INSTRUCTIONS - HARLEY-DAVIDSON Rostock GmbH
Contents
1. 10 ml of transmission lubricant or until the lubricant level on the dipstick of the filler plug is at the FULL mark with the motorcycle in a level upright position and the filler plug resting on the threads 14 Install the transmission filler plug dipstick in the clutch release cover Tighten the plug to 25 75 in Ibs 2 8 8 5 Nm 15 Adjust the clutch cable See CLUTCH ADJUSTMENT in your service manual 16 Install the exhaust system See EXHAUST SYSTEM INSTALLATION in your service manual 17 Refer to your Exhaust System in your Service Manual and follow the instructions given to install the complete exhaust with heat shields J03475 Awarnine Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a WARNING 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 18 Refer to your Service Manual and follow instructions given to reconnect the battery cables positive cable first and install the seat 19 See your Service Manual TRANSMISSION LUBRI CANT and replace the transmission fluid after the first 500 miles Refer to your Service Manual and follow the instruc tions for the proper service in2. cMOTOR2 HARLEY DAVIDSON WY J03475 INSTRUCTIONS REV 09 10 2004 Kit Numbers 38752 04 CABLE SIDECOVER RELEASE KIT FOR SCREAMIN EAGLE 6 SPEED TRANSMISSION General This kit is designed to fit motorcycles equipped with Screamin Eagle 6 speed transmissions WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate Service Manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer per form the installation Improper installation of this kit could result in death or serious injury 00333a NOTE A Service Manual for your model motorcycle is available from any Harley Davidson Dealer To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a 1 Disconnect battery cables negative cable first 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 Clutch Release Cover Assembly 1 Install clutch cable fitting into clutch release cover Do not tighten cable fitting at this time NOTE Replace cable fitting O ring if damaged or deformed NOTE Stock 5 Speed Side Cover is shown for illustration purposes only in Figure 1 N See Figu
3. re 1 Place outer ramp 1 in clutch release cover 2 recess with tang 3 in cover slot w Apply a multi purpose grease to the three balls 4 and outer ramp sockets 5 Place a ball in each of three outer ramp sockets ha Hold coupling 6 with button facing outboard Place cable end in recess of coupling With ball sockets facing outboard place hook of inner ramp 7 on button of cou plng Holding inner ramp and coupling together turn the assembly over a Place inner ramp ball socket side down over balls in outer ramp sockets WARNING 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 6 Install the retaining ring so that the opening is above and to the right of the outer ramp tang slot in the clutch release cover NOTE Obtain the Screamin Eagle 6 Speed Side Cover Gasket H D Part Number 35148 03 supplied with the 6 Speed Transmission or Gear Set Kit This gasket is also sold separately 7 See Service Parts List a Apply transmission lubricant or SYN3 to both ends of the center clutch pushrod 10 and install center pushrod into the mainshaft Outer ramp Clutch release cover Tang Balls Outer ramp socket Coupling Inner ramp Figure 1 Install Outer Ramp and Balls 1 of 3 b Assemble the right clutch pushrod 9 by placing one pushrod thrust
4. terval thereafter 2of3 SMOTORZ e Part No 38752 04 Date 9 04 Service Parts Cable Sidecover Release Kit for Screamin Eagle 6 Speed Transmissions i06752 ee N 7 Description Part No Ramp ball bearing 3 8873 Outer ramp 25605 00 Inner ramp 25604 00 Ramp retaining ring 10998 Chrome clutch release cover 35157 03 Pushrod thrust washer 2 37313 80 Pushrod bearing 37312 75 Pushrod retaining ring 11096 Clutch pushrod right 35149 03 Clutch pushrod center 37088 85 Clutch cable coupler 34920 86A SE TTE g J03475 3 of 3
5. washer 6 over the small end of the right pushrod Apply transmission lubricant or SYN3 to pushrod bearing 7 and install on small end of the right pushrod Install the next pushrod thrust washer 6 on the small end of the right pushrod Gently install the pushrod retaining ring 8 into the right pushrod groove Ensure that the retaining ring is fully seated in the groove c Install the right pushrod assembly into the main shaft after the center pushrod 8 Hang a new gasket on the dowels NOTE Obtain two 2 1 4 in 67mm long screws H D Part Number 4717A and four 1 1 2 in 38mm long screws H D Part Number 4718A These items are supplied with the 6 Speed Transmission or Gear Set and are also sold separately 9 Holding clutch release cover in position install six sock et head screws Tighten screws to 84 132 in lbs 9 5 14 9 Nm 10 Tighten clutch cable fitting to 36 60 in Ibs 4 7 Nm 11 Check the O ring on the transmission lubricant drain plug for tears cuts or general deterioration Replace as necessary Install the transmission lubricant drain plug and tighten to 14 21 ft lbs 19 28 Nm CAUTION Do not overtighten filler or drain plugs Overtightening plugs may cause leaks 12 Obtain the Transmission filler plug dipstick H D Part Number 37075 87 and O ring H D Part Number 11132 supplied with 6 Speed Transmission or Gear Set Install O ring on dipstick 13 Fill the transmission with 20 24 oz 590 7
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