Instruction Sheet For JIMS® Right Side Drive 6
Contents
1. SHOWN CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Faia fot areg Davidsoni 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 A Division of Thiessen Products INC CUSTOMER SUPPORT FOR ANY QUESTIONS ON INSTALLATION OR SERVICE PLEASE CONTACT JIMS TECHNICAL DEPARTMENT 805 482 6913 WARRANTY PROVISIONS All JIMS Parts are guaranteed to the original purchaser to be free of manufacturing defects in mate rials and workmanship for a period of 1 one year from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at JIMS option if the parts are returned to us by the purchaser within the 1 one month warranty period or within 10 ten days thereafter In the event warranty service is required the original purchaser must call or write JIMS immediately with the problem Some problems can be rectified by a telephone call and need no further course of action A part suspected of being defective must not be replaced by a Dealer without prior Authorization from JIMS If it is deemed necessary for JIMS to make an evaluation to determine whether the part is defective it must be packaged properly to prevent further damage and be returned prepaid to JIMS with a copy of th2. 4 Install final drive pulley or sprocket that you are using for your final drive system Not supplied in this kit 5 Install Mega Nut JIMS No 1708 supplied in this kit over FIGURE 5 the main drive gear on right side of transmission Refer to the instruction sheet that comes with the mega nut Primary Side 2 Install Quad Seal JIMS No 11165 supplied in this kit over Mainshaft Bearing Boss on the left side of Trans If not already installed by manufacturer Refer to Figure 4 NOTE Left side will have a Bearing Boss not a Main Drive Gear 3 Install Mainshaft Seal Spacer JIMS No 8437 supplied in this kit over Mainshaft Bearing Boss on left side of Trans with the chamfered side to the inside Be sure not to roll the lip of the seal over during installation If not already installed by manufacturer Refer to Figures 5 amp 6 4 Install Mainshaft Nut Seal Spacer Lock Nut JIMS No 35211 91B supplied in this kit over the Mainshaft Bearing Boss Apply a small amount of Red Loctite about drops to the 1 0 threads of the Lock Nut and 3 drops to the O D threads of the Mainshaft Bearing Boss threads Also apply trans lube to the Face of the Nut Torque Nut 150 160 ft lbs with JIMS Tool No 94660 37A Mainshaft Sprocket Locknut Wrench Hefer to the instruction sheet that comes with the tool 5 Install Primary Drive as indicated in your Service Manual 6 Install clutch adiusting screw JIMS No
3. 1 Install Center Clutch Pushrod JIMS No 37088 90 supplied in this kit First grease both ends of the pushrod then slide it into the Mainshaft until it is flush with the end of the mainshaft threads pushrod may be installed in either direction 2 Install sealed bearing JIMS No 8451 onto the end of the Right Clutch Pushrod JIMS No 8452 both supplied in this kit 3 Install retaining ring JIMS No 8453 supplied in this kit L I7 n Wy into the groove onto the end of the right pushrod so that it a holds the sealed bearing in place 4 Install the Right Pushrod assembly from above steps First grease the end without a bearing and slide the greased end into the end of the Mainshaft until the bear ing is against the Mainshaft 5 Inspect that both O Rings JIMS No 11273 supplied in FIGURE 7 this kit have stayed in place over the Hollow Dowels in the pulley cover Refer to Figure 7 6 Install Pulley Cover over the end of Mainshaft Apply a small amount of Trans Lube to both the inner and outer sealing surfaces of each Seal and the sealing surface of the Mainshaft 7 Install the three 5 16 screws JIMS No 1118 supplied in this kit Apply a small amount of trans Lube or Blue Loctite to each screw and the 3 screw holes Torque each screw to 13 16 ft lbs a criss cross pattern CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOL
4. 47 4 2135 _ SCREW PILLOW BLOCK ALLEN 1 34091 85 RACE MAINSHAFT 49 1 12045 SEAL SHIFTER 50 1 8978A BEARING TRAPDOOR SMALL 51 1 6497HW WASHER SHIFTER SEAL 52 1 8418 _BEARING TRAPDOOR COUNTERSHAFT RSD 53 1 11150 _RETAINER SHIFTER SHAFT 54 1 8996 BEARING MAIN CASE 56 4 1215 WASHER PLAIN SPECIAL PILLOW BLOCK 57 1 34904 86 GASKET LID FXST amp FLHT 60 1 1258 SCREW 1 4 20 x 1 1 4 SHCS TRAP DOOR 63 1 8425 SHIFT DRUM RSD 64 1 8413 SHIFT FORK 3RD 5TH RSD 65 1 8414 _ SHIFT FORK 4TH 6TH RSD 66 1 8415 _ SHIFT FORK 1ST 2ND RSD 67 1 34978 00A SCREW CENTERING PIN 70 5 8876 BEARING SPLIT CAGE 74 2 8081 SHAFT SPACER 72 1 37075 87 DIPSTICK W O RING CHROME 73 1 7514 SLEEVE SHIFTER SHAFT 34979 00 74 1 8446 SHAFT SHIFT FORK 76 1 3784 SET SCREW SHIFT FORK SHAFT 77 1 8012 1 SHRINK WRAP 1 x 2 1 2 78 1 8440 SPACER SENSOR 79 1 2401 _CAP BLK PLASTIC 80 1 739A PLUG TRAPDOOR 86 3 1261 SCREW 1 4 20 x 1 1 2 SHCS CHROME DOOR 87 3 8092 SCREW 5 16 18 x 1 1 2 SHCS CHROME DOOR 88 1 8417 _ TROUGH OIL PICK UP RSD 89 14 35626 94 GEAR 5TH COUNTERSHAFT 90 1 8295 _GEAR 5TH MAINSHAFT 93 1 1259 SCREW 1 4 20x3 4 SHCS CHROME SENSOR PLATE 95 1 37088 90 PUSHROD CENTER 96 1 8452 RIGHT PUSHROD 97 1 8453 RETAINER PUSHROD 98 1 8451 BEARING PUSHROD 99 1 8326 SCREW ADJUSTER CLUTCH HUB 101 1 1708 15 INSTRUCTION SHEET MEGA NUT
5. Figure 9 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Taria for 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 Q No 8236 IS 2 Install Mounting Screw JIMS No 1259 supplied in this kit Apply a small amount of Trans Lube or Blue Loctite to the screw and thread the screw into the hole in the case Torque to 7 9 ft lbs Refer to Figure 9 REV C 8 07 Spacer No 8440 FIGURE 9 DISASSEMBLY In the unlikely event that you would need to disassemble your complete Transmission we have provided some Instructions that will help you This kit is basically easy to Disassemble but does require some special tools For replacement parts see materials list NOTE Read all instructions before perform ing work The transmission disassembly is the same as assembly but in reverse order Always disconnect the Battery Ground Cable at the battery to prevent injury Your work area should be well lit Wear Safety glasses over your eyes and protective clothing when working around power tools and compressed air Protect your skin from solvents and use only in a well ventilated area Degreasers are flammable and are a fire hazard Use common sense and exercise good judgment Securely mount the trans Case if not installed in Motor
6. SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Fania fot 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 15
7. 2 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 c Remove Outboard Bearing JIMS No 8419 from the same side as the Seal Retaining Plate d Install new Outboard Bearing with the sealing side facing the Trans Case MECHANICAL PULLEY COVER e Reinstall new Seal with JIMS Tool No 2256 Note Do not press new seal in too far f Place the seal retainer plate over the seal aligning the 3 holes g Apply one drop of Blue Loctite onto the threads of each Seal Retainer Plate Screw JIMS No 1112 Thread the screws into the holes in the pulley cover and FACING TRANS torque to 60 in Ibs CASE 2 To repair the Mechanical Clutch Pulley Cover IET 22 2 a Follow assembly found above under assembly of CRAT COM DOWEL ENO COVER TO TRAPDOOR i 2 273 _ O RING END COVER DOWEL TO TRAPDOOR Mechanical Clutch Pulley Cover in reverse order 8873 3 8 RAMP 8443 GASKET MECH END COVER RSD 3 To repair the Hydraulic Clutch Pulley Cover Tasso era OUTER Cuma Govan Remove the six screws JIMS No 8430 holding the 6141 T O RING SEAL RETAINER RSD Hydraulic End Cover onto the Pulley Cover 401 41 34259 SEAL RETAINER san 1 SCREW 5 16 18 x 1 1 4 SHCS CHROME BEARING PULLEY COVER RSD 12035B PULLEY COVER 2 8433 SETSCREW 1 16 NPT x 5 16 STAINLESS STEEL 1074 SCREW 1 4 20 x 7 8 SHCS CHROME END CVR 1112 SCREW 8 3
8. 2 x 3 8 FHSS SEAL RETAINER b Remove the three Screws JIMS 1112 holding the Seal Retaining Plate JIMS No 8428 and remove the Seal Retaining Plate amp Seal c From the inside of Pulley Cover push on the end of the Piston JIMS No 8429 until it is pushed free from the Pulley Cover 55 E d Replace any Seals or O rings that you deem none serviceable See Parts list in this Instruction sheet Note Replace Seal and O rings one at a time so that any sealing directions can be maintained Apply DOT 5 Brake Fluid to all working surfaces e Reinstall new Seal with JIMS Tool No 2256 Note Do not press new seal in too far or damage to cover may occur f Place the Seal Retainer Plate over the seal aligning AMA DESCRIPTION A PULLEY COVER HYDRAULIC CHROMED RSD the 3 holes END COVER HYDRAULIC CHROMED RSD g Apply one drop of Blue Loctite onto the threads of each Seal Retainer Plate Screw JIMS No 1112 W SEAL HYDRAULIC PISTON Thread the screws into the holes in the pulley cover 61 6 8430 SCREW 10 24 x 3 8 SHCS CHROME END COVER and torque to 60 in lbs 01 8431 SCREW 1 428 T CRONE h Apply one drop of Blue Loctite onto the threads of ata each Hydraulic End Cover screw JIMS 8430 834 111 M PUE COUR CHROME Thread the screws into the holes in the pulley cover 2 120358 SEAL PULLEY COVER and torque in a cr
9. 3 Fork No 8415 Case shown cut away for clarity FIGURE 3 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfptmame Faia fot farleg Moiorcyclet 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 4 No 8236 IS REV C 8 O7 INSTRUCTIONS FOR INSTALLING MAIN SEAL SPACERS AND TORQUING MAINSHAFT NUTS FOR BOTH SUPER KITS AND COMPLETES 1 Slide all 3 Shift Forks into any gear locking the trans and keeping the gears from turning for final torquing of the mainshaft nuts Note You may need to install the right side Final Drive Pulley first this will allow the use of JIMS Tool No 2260 Sprocket Locker to hold the Pulley and Mainshaft from turning instead of the gear set as you are Torquing both Mainshaft Nuts Final Drive Side Right Side 2 Install Quad Seal JIMS No 11165 supplied in this kit FIGURE 4 over the Main Drive Gear on the right side of the Transmission If not already installed by manufacturer Refer to Figure 4 Chamfered 3 Install Main Drive Gear Seal Spacer JIMS No 8424 Side supplied in this kit over the Main Drive Gear on the right side of the transmission with the chamfered side toward the inside Be sure not to roll the lip of the seal over during installation If not already installed by manufacturer Refer to Figures 5 amp 6
10. 8326 oplied in this kit NOTE For hvdraulic cl h adjust ment rd CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS section SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Taria fot 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 Q No 8236 IS REV C 8 O7 INSTRUCTIONS FOR INSTALLING SHIFT DRUM PILLOW BLOCKS AND TOP LID 1 Place the Drum assembly with Pillow Blocks over the 3 Pins of Shift Forks move forks as needed to line up with the tracks in the Shift Drum At the same time lining the Pillow Blocks over and onto the 4 Split Dowel Pins See your Late H D Service Manual 2 Install four 1 4 Pillow Block Mounting Washers JIMS No 1215 over the four 1 4 Pillow Block Mounting screws JIMS No 2135 both part numbers supplied int his kit Apply a small amount of Lube or Blue Loctite to each screw and torque to 7 9 ft lbs in criss cross pattern See your Late H D Service Manual 3 Install Top Cover Gasket JIMS No 34904 86 supplied in this kit per your H D Service Manual Install your Top Cover Lid with your mounting hardware See your H D Service Manual Install Vent Hose No 42533 91A not supplied in this kit to your Top Lid Elbow Fitting Refer to your H D Service Manual INSTRUCTIONS FOR INSTALLING PULLEY COVER HYDRAULIC AND MECHANICAL CLUTCH
11. ARING THE TRANSMISSION CASE TO INSTALL JIMS R S D 6 SPEED SUPER KIT COMPLETES HAVE BEEN PREPARED 1 Remove Old Gear set and all Case Bearings Refer to your H D Service Manual NOTE If Dowel Pin H D No 634 came out upon the Gear Set removal it will need to be reinstalled back into the Trans Case Refer to your H D Service Manual 2 Upgrade Shifter Shaft Bushing for 1990 99 Big Twins and 1999 2000 T C FLHT FXR amp FXD by removing the existing Shifter Shaft Bushing and installing a new longer shifter Shaft Bushing Sleeve JIMS No 7514 sup plied in this kit Follow the Instruction Sheet provided with JIMS Tool No 1664 and refer to your Late H D Service Manual for Shifter Shaft Assembly 3 Wash and rinse out the entire inside of your trans case 4 Install Main Drive Gear Bearing JIMS No 8996 supplied in this kit using JIMS Tool No 35316 80 Follow the Instruction Sheet provided with Tool or Refer to your H D Service Manual 5 Install Retaining Ring JIMS No 11161 Supplied in this kit Refer to your Service Manual NOTE NEVER install any bearings into the Case by applying pressure to the inner race Doing so will destroy the bearing 6 Install new Main Seal JIMS No 12067 supplied in this kit with JIMS Tool No 95660 85 used with JIMS Tool No 95660 42 Refer to you H D Service Manual 7 Install Countershaft End Bearing JIMS No 8977 Refer to your Service Manual NOTE Install Countershaft Bearin
12. Installing Pulley Covers 4 Remove Top cover and Shift Drum Slide the three Shift Forks into any gear to lock the Trans to keep the gears from turning for removal of the Mainshaft Nuts and Countershaft Bearing Lock Screw 5 Remove Countershaft Bearing Seal Cover JIMS No 8421 and Discard 6 Remove Countershaft Bearing Lock Screw JIMS No 1727 NOTE You may need to apply heat to remove the 1727 countershaft lock screw NOTE For re assembly of countershaft Bearing Lock Screw re torque to 12 ft Ibs with a 1 2 a drop of Blue Loctite applied to threads of the screw 7 Remove Shifter Shaft Set Screw JIMS No 3784 8 Remove Shifter Shaft JIMS No 8446 9 Remove the three Shift Forks JIMS No s 8413 8414 and 8415 10 Remove all trap door hardware holding the trap door to the Transmission Case 11 Remove trap door from Trans Case using the trap door Puller Tool JIMS No 998 Refer to the instruction sheet that comes with the tool 12 Remove the Oiling Trough JIMS No 8417 by removing the two mounting screws JIMS No 8426 NOTE For assembly of the Oiling Trough screws torque to 60 in Ibs with drop of Red Loctite 13 Re install trap door without the gear set onto the case in order to remove the Main Drive Gear from the trap door using the Main Drive Gear Bearing remover JIMS No 35316 80 NOTE The Main Drive Gear Main Bearing JIMS No 8978 and Lock Ring No 11057 will need to be replaced after the Main Drive Gear has b
13. NG SMALL SHOULDER BOLT 10 24 y 25 x 3 4 SEAL END CAP 50MM x 8MM RETAINER COUNTERSHAFT BEARING RSD SCREW 5 16 18 x 1 FHSS RETAINER DOOR BEARING SMALL LEFT PILLOW BLOCK WITH BEARING amp RETAINER GEAR 2ND COUNTERSHAFT RSD GEAR 3RD amp 4TH COUNTERSHAFT RSD GEAR 1ST COUNTERSHAFT RSD GEAR 2ND MAINSHAFT RSD GEAR 3RD MAINSHAFT RSD GEAR 4TH MAINSHAFT RSD GEAR 6TH MAINSHAFT RSD GEAR 1ST MAINSHAFT RSD RETAINER MAINSHAFT COUNTERSHAFT THRUST WASHER MAINSHAFT COUNTERSHAFT SPACER PRIMARY SIDE NUT LEFT MAINSHAFT RSD SEAL MAIN CASE RETAINING RING SHIFT DRUM Faia fot Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 PARTS DIAGRAM FOR TOP LID GEARS SHIFT FORKS AND TRAP DOOR ASSEMBLY o 8 9 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Tania fot aeg Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 PARTS LIST FOR PILLOW BLOCK ASSEMBLY COUNTERSHAFT ASSEMBLY SHIFTER ASSEMBLY MAINSHAFT ASSEMBLY WITH CLUTCH PUSHROD NO JIMS P N DESCRIPTION 45 1 8420 THRUST WASHER 30MM x 47MM x 034 46 6 8356 PIN SHIFT DRUM
14. No 8236 IS REV C 8 O7 JIMS R S D 6 Speed Overdrive complete Transmission Kit numbers 8248 8249 8250 8251 8252 8253 8259 8260 8266 and 8267 We have included this instruction sheet for reference to disassemble the trans mission Disassembly is the same as assembly but in reverse order READ ALL INSTRUCTIONS BEFORE PERFORMING WORK Prior to installation of this kit please read and follow the procedures and safe ty precautions to reduce the risk of personal injury IF YOU DO NOT KNOW WHAT YOU ARE DOING DO NOT DO IT No information in this instruction sheet pertaining to motorcycle repair is represented as fool proof or even alto gether safe Some people can ruin a mechanic s vise with a tack hammer Even something safe done incorrectly or incompletely can and will backfire You are responsible for the safety of your work and knowledge of the tools repair equipment components methods and concepts needed to complete these tasks You must carefully and systematically perform each and every step safely All information listed in this instruction sheet has been tested re tested and used daily in JIMS Research and Development Department JIMS IS NOT RESPONSIBLE FOR THE QUALITY AND SAFETY OF YOUR WORK If you are not sure about any of the procedures in these instructions have a reputable H D repair shop perform these procedures for you WARNING Always disconnect the Battery Ground Cable at the battery to prevent
15. S THE LAST TOOLS YOU WILL EVER NEED TO BUY Feifotmance Taria fot 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 INSTRUCTIONS FOR CONNECTING HYDRAULIC CLUTCH LINE 1 Connect your Hydraulic Clutch Line Fill the Master Cylinder with clean DOT 5 Brake Fluid and bleed the system Refer to your H D Service Manual Brake Bleeding section 2 Fill Trans with Gear Oil JIMS No 1231 or equivalent to the same as an H D 5 speed Change Oil after the first 500 Miles Refer to your H D Service Manual After installing the clutch adjusting screw JIMS No 8326 supplied in this kit into the clutch hub thread the adjusting screw clockwise until all free play has been removed from both pushrods and Hydraulic Piston The clutch pressure plate will just start to be pushed away from the clutch pack 4 Turn adjusting screw counterclockwise one full turn and tighten lock nut Bleed the system as performed in Brake Bleeding section of your H D Service Manual OR INSTRUCTIONS FOR CONNECTING MECHANICAL CLUTCH CABLE You need to remove the Actuator Cover to install your Clutch Cable Note Two of the screws are shorter Be sure to note their locations 1 Remove the six screws that hold the Actuator Cover to the Pulley Cover 2 Connect your Clutch Cable with O Ring not supplied in this kit Clutch Cable Mount and Ramp Assembly sup plied
16. VER NEED TO BUY Petfotmance Fas fot farleg Davidson 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 Special Parts Needed To install Special Tools Required Continued JIMS 6 Speed Super Kit JIMS Part No Description JIMS Part No Description Trans Stand Good Quality Gear Oil Modular Engine amp Trans Stand Kit Speedo Block Off Plate Main Drive Gear Seal Protector Depending on application Shift Lever Pivot Sleeve R amp 42533 91A Vent Hose Good Quality DOT 5 Brake Fluid Speedo Recalibration Module Depending on pulley and tire size NOTE Spacer No 8424 is for Belt Pulley applications if you will be using a Sprocket you need to shorten or lengthen this spacer for proper Chain alignment to Rear Sprocket NOTE To use Hydraulic Pulley Cover JIMS No 8422 you will need a Hydraulic Clutch Master Cylinder simi lar to H D No 45232 03A a Clutch Line Braided Stainless Brake Line that is about 70 inches long depending on Handle Bars Risers and Frame similar to H D No 38669 03 except with a Banjo fitting at each end two Banjo Bolts like H D No 41747 82A and Sealing Washer gasket like H D No 41731 01 NOTE Refer to your Service Manual and parts book for the proper year and model you will be installing this kit in for reference Also Use a Late H D 2002 Pres Big Twin Service Manual and parts book for reference INSTRUCTIONS FOR PREP
17. cycle with JIMS Tool No 1145 Complete Modular Engine amp Transmission Stand Kit or JIMS Tool No 1289 Trans Stand Special Tools Required to un install JIMS R S D 6 Speed Super Kit JIMS Part No Description 35316 80 5 speed Maindrive Gear Tool 34902 84 Mainshaft Bearing Race Tool 94660 37A Mainshaft Sprocket Locknut Wrench 38515 90 Clutch Spring Compressor 1990 97 Big Twin Sprocket Locker omall Lock Ring Pliers Large Lock Ring Pliers External Lock Ring Pliers Primary drive Locking Tool 5 speed Main Bearing Remover Main and Counter Shaft Installer Solvent 184 Brass Hammer Trans Stand Modular Engine amp Trans Stand Kit Door Puller Tool CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Faia fot Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 O7 INSTRUCTIONS FOR DISASSEMBLY OF YOUR JIMS R S D 6 SPEED OVERDRIVE 1 Remove Primary Covers and Clutch components as shown in your H D Service Manual 2 Drain the oil from Transmission by removing Drain Plug from the trap door JIMS No 739A or if your Trans Case has other means of Oil Drain you may use that 3 Remove Pulley Cover in the reverse order of assembly for installing Pulley Covers Refer to instructions for
18. e original invoice of purchase and a detailed letter outlin ing the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by JIMS and the part was found to be defective repair replace ment or credit will be granted ADDITIONAL WARRANTY PROVISIONS 1 JIMS shall have no obligation in the event a JIMS part is modified by any other person or organization 2 JIMS shall have no obligation if a JIMS part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the part 3 JIMS shall not be liable for any consequential or incidental damages resulting from the failure of a JIMS Part the breach of any warranties the failure to deliver delay in delivery delivery in nonconforming condition or for any other breach of contract or duty between JIMS and a cus tomer 4 JIMS Parts are designed exclusively for use in Harley Davidson Motorcycles JIMS Shall have no warranty or liability obligation if a JIMS part is used any other application 5 Any JIMS parts or tools that are returned and replaced become the property of JIMS and will not be Returned under any circumstance THANK YOU FOR PURCHASING JIMS AMERICAN MADE PRODUCTS LOG ONTO WWW JIMSUSA COM FOR MORE INFORMATION ON ADDITIONAL PRODUCTS AVAILABLE FROM JIMS CAUTION WEAR
19. een removed from the bearing 14 Remove both trap door bearings as you would for any 5 speed rebuild NOTE Take note of the Lock Ring locations before removing them from the trap door 15 Replace Countershaft and Main Drive Gear Bearings and Lock Rings Be sure to install them in the same positions as the ones that were removed 16 Remove all Gears from the Main and Countershafts the same as you would for any 5 Speed Transmission following the Parts List as laid out in this Instruction Sheet 17 Remove any other Parts Bearings or Seals from the Transmission Case as you would for any 5 Speed INSTRUCTIONS FOR REPAIRING PULLEY COVER BEARINGS AND SEALS HYDRAULIC amp MECHANICAL CLUTCH 1 To replace outboard Bearing Support JIMS No 8419 Hydraulic amp Mechanical a Remove all 3 Screws JIMS No 1112 holding the Seal Retaining Plate JIMS No 8428 and remove the Seal Retaining Plate b Remove Seal JIMS No 12035B NOTE There are two No 12035B seals The outer seal can only be removed from the clutch activator side For the Hydraulic Clutch version you must first remove the slave cylinder piston For mechanical you must first remove the clutch actuator cover CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Faia fot farleg Moiorcycles 555 DAWSON DRIVE CAMARILLO CA 9301
20. g by applying pressure to the LETTER side of bearing ONLY 8 Install Shifter Shaft Seal JIMS No 12045 supplied in this kit Refer to your H D Service Manual 9 Install Shifter Assembly JIMS No 8325 supplied in this kit Refer to your Late H D Service Manual CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fas fot Havley Vavidton 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REv C 8 07 10 Install Shifter Shaft Washer JIMS No 6497HW and Retaining Ring JIMS No 11150 supplied in this kit Refer to your Late H D Service Manual 11 Install Shifter Shaft Centering Pin Bolt JIMS No 34978 00A supplied in this kit Torque Bolt to 10 ft lbs Refer to your Late H D Service Manual s Caution Center shifter assembly return spring on each side of centering bolt INSTRUCTIONS FOR PREPARING THE TRANSMISSION TOP COVER TO CLEAR THE NEW SHIFTING LEVER WHEN INSTALLING JIMS R S D 6 SPEED SUPER KIT INTO ANY 1990 99 BIG TWINS AND 1999 2000 T C FLHT FXR amp FXD MODELS NOTE The Top Cover for Completes have been Prepared NOTE 2000 Present FXST and 2001 Present FLHT amp FXD models do not need modifying 1 Place new Top Cover Gasket JIMS No 34904 86 on the Trans Top Cover flange 2 Use 4 of your Top Cover screws to hold Gaske
21. in this kit according to your H D Service Manual 3 Install the connected assembly into the Actuator Cover JIMS No 8442 according to your H D Service Manual 4 Place Actuator Cover Gasket JIMS No 8443 and Actuator Cover onto the end of the Pulley Cover Note Gasket may be installed dry 5 Install the two short 7 8 screws JIMS 1074 and the four 1 1 8 screws JIMS No 1116 that hold the Actuator Cover Apply a small amount of Trans Lube or Blue Loctite to each screw Thread the six screws into their correct locations as shown in Figure 8 Torque screws to 84 108 in lbs in a criss cross pattern 6 Adjust Clutch according to your H D Service Manual 1 1 4 x 7 8 screw Q 7 Fill Trans with Gear Oil JIMS No 1231 or equivalent to 84 108 in ibs 9 5 12 2Nm the same level as an H D 5 speed Change Oil after the first 500 Miles Refer to your H D Service Manual 2 1 4 x 1 1 8 screw 84 108 in Ibs 9 5 12 2Nm INSTRUCTIONS FOR INSTALLING ELECTRONIC SPEED SENSOR Note If you will be running an Electronic Speed Sensor you will need to place a Speed Sensor Spacer JIMS No 8440 supplied in this kit over the O Ring end of your Speed Sensor If you are not using an electronic speedo sensor use block off plate JIMS No 8042K on the case 1 Place the Speed Sensor with the spacer into the trans case with the O Ring side down so that the mounting screw hole lines up with the threaded hole in the case Refer to
22. injury Your work area should Special Tools Required to install be well lit Wear safety glasses over your eyes and pro JIMS R S D 6 Speed Super Kit tective clothing when working around power tools and The only special tools required are tools that may compressed air Be careful with chemicals when cleaning also be required for 5 speed installation parts Protect your skin from solvents and use only in a well ventilated area Degreasers flammable and are JIMS Part No Description fire hazard Just use common sense and exercise good 35316 80 5 speed Main Drive Gear Tool judgment Securely mount the trans case if not installed 34902 84 Mainshaft Bearing Race Tool in Motorcycle with JIMS Tool No 1145 Complete Modular 94660 37A Mainshaft Sprocket Locknut Wrench Engine amp Transmission Stand Kit or JIMS Tool No 1289 Big Twin Sprocket Locker Trans Stand This kit is basically easy to install but does Small Lock Ring Pliers require some special tools See tool list Large Lock Ring Pliers NOTE Any time you see It is an indication to lube using 2 Bearing Remover JIMS No 1231 Transmission Oil for a lubricant nae Example Apply small amount of Trans Lube rass Hammer Continued Next Page to Parts being installed in this kit CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL E
23. iss cross pattern Refer to Figure 2 9 Torque all four 1 4 screws to 84 108 in lbs in a criss cross pattern Refer to Figure 2 INSTRUCTIONS FOR INSTALLING JIMS R S D SHIFT FORKS 1 Place the 1st 2nd gear Shift Fork JIMS No 8415 into Fork Slot of the 3rd 4th combo gear JIMS No 8405 by putting it down through the Top Cover opening and sliding into place as shown in 3 2 Place the 3rd 5th gear Shift Fork JIMS No 8413 into Fork Slot of the 2nd gear JIMS No 8403 by putting it down through the Top Cover opening and sliding it into place as shown in Figure 3 3 Place the 4th 6th gear Shift Fork JIMS No 8414 into the Fork Slot of the 1st gear JIMS No 8401 by putting it down through the Top Cover opening and sliding it into place as shown in Figure 3 4 Slide Shift Fork Shaft JIMS No 8446 Supplied in this kit through the hole in the trap door all three Shift Forks and into the Left side of Trans Case Refer to you H D Service Manual 5 Install Shifter Shaft Set Screw JIMS No 3784 supplied in this kit by first applying a small amount of Blue Loctite to threads and tightening until you have about 020 endplay on the Shifter Shaft REV 8 07 3 1 4 x 1 1 4 screw 84 108 in Ibs 9 5 12 2Nm 4 1 4 x 1 1 2 screw 84 108 in Ibs 9 5 12 2Nm 3 1 5 16 x 1 1 4 screw Q 13 16 ft lbs 17 6 21 7Nm 2 5 16 x 1 1 2 screw 13 16 ft lbs 17 6 21 7Nm FIGURE 2 Fork No 841
24. iss cross pattern 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 10 No 8236 IS REV C 8 O7 PARTS DIAGRAM FOR PILLOW BLOCK ASSEMBLY COUNTERSHAFT ASSEMBLY SHIFTER ASSEMBLY MAINSHAFT ASSEMBLY WITH CLUTCH PUSHROD e ath 0 e rz U L CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Faia fot 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 No 8236 IS REV C 8 07 PARTS LIST FOR TOP LID GEARS SHIFT FORKS AND TRAP DOOR ASSEMBLY NO QTY JIMS P N 1 N o 11161 8416 1 7999M3 8412 1 8409 1 8999C 8324 8352 8977 1708 1 1207 33304 00 8424 11165 12044A 11057 8426 8421 8427 1727 11020 33301 00A 8404 1 8405 1 8402 1 8403 1 8407 1 8406 1 8408 1 8401 1 11067 6003 8437 35211 91B 12067 11342 DESCRIPTION RETAINER CASE TRAPDOOR CHROME RSD CASE FXST EVO POLISHED MAINSHAFT ASSEMBLY RSD COUNTERSHAFT WITH 6TH GEAR RSD LID TOP CHROME ASSEMBLY LEVER SHIFTER GASKET TRAPDOOR BEARING COUNTER SHAFT MEGA NUT SCREW 1 4 20 x 3 4 SHCS PLAIN RIGHT PILLOW BLOCK WITH BEARING amp RETAINER SPACER RIGHT PULLEY QUAD SEAL SEAL MAINSHAFT TRAPDOOR RSD RETAINER CASE BEARI
25. nto the Trans Case 2 Gently place the Gear Set Trap Door Assembly into the Trans Case by sliding the Mainshaft through the Main Drive Gear Case Bearing while slowly pushing the Trap Door Assembly inward until the Trap Door makes contact with the two Dowel Pins in the Trans Case Refer to your H D Service Manual A non marring hammer is helpful to tap the Trap Door Assembly over the Dowel Pins without risking damage to the Aluminum Chrome of the Trap Door Assembly CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Taria fot 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 Q No 8236 IS 3 Apply a small amount of lube or Blue Loctite to the one 5 16 screw JIMS No 1118 three 5 16 screws JIMS No 8092 one 1 4 screw JIMS No 1258 and three 1 4 screws No 1261 all screws supplied 4 Thread the shorter 5 16 screw JIMS No 1118 into the lower front hole of the trap door 5 Thread the three 5 16 screws JIMS No 8092 into the remaining lower three holes in the trap door 6 Thread the shorter 1 4 screw JIMS No 1258 into the upper front hole in the trap door 7 Thread the three 1 4 screws JIMS No 1261 into the remain ing upper three holes in the trap door 8 Torque all four 5 16 screws to 13 16 ft lbs in a cr
26. t in place by slipping screws thru the Gasket and into the Top Cover 3 Mark the inside exposed portion of the flange as shown in Figure 7 The Material to be removed is 060 wide by 1 80 Deep Remove Top Cover screws and Gasket 4 With a die grinder tool remove the casting rib until it is the same height as the adjacent surface area Clean Top Cover of all loose material including screw holes as shown in Figure 7 5 With shifter assembly installed in transmission Install Top Cover with gasket using only 2 screws loosely so cover can move if Shifter Arm is making contact with Top Cover 6 While watching to see if the Top Cover moves forward shift the transmission into first gear firmly holding the shift lever down If there is no forward movement of the Top Cover then the modification is complete If any forward movement of Top Cover is observed then more of the casting rib must be removed Repeat Step 4 as necessary INSTRUCTIONS FOR INSTALLING JIMS R S D 6 SPEED SUPER KIT PARTS INTO CASE COMPLETES HAVE BEEN PREPARED Note Remove Pulley Cover from Trap Door set aside for final installation 4 Caution O Rings have been installed prior to shipping 1 Place Trap Door Gasket JIMS No 8352 supplied in this kit over the two Dowel Pins on Case Refer to your H D Service Manual Note Do not remove the Mainshaft Protective Cover on the Clutch Hub spline end of Mainshaft It can be removed after Super Kit has been installed i
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