98-902 Instructions
Contents
1. verifying that there is no interference with a soft blow hammer will then fully seat the shafts amp trap door See fig 4 Once gear set is installed use the supplied 5 16 18x1 1 2 8 1 4 20x1 1 2 bolts to secure the trap door Torque the 5 16 bolts to 15 ft Ibs w red loctite high strength Torque the 1 4 bolts to 9 ft lbs w red loctite high strength See fig 5 FIG 5 At this time check to make sure all gears rotate freely amp that all slider gears slide with no interference Lightly lube amp install supplied quad seal onto main drive gear See fig 6 Install Main seal using special tool 497 164 See fig 7 zug Install original spacer onto mainshaft NOTE Beveled side goes in towards quad seal see fig 8 Install supplied transmission drain plug amp supplied speedo sensor plug with gasket Install supplied shifter forks onto appropriate slider gears see fig 9 FIG 7 Lightly lube amp install shift fork shafts short shaft supplied in kit NOTE Short shaft is installed from the right side with the threaded hole facing out Long shaft is installed from the left side amp should not protrude from the right side of case see fig 10 Install shift fork shaft allen head plugs Use red loctite to prevent movement of plug amp to aid in sealing NOTE Plug on right side will seat fully To prevent distortion of shift fork shaft torque to 5 ft lbs do not overtorque Thread the allen h2. ULTIMA 6 SPEED BUILDERS KIT 98 902 INSTALLATION INSTRUCTIONS Ultima recommends that these kits be installed by a trained amp qualified mechanic with knowledge of the Harley Davidson style 5 speed transmission Ultima 6 speed builders kit should only be installed in a known good transmission case amp should be thoroughly inspected during the described conversion process If transmission housing does not pass inspection Midwest offers replacement 5 spd cases in natural black amp polished finishes The Ultima 6 speed builders kit will fit in most OEM amp aftermarket transmission housings without modification However due to some casting variations some modification may be necessary If possible leaving the transmission mounted in the motorcycle frame not only saves time but makes the process easier amp helps prevent potential damage to the housing Due to variations in neutral switch styles normally open normally closed changing your neutral switch may be required If shifting from neutral is difficult shimming of the neutral switch may be required SPECIAL TOOLS REQUIRED e 1990 or later Factory Service Manual e Retaining ring pliers e Midwest P N 97 166 Trans Main Drive Gear Tool e Midwest P N 97 164 Main Drive Gear Bearing Seal Installer e Midwest P N 97 88 Countershaft Sprocket Nut Wrench e Midwest P N 97 85 Mainshaft Bearing Race Tool REV 09 8 14 DISASSEMBLY For 5 speed gear set removal refer to your facto
3. blue loctite med strength Install clutch pushrod amp supplied throwout bearing lightly lube both See fig 15 Install supplied clutch release cover gasket amp clutch release cover using supplied 1 4 20 bolts Torque 1 4 20 bolts to 9 ft Ibs using blue loctite med strength If required install supplied bearing inner race wet primary onto mainshaft using special tool 97 85 NOTE Open belt primarys dry primary do not require a bearing inner race See fig 16 FIG 16
4. ead plug on left side until just below flush with housing See fig 11 At this time verify shift forks slide freely on their shafts Put gear set in neutral no gear dogs mesh interlock FIG 11 Install supplied pillow blocks onto shift drum Do not lose shims NOTE Lube pillow block bearings NOTE Most drum assemblies only require the 040 shim for proper endplay Only use 008 shim if required See fig 12 Install shift drum assembly onto trans using alignment dowels as a guide NOTE Care must be taken to align shifter fork dowels to shift drum guides Putting shifter drum in the neutral position will aid in alignment See fig 13 Once shift drum assembly is fully seated on transmission case bolt down with the original 1 4 20 bolts Torque 1 4 20 bolts to 9 ft Ibs using blue loctite med Strength At this time lift shift detent 8 shifter pawl arm amp verify that the shift drum has free motion amp proper endplay 002 010 Shim accordingly See fig 14 Once proper shift drum endplay has been achieved place transmission in 3rd gear amp adjust the pawl assembly so that there is no free play in the downshift motion to 2nd gear All free play should be in the upshift motion going from 3rd to 4th gear Once this has been achieved tighten down the pawl adjusting lock nut Install supplied top cover gasket amp top cover using the original 1 4 20 bolts Torque 1 4 20 bolts to 9 ft lbs using
5. ry service manual You will need to remove the main drive gear main drive gear bearings retaining clip 4 countershaft needle bearings NOTE Removal of the shifter arm is not necessary for 99 amp earlier transmissions NOTE Removal of the shifter arm is necessary for 2000 amp later transmissions After trans housing is disassembled thoroughly clean amp inspect ASSEMBLY For 2000 later models removal of approximately 1 4 of an inch off of the shifter arm bushing is likely required Doing so will allow installation of the retaining clip amp washer onto the shifter arm It is good practice to double check how much material should be removed before cutting the bushing See fig 1 amp 2 Install supplied Main drive gear bearings amp countershaft needle bearings using special tool 497 164 NOTE Lightly coat bearings with assembly lube or gear oil for easier installation Install supplied Main drive gear retaining clip amp verify that it is fully seated and cannot come out Do not re use old bearings or retaining clip Install supplied Main drive gear into bearings using special tool 497 166 See fig 3 Install supplied trap door gasket 8 verify that it is on correctly Install supplied 6 speed gear set making sure to align the countershaft with the needle bearing assembly Slowly slide in gear set until the mainshaft amp countershaft will not slide in any further Lightly tapping on the trap door while
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