104 03 Clutch Release Cover Mainshaft 6th Gear 35131 03 Lower Screw 4 4718A Mainshaft 1st Gear 35134 03 Mainshaft Countershaft Countershaft 3rd Gear Retaining Ring 8 11067 Mainshaft 2nd Gear 2 35135 03 MainshaftThrust Washer 2 6003 Countershaft 4th Gear 35136 03 Sprocket Spacer 33344 94 Shift Ring 1 2 3 4 2 35137 03 Mainshaft Race 34091 85A Shift Ring 5 6 35138 03 Main Case Seal 12067B Chrome Trapdoor No Ear 35158 03 Quad Seal 11165 Splined Sleeve 2 35140 03 Top Lid Vent Fitting 62375 57A Shifter Fork Shaft 34088 87A Mainshaft 5th Gear 35237 03 Shifter Fork 1 2 Assembly 35143 03 Shifter Seal Washer 6497HW Shifter Fork 3 4 Assembly 35144 03 Speed Sensor Plate Gasket 35152 03 Shifter Fork 5 6 Assembly 35145 03 Neutral Switch 33904 00A Split Cage Bearing 5 8876A Top Lid Chrome 34541 00 Door Roll Pin 634 J03479 50f6 MOTOR e Service Parts Part No 33045 03A Date 10 2005 Softail 6 Speed Transmission Black and Chrome Description Qty Main Case Bearing Trapdoor Gasket Clutch Release Cover Gasket Top Lid Gasket Shifter Seal Shifter Retaining Ring Trapdoor Upper Screw 2 Pillow Block Screw 4 Shifter Centering Screw Chrome Dipstick Dipstick O Ring Countershaft Bearing Top Lid Screw 4 Clutch Release Cover and Top Lid
8. mounting bolt Lift sensor from the transmission case and set aside for later re installation 8 Refer to NEUTRAL SWITCH and disconnect the connec tors from the neutral switch 9 Refer to PRIMARY CHAINCASE in the Service Manual and follow the instructions given to remove the primary chaincase housing 10 Refer to EXHAUST SYSTEM in the Service Manual and remove the exhaust 11 See the REAR WHEEL REMOVAL and loosen but do not remove rear axle to relieve drive belt tension and remove the belt from the sprocket from the transmission 12 Refer to OIL TANK REMOVAL in the Service Manual and follow the instructions given to drain remove the oil tank and detach the vent feed and return lines 13 Refer to CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover Set the cable aside for later re installation 1of6 NOTE If vehicle is equipped with a shotgun style exhaust system FLSTF I FXSTD I and FLSTN I or FLSTSC I re use or install new Part Number 3300 longer screws for mounting exhaust bracket to transmission side door Torque screws to 13 16 ft lbs 17 6 21 7 Nm 14 Remove and discard top cover and pull the top cover out the right side of the motorcycle for added clearance 15 Position a jack with a wooden block under the engine Support the transmission and rear fork assembly with a series of jacks 16 Refer to REAR FORK
9. on 1 Position motorcycle on a suitable lift AWARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 2 Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first 3 Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps 4 Refer to PRIMARY CHAINCASE COVER REMOVAL in the Service Manual and follow the instructions given to remove the primary chaincase cover Awarnine Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a 5 See the PRIMARY CHAIN and COMPENSATING SPROCKET REMOVAL in the Service Manual and use the instructions given to remove the primary drive assem bly 6 Refer to the STARTER REMOVAL in the Service Manual and remove the the starter 7 See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the
10. w the instructions given to add primary chaincase lubricant to proper level Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 0031 2a 14 Install the side cover For Cable Actuated Clutch Follow the instructions in the SE 6 Speed Cable Clutch Side Cover and Release Pushrod Kit Part Number 38752 04 For Hydraulic Clutch Follow the instructions in the Hydraulic Clutch Side Cover and Release Pushrod Kit Part Number 38753 04 and in the Hydraulic Clutch Kit Part Number 45033 03 Black or 45383 03 Chrome 2 of 6 MOTOR e Service Parts Part No 33044 03A Date 10 2005 Softail 6 Speed Transmission Silver and Chrome NS 8 Bu baa 104 24 25 au 2425 24 WV 4 69 68 67 66 65 14 Description Qty Mainshaft Countershaft Countershaft 1st Gear Mainshaft 3rd Gear Countershaft 2nd Gear 2 Mainshaft 4th Gear Mainshaft 6th Gear Mainshaft 1st Gear Countershaft 3rd Gear Mainshaft 2nd Gear 2 Countershaft 4th Gear Shift Ring 1 2 3 4 2 Shift Ring 5 6 Chrome Trapdoor No Ear Splined Sleeve 2 Shifter Fork Shaft Shifter Fork 1 2 Assembly Shifter Fork 3 4 Assembly Shifter Fork 5 6 Assembly Split Cage Bearing 5 J03479 RK A ON 49 N
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