INSTRUCTIONS - Harley
Contents
1. ZE HARLEY DAVIDSON WY J03322 INSTRUCTIONS REV 02 11 2005 Kit Number 33136 04 and 33137 04 SCREAMIN EAGLE FLHT 6 SPEED TRANSMISSION General The Screamin Eagle FLHT 6 Speed Transmission kit fits 2002 and later Harley Davidson Touring model motorcycles Kit No Description 33136 04 Silver 33137 04 Black Table 1 Transmission Ratios An additional kit for the side cover will be required The kit number depends on if the motorcycle is using the existing clutch cable or is being converted to a hydraulically actuated clutch Kit No Description 38752 04 SE 6 Speed Cable Clutch Side Cover and Release Pushrod Kit 45033 03A Hydraulic Clutch Kit black 45383 03A Hydraulic Clutch Kit chrome 38753 04 SE 6 Speed Hydraulic Side Cover amp Release Kit See the Service Parts illustration for a list of service parts in this kit Required Service Parts and Tools Installation of this kit will require additional service parts and supplies Specialized tools will include Hose Clamp Pliers HD 41137 and Hose Clamp Pliers HD 97087 65B A VvVARNING 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 This instruction sheet references Service2. PROCEDURE to fill the transmission with lubri cant a Verify that the transmission drain plug O ring are installed in the pan and tightened to 14 21 ft lbs 19 28 Nm b Remove the filler plug dipstick and fill the transmission with 20 24 oz of Harley Davidson Semi Synthetic Transmission Lubricant Fill until the level is at the F FULL mark with the motorcycle upright c Tighten the filler plug to 25 75 in Ibs 2 8 8 5 Nm 3 Follow the Service Manual ENGINE OIL FILTER PRO CEDURE to fill the oil tank and engine with oil a Verify that the the engine drain plug O ring is installed in the pan and tightened to 14 21 ft lbs 19 28 Nm c Through the oil filler dipstick spout fill with 3 1 2 3 3 liters of the grade of oil specified for the lowest ambient operating temperature d Follow Service Manual instructions to perform an engine oil level COLD CHECK and add as required 4 For hydraulic clutch If installing a Hydraulic Clutch Side Cover and Release Pushrod Kit Part No 38753 04 and a Hydraulic Clutch Kit Part No 46414 05 chrome or 46415 05 black follow the instruction sheet in the kit to fill and bleed the clutch fluid lines J03322 Return the Motorcycle to Service 1 Follow the Service Manual REAR BELT DEFLECTION instructions to measure and adjust drive belt deflection AwarnineG Connect positive battery cable first If positive cable should contact ground with negative cable
3. 03 54 Trapdoor chrome no ear 35158 03 Gear mainshaft 6th 35131 03 55 Plug drain door 45830 48 Countershaft 35059 03 56 Dipstick O ring 11132 Mainshaft 35058 03 57 Dipstick chrome transmission 37075 87 Shift ring 1 2 3 4 2 35137 03 58 O ring speedo sensor 11289A Shift ring 5 6 35138 03 59 Shifter shaft assembly 35146 03 Spline sleeve 2 35140 03 60 Pin roll 634 Shift fork assembly 1_2 35143 03 61 Switch neutral indicator O ring 33904 00 Shift fork assembly 3_4 35144 03 62 Meganut 35236 03 Shift fork assembly 5 6 35145 03 63 Sprocket transmission 32T 40250 94C Shift drum assembly 35142 03 64 Screw meganut 2 4069A Pin shift drum 6 33385 02 65 Screw lever 856A Retainer shift drum 11242 66 Lever shifter rod 33849 97 Support assembly left cam w bearing 33301 00A 67 Centering pin 34978 00A Locknut mainshaft amp countershaft 2 35078 79 68 Screw top cover 8 4740A Gear mainshaft 5th 35237 03 69 Transmission cover chrome 34541 00 Gear countershaft 5th 35238 03 70 Vent hose 42533 91A Split gage bearing 5 8876A 71 Fitting upper cover 62375 57A Screw lower trap door 4 3249 72 Screw oil pan 12 4741A Screvv speedo sensor plate 3594 73 Gasket oil pan 26077 99A Screvv pillovv block 4 3909 74 Hose oil 2 62726 99 Screvv upper side cover 4 4717A 75 Clamp 2 10249 Screw lower side cover 4 4718A 76 Hose crankcase to tank vent 45808 02 Screw trap door upper 2 4814A 77 Oil pan assembly Screw shift fork shaft 3
4. 6 Speed Transmission 1 2 Slide the 6 speed transmission with oil pan from the right side of the frame into position a Center the the transmission rear mounts between the rear swingarm mounts b See Figure 4 Move transmission forward to engage the 2 ring dowels in the lower flange of crankcase Align the bolt holes on the transmission to the engine by threading in and finger tightening the 4 bolts and washers NOTE Use OPEN End Crowfoot Snap On FC018 on the upper left and upper right transmission housing to crankcase bolts 3 See Figure 5 Tighten the transmission bolts in a cross pattern torque sequence a 1St pass tighten to 15 ft lbs 20 3 Nm b 2nd pass tighten to 30 35 ft lbs 40 7 47 5 Nm Assemble the pivot shaft assembly pivot shaft locknut cup washer rubber mount and outer spacer and coat the pivot shaft with Loctite Anti Seize J03322 Figure 1 Vehicle Speed Sensor behind engine oil fill plug dipstick mz Figure 3 Exhaust Bracket on 5 Speed Side Door side cover removed 2of6 10 11 12 13 Slide rear swingarm assembly into position aligning with mounting boss of transmission case Follow the Service Manual REAR SWINGARM INSTAL LATION instructions to position the rubber mounts in the rear swingarm bracket Install pivot shaft and tighten locknut to 45 50 ft lbs 61 0 67 8 Nm Install the flat washer lockwasher and locknut to fasten shift
5. 784 black 62489 99 Thrust washer main countershaft 2 6003 silver 62490 99 Washer shifter seal 6497HW 78 Filler cap engine oil Sprocket spacer 33344 94 black 62846 99 Mainshaft race 34091 85A silver 62849 99 Retaining ring door 2 35087 99 79 Oil filler spout assembly Retaining ring main countershaft 8 11067 black 62455 02 Retaining ring shifter 11150 silver 62456 02 Bearing trapdoor 2 8992A Trans case assembly Seal main case 12067B black 34839 04 Seal shifter 12045 silver 34838 04 Quad seal 11165 Trans case black amp silver subcomponents Gasket trap door 35147 03 Retaining ring 11161 Gasket side cover 35148 03 Bearing main 8996A Gasket oil spout 62432 93B Bearing closed end 8977 J03322 5 of 6 Replace Lubricants Be sure that no lubricant gets on tires wheels or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047a 1 Follow the Service Manual PRIMARY CHAIN LUBRI CANT PRIMARY CHAIN LUBRICANT to fill the primary chain case a Verify that the drain plug O ring is installed and tighten to 36 60 in lbs 4 1 6 8 Nm b Fill with 32 ounces 946 ml of Harley Davidson Primary Chaincase Lubricant through inspection cover c Follow the Service Manual to install a new gasket and cover Tighten the cover screws to 84 108 in Ibs 10 12 Nm 2 Follow the Service Manual TRANSMISSION LUBRI CANT
6. Manual instruc tions A Service Manual for your model motorcycle is avail able from any Harley Davidson dealer Installation Prepare the Motorcycle for Service 1 Mount the motorcycle on a suitable lift 2 Follow Service Manual instructions given to remove the seat Awarninc 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 GC 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 3 Disconnect the battery cables negative cable first a Remove bolt and negative cable b Remove bolt and positive cable Access the 5 Speed Transmission 1 Place a container under the engine remove the engine and transmission lubricant drain plugs to drain engine and transmission fluids 2 To access the existing 5 speed transmission follow the Service Manual instructions in the following sections a SADDLEBAGS REMOVAL b EXHAUST SYSTEM REMOVAL NOTE The right muffler and crossover pipe can be removed in 1 piece and the left muffler and the front and rear header pipes can be removed in 1 piece Refer to the Service Manual Section REMOVING ENGINE FROM CHASSIS for instructions c REAR WHEEL REMOVAL NOTE Positio
7. connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 2 Connect the battery cables positive cable first a Tighten the bolts to 60 96 in lbs 6 8 10 9 Nm b Coat both terminals with Electrical Contact Lubricant Part No 99861 02 c Rotate the hold dovvn clamp to rest the rubber pad on the battery edge Tighten to 15 20 ft lbs 20 27 Nm Awarnine After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 3 Follow Service Manual instructions to install the seat 4 Tum ignition light key to IGNITION to verify neutral indi cator lamp illumination in neutral Test Ride Motorcycle 1 Test ride the motorcycle a Shift into and out of each gear b Shift into and out of neutral c Verify operation of speedometer and vehicle speed sensor 2 Follow Service Manual instructions to perform an engine oil level HOT CHECK Initial Service Follow the Service Manual instructions to replace the trans mission lubricant after 500 miles NOTE After the initial service follow the Scheduled Maintenance Table in the Service Manual and change the engine and transmission fluids at scheduled service intervals 6 of 6
8. er rod to the new 6 speed shift lever tighten lock nuts to 80 120 in lbs 9 0 13 6 Nm Install the exhaust bracket and tighten bolts to 13 16 ft Ibs 18 22 Nm Install oil supply return and breather hoses a Fit new clamps onto ends of hoses b Push and push hoses onto oil fittings c Crimp supply and return clamps with Hose Clamp Pliers HD 41137 d Crimp breather hose clamp with Hose Clamp Pliers HD 97087 65B Secure oil hose cover to transmission and alternately tighten screws to 84 108 in Ibs 10 12 Nm Install the vehicle speed sensor and tighten to 84 132 in lbs 9 5 14 9 Nm Push the neutral indicator light connectors onto the neutral indicator switch Install Primary Chaincase 1 2 Follow the Service Manual PRIMARY CHAINCASE INSTALLATION instructions to install the primary chain case primary chain clutch engine compensating sprocket chain tensioner assembly the starter drive mechanism and the chaincase cover Remove the inspection cover Install Side Cover Release Kit 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 No 38752 04 For hydraulic clutch Follow the instructions in the Hydraulic Clutch Side Cover and Release Pushrod Kit Part No 38753 04 and in the Hydraulic Clutch Kit Part No 45033 03 black or 45388 03 chrome Install Removed Components 1 To install t
9. he components removed to access the 5 speed transmission follow the Service Manual instruc tions in the following sections a REAR SWINGARM INSTALLATION b REAR WHEEL INSTALLATION c STARTER INSTALLATION d EXHAUST SYSTEM INSTALLATION e SADDLEBAGS INSTALLATION J03322 i06772 Figure 4 Ring Dowels oil filler spout and side cover removed i06779 Figure 5 Transmission to Crankcase Torque Sequence transmission view from front Instructions continued on page 6 3 of 6 Part No 33136 04 amp 33137 04 Date 02 05 SUE ervice ar s Screamin Eagle FLHT 6 Speed Transmission 106787 38 J03322 4of6 C N Part No 33136 04 amp 33137 04 Date 02 05 s Service Parts Screamin Eagle FLHT 6 Speed Transmission Description Qty Part No Item Description Qty Part No Gasket sensor plate 35152 03 47 Gasket lid 34904 86D Plate sensor 35153 03 48 Shaft shift fork 34088 87A Gear countershaft 4th 35136 03 49 Support assembly 33304 00 Gear mainshaft 1st 35134 03 50 Sleeve detent arm spring 33375 00A Gear countershaft 35080 03 51 Detent follower assembly 33364 00A Gear 3rd main 2nd counter 2 35083 03 52 Spring detent arm 33374 00 Gear mainshaft 4th 35104 03 53 Pivot screw detent arm 33376 00 Gear 3rd counter 2nd main 2 35135
10. n a jack with a wooden block under the engine and transmission oil pan to support the weight of the 5 speed transmission d REAR SWINGARM REMOVAL e STARTER REMOVAL f CLUTCH RELEASE COVER 1 of 6 Remove the Primary Chaincase Follow the Service Manual PRIMARY CHAINCASE REMOVAL instructions to remove the cover the primary chain clutch engine compensating sprocket chain tensioner assembiy alternator and starter drive mechanism and the primary chaincase Remove the 5 Speed Transmission 1 Remove the locknut lockvvasher and flat vvasher to separate the the shift rod from the 5 speed transmis sion shifter arm Remove oil hose cover and oil hoses at the crankcase a Remove screws and cover b Use side cutters to remove clamps on crankcase end of oil supply return and crankcase breather hoses See Figure 1 Locate vehicle speed sensor and remove screw and the sensor from the existing transmission case See Figure 2 Remove connectors from neutral switch See Figure 3 Remove the fasteners from the transmis sion exhaust bracket Remove the 4 bolts and washers connecting the trans mission to the engine NOTE After removing the bolts the transmission is unattached to the frame or the engine and is resting on the support jack 7 See Figure 4 From the right side slide the transmission toward the rear of the motorcycle to clear the ring dow els and lift the transmission out of the frame Install
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