6 SPEED TRANSMISSION SUPER KIT - Harley
Contents
1. 57 56 5 EP Powe S Ace i Oo SSH Zu UI e ES ag 52 47 ag T Le 35 43 34 e KR af IA 8 en 00 21 d i 60 61 M j E T 5 10 4 201819 h el RA e K E ili sac ES IV t 4 ON Se A j l 39K A dh 20 t Ae MHS 50 d A EEN i i ii M e d 23 2422 22 23232224 eee 30 2827 9 2 29 526 EE Figure 6 Service Parts 6 Speed Transmission Super Kit Table 2 Service Parts Table Item Description Quantity Item Description Quantity 1 Mainshaft 33 Chrome Trap Door with Ear 2 Countershaft 34 Shifter Shaft Assembly 3 Countershaft 1st Gear 35 Pillow Block Dowel 4 4 Mainshaft 3rd Gear Countershaft 2nd Gear 2 36 1 Pillow Block Screw 4 5 Mainshaft 4th Gear 37 Trap Door Plug 6 Mainshaft 6th Gear 38 Countershaft Bearing 7 Mainshaft 1th Gear 39 Lower Clutch RLS CVR Screw 4 8 Countershaft 3rd Gear Mainshaft 2nd Gear 2 40 Upper Clutch RLS CVR Screw 2 9 Countershaft 4th Gear 41 Lower Trap Door Screw 3 10 Shift2. Item Description Quantity Part Number Item Description Quantity Part Number Mainshaft 35058 03 34 Shifter Shaft Assembly 35146 03 2 Countershaft 35059 03 35 Pillow Block Dowel 4 609 2 Countershaft 1st Gear 35080 03 36 Pillow Block Screw 4 3909 4 Mainshaft 3rd Gear Countershaft 35083 03 37 Trap Door Plug 45830 48 2nd Gear 2 5 Mainshaft 4th Gear 35104 03 38 Countershaft Bearing 8977 6 Mainshaft 6th Gear 35131 03 39 Lower Clutch RLS CVR Screw 4 4718A 7 Mainshaft 1st Gear 35134 03 40 Upper Clutch RLS CVR Screw 2 4717A 8 Countershaft 3rd Gear Mainshaft 35135 03 41 Lower Trap Door Screw 3 3249 2nd Gear 2 9 Countershaft 4th Gear 35136 03 42 Upper Trap Door Screw 4814A 10 Shift Ring 1 2 3 4 2 35137 03 43 Shift Fork Shaft 4 34088 87A 11 Shift Ring 5 6 35138 03 44 Case Modification Tool 35155 03 12 Shift Drum Assembly 35142 03 45 Shifter Seal Washer 4 6497HW 13 Pillow Block Left 33301 00A 46 Shift Fork Shaft Screw 2 3784 14 Shift Drum Retainer 11342 47 Sensor Plate Gasket 3 35152 03 15 Shifter Fork 1 2 Assembly 35143 03 48 Countershaft 5th Gear 35238 03 16 Shifter Fork 3 4 Assembly 35144 03 49 Speedo Sensor Plate Screw 4705 17 Shifter Fork 5 6 Assembly 35145 03 50 Dipstick O Ring 11132 18 Trap Door Bearing 2 35087 99 51 Chrome Dipstick 37075 87 19 Trap Door Bearing 2 8992A 52 Sensor Plate 35153 03 20 M
3. which could cause death or serious injury disconnect negative battery cable before proceeding 00048a NOTES While the two threaded holes at the top of the flange are used for mounting of the drill plate the fork shaft hole center thru hole is used as the pilot for the drill bits Detailed instructions on removing the main drive gear and bearing can be found in the 2005 Touring Model Service Manual Part Number 99483 05 Section 7 7 MAIN DRIVE GEAR BEARING The front dowel pin may be stuck in the side door after removal If this occurs remove the dowel pin from the side door and install it back into the transmission case is02550 Figure 1 Install Drill Plate to Transmission Case 1 of 7 1 Using the appropriate service manual proceed as follows a Drain the primary chaincase and transmission lubri cants b Unthread bolt and remove battery negative cable black from battery negative terminal c Remove the primary chaincase cover Remove the clutch assembly primary chain and compensating sprocket components Remove the starter jackshaft assembly and primary chaincase d Remove the exhaust system as necessary to gain complete access to the transmission side door e Remove the starter f Remove the clutch release cover Remove the clutch cable from the clutch release cover g Remove the vehicle speed sensor Remove the transmission top cover i Remove the drum support b
4. new cloth until the cloth comes out clean 13 Carefully inspect the transmission case for any metal shavings or debris Repeat Steps 10 through 12 if any debris is found 14 Remove the masking tape to uncover remaining holes and bores 15 Thoroughly inspect each bore for any metal shavings dust or debris Alternately direct compressed air into each bore to be certain that it is clean and dry INSTALLATION NOTES Detailed instructions on installing the main drive gear and bearing can be found in the 2005 Touring Model Service Manual Part Number 99483 05 Section 7 7 MAIN DRIVE GEAR BEARING Prelube all bearings and shafts with clean transmission lubri cant prior to installation 2of7 1 Using the appropriate service manual proceed as follows a Install the countershaft needle bearing b Install the main drive gear and bearing c Install the new shifter seal Install shifter shaft assembly from inside the transmission case Install new shifter seal washer and new retaining ring NOTES Leave the shrink wrap on the mainshaft until side door installa tion is complete Installation of the side door with the shrink wrap removed may result in damage to the main drive gear seal Be sure to remove the plastic cap and cable strap from the mainshaft before side door installation Blow away any styro foam bits or other packaging material that might be clinging to gears or splines 2 Install the transmission side doo
5. Ring 1 2 3 4 2 42 Upper Trap Door Screw 11 Shift Ring 5 6 43 Shift Fork Shaft 12 Shift Drum Assembly 44 Case Modification Tool 13 Pillow Block Left 45 Shifter Seal Washer 14 Shift Drum Retainer 46 Shift Fork Shaft Screw 15 Shifter Fork 1 2 Assembly 47 Sensor Plate Gasket 16 Shifter Fork 3 4 Assembly 48 Countershaft 5th Gear J03484 5 of 7 Table 2 Service Parts Table Item Description Quantity Item Description Quantity 17 Shifter Fork 5 6 Assembly 49 Speedo Sensor Plate Screw 18 Door Retainer Ring 2 50 Dipstick O Ring 19 Trap Door Bearing 2 51 Chrome Dipstick 20 Mainshaft Countershaft Locknut 2 52 Sensor Plate 21 Speed Sensor O Ring 53 Pillow Block Right 22 Split Cage Bearing 5 54 Sleeve Detent 23 Mainshaft Countershaft Retaing Ring 8 55 Detent Follower 24 Mainshaft Thrust Washer 2 56 Spring Detent Arm 25 Spacer Sprocket 57 Screw Detent Arm 26 Mainshaft Race 58 Trap Door Gasket 27 Main Case Seal 59 Side Cover Gasket 28 Case Bearing Retaining Ring 60 Shifter Seal 29 Quad Seal 61 Shifter Retaining Ring 30 Main Case Bearing 62 Lower Trap Door Stud 31 Mainshaft 5th Gear 63 Upper Trap Door Stud 32 Spline Sleeve 2 64 Lid Gasket FXD Models J03484 6 of 7 Table 3 Service Parts 6 Speed Transmission Super Kit
6. ainshaft Countershaft Locknut 35078 79 53 Pillow Block Right 33304 00 2 21 Speed Sensor O Ring 11289A 54 Sleeve Detent 33375 00A 22 Split Cage Bearing 5 8876A 55 Detent Follower 33364 00A 23 Mainshaft Countershaft Retaing 11067 56 Spring Detent Arm 33374 00 Ring 8 24 Mainshaft Thrust Washer 2 6003 57 Screw Detent Arm 33376 00 25 Spacer Sprocket 33344 94 58 Trap Door Gasket 35147 03 26 Mainshaft Race 34091 85A 59 Side Cover Gasket 35148 03 27 Main Case Seal 12067B 60 Shifter Seal 12045 28 Case Bearing Retaining Ring 11161 61 Shifter Retaining Ring 11150 29 Quad Seal 11165 62 Lower Trap Door Stud 16708 95 30 Main Case Bearing 8996A 63 Upper Trap Door Stud 16709 95 31 Mainshaft 5th Gear 35237 03 Items Not Shown 32 Spline Sleeve 2 35140 03 Lid Gasket FXD Models 134917 99B 33 Chrome Trap Door with Ear 35139 03 J03484 7 of 7
7. cMOTOR HARLEY DAVIDSON WY J03484 INSTRUCTIONS REV 2005 10 05 6 SPEED TRANSMISSION SUPER KIT GENERAL Kit Number 33103 03A Models This kit fits 2001 to 2005 Dyna model motorcycles Table 1 Gear Ratio GEAR STOCK 5 SPEED SE 6 SPEED First 3 210 3 210 Second 2 209 2 209 Third 1 572 1 572 Fourth 1 226 1 226 Fifth 1 000 1 000 Sixth N A 0 885 Additional Parts Required Requires separate purchase of cable Sidecover Release Kit or Hydraulic Sidecover Release Kit See retail catalog for part numbers In addition to the above kits the 2005 Dyna Model Service Manual Part Number 99483 05 and Main Drive Gear Remover amp Installer Kit Part Number 35316 B must be purchased See your Harley Davidson dealer A Service Manual for your model motorcycle is available at any Harley Davidson Dealer IWAN IN 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 a Harley Davidson dealer perform the installation Improper instal lation of this kit could result in death or serious injury 00308a Kit Contents See Figure 6 and Table 3 REMOVAL NOTE Leave the transmission case in the frame unless the case itself requires replacement For ease of illustration photographs show the case removed J03484 WARNING To prevent accidental vehicle start up
8. clutch assembly primary chain and compensating sprocket components Install the primary chaincase cover h Install drain plug and fill the primary chaincase with the recommended lubricants is02551 Figure 3 Install 3 4 Shifter Fork Onto Shift Ring 3 of 7 4 Install plate with gasket over vehicle speed sensor bore in transmission case using existing hardware 5 Install vehicle speed sensor at top of transmission side door using new O ring 6 Install 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 Cable 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 TRANSMISSION SERVICE Figure 4 Install 1 2 Shifter Fork Onto Shift Ring 7 Replace the transmission lubricant after the first 500 miles Thereafter refer to the Service Manual and change the men lubricant at the recommended service intervals Figure 5 Orient Shift Drum Support Block Dowels J03484 4 of 7 SERVICE PARTS is02549
9. haft are fully engaged with main shaft 4th gear i Slide fork shaft through holes in shifter forks and then fully install side door Be sure that end of fork shaft engages blind hole on left side of transmission case j Install fork shaft set screw in transmission side door Tighten screw until the shaft has minimum endplay but still rotates freely k Install new side door plug into side door L Remove shrink wrap from the mainshaft J03484 NOTE The 2005 Touring Models Service manual Part Number 99483 05 includes detailed instructions on installing the mainshaft oil seal quad seal spacer sleeve sprocket and sprocket nut in Section 7 7 MAIN DRIVE GEAR BEARING 3 Using the appropriate service manual proceed as follows a Install four new drum support block dowels in deck of transmission case Orient the dowels so that the split line is aligned left to right Install new drum sup port blocks with new shift drum b Rotating output shaft by hand shift through all six gears to verify proper operation Input shaft may need to be rocked back and forth to get all gears to shift c Install the mainshaft oil seal quad seal spacer sleeve sprocket spacer sprocket and sprocket nut d Install the new bearing inner race onto the transmis sion mainshaft e Install the transmission top cover with new gasket f Install the starter g Install the primary chaincase and starter jackshaft assembly Install the
10. he transmis sion case to catch the metal shavings and debris ACAUTION Always wear proper eye protection when drilling Flying debris could cause serious eye injury 00402c 6 Starting with a 3 8 inch drill bit alternately use progres sively larger bits to enlarge the fork shaft hole Finish the drilling operation with a 3 4 inch drill bit 7 Remove all remaining material up to the edge of the drill plate with a die grinder or similar tool 8 Using emery cloth steel wool or a fine tooth file remove any burrs or ridges that may exist from the drilling or cut ting operation NOTE Abrasive particles can damage machined surfaces and result in premature failure 9 Carefully pull out shop cloths from inside the transmission case Exercise care to keep any debris captured by the cloths from falling into the transmission case 10 Place drain pan beneath transmission case and remove tape from drain hole Thoroughly flush the transmission case with a non volatile cleaning solution or solvent to remove any metal shavings dust or debris that might remain For best results use a squirt bottle to direct a stream of solvent through the transmission top cover opening Repeat procedure as necessary draining excess solvent through the drain hole 11 Using low pressure compressed air thoroughly blow out all solvent 12 Using aclean lightly oiled cloth thoroughly wipe the inside of the transmission case Repeat this step with a
11. locks and shift drum Remove the drum support block dowels from deck of transmission case j Remove the fork shaft and shifter fork assemblies k Remove the bearing inner race from the transmission mainshaft L Remove the transmission side door and the main shaft countershaft assembly m Remove the shifter shaft assembly and shifter seal n Remove the main drive gear and bearing o Remove the countershaft needle bearing NOTE While the two threaded holes at the top of the flange are used for mounting of the drill plate the fork shaft hole center thru hole is used as the pilot for the drill bits 2 Using masking tape cover all the side door flange holes in the transmission case with the exception of the top three 3 From inside the transmission case tape over all bores as follows e Vehicle speed sensor and mounting screw bores e Transmission top cover and shift drum support block screw bores e Transmission drain hole bore e Main drive gear bearing bore e Countershaft needle bearing bore e Fork shaft bore e Shifter shaft bore NOTE Be sure drill plate is properly oriented Improper orientation will result in damage that requires replacement of the transmission case J03484 4 See Figure 1 Obtain the drill plate Part Number 35155 03 provided in kit and fasten to top of side door flange using old and new vehicle speed sensor mounting screws 5 Spread one or two clean shop cloths inside t
12. r and mainshaft counter shaft assembly as follows a Hang new side door gasket on dowels in side door flange of transmission case b Start side door and mainshaft countershaft assembly into transmission case but stop so that all gears remain on the outboard side c Note that there are three shifter forks each of which are stamped for easy identification Set aside the 5 6 shifter fork the 3 4 shifter fork and the 1 2 shifter fork in that order d Install the 5 6 shifter fork into the shift ring outboard of the 6th gear on the mainshaft shift ring closest to the main drive gear e Install the 3 4 shifter fork into the shift ring between the 4th and 3rd gears on the mainshaft shift ring closest to the side door Be sure the dogs on the shift ring are engaged with mainshaft 3rd gear and then rotate shifter fork toward the countershaft until the slot in the fork engages the edge of the shift ring between 1st and 2nd gears on the countershaft This engagement is necessary to obtain the proper clear ance for side door installation f Slide side door assembly further into transmission case stopping about one inch before mating flanges make contact Start fork shaft through hole in side door Through the transmission top cover opening install the 1 2 shifter fork into the shift ring between 1st and 2nd gears on the countershaft For proper clearance be sure the dogs on the 3 4 shift ring closest to side door on the mains
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