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1. sm e ZN Ke 61 J 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 Fads fot laeg Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 13 No 8273 IS Customer Support For any installation on service or Questions 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 materials and workmanship for a period of 12 twelve months 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 12 twelve month warranty period or with in 10 ten days thereafter In the event warranty service is required the original purchaser must call or write JIMS immedi ately with the problem Some problems can2. No 8273 1S REV B d ve INSTRUCTIONS FOR THE FOLLOWING PART NOS 8280 8279 8282 8283 8284 8273 8274 8275 These instructions are for installation of both Super Kit or complete transmission for EVO or Twin Cam These instructions are also reference for disassembly Disassembly is the same as assembly but in reverse order READ ALL INSTRUCTIONS BEFORE PERFORMING WORK IF YOU DO NOT KNOW WHAT YOU ARE DOING DO NOT DOIT No information in this instruction sheet pertaining to motorcycle repair is represented as fool proof or even altogether 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 com ponents 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 injury Your work area should be well lit Wear safety glasses over your eyes and protective clothing wh
3. Apply a small amount of lube or Blue Loctite to each of the four 5 16 screws JIMS No 1118 and thread them into the four 5 16 screw holes Torque to 13 16 ft lbs in a criss cross pattern as shown in Figure 5 No 33344 94 NOTE If you have removed the mainshaft protective cover foo already install a lubed tool JIMS No 2256 2 main drive ci NXN gear seal protector inside the main drive gear seal The f d mainshaft protective sleeve covering the clutch hub spline A FIGURE 7 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 Faia fot Havley Varidton Moiorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 7 No 8273 1S REV B Instructions for installing the 1st and 2nd Gear Shift Fork JIMS No 8347 1 Place the final remaining shift fork for the 1st and 2nd gear JIMS No 8347 into fork slot of 1st and 2nd shift ring JIMS No 8341 putting it down through the top cover opening and slide it into the shift ring 2 Slide shift fork shaft JIMS No 34088 87 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 your late HD Service Manual 3 Install shifter shaft set screw JIMS No 3784C supplied in this kit Tighten until you have about 020 end play
4. No 8347 is installed after the Super Kit has been installed into case 12 Place trap door gasket JIMS No 8352 over the two dowel pins on the trans case Refer to your Late H DT Service Manual 2 1 4 in screw 84 108 in lbs 9 5 12 2Nm Quad Seal No 11165 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 Fats for laeg Davidson date 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 6 No 8273 1IS REV B main drive gear 13 Apply a small amount of lube to the inside of the A a Zeg r towards seal on the mainshaft can also be used as a seal protector as the mainshaft is being installed thru the main drive gear S J f as shown in Figure 4 DS A 14 Gently place the gear set trap door assembly S into the case by sliding the mainshaft through the main drive gear bearing and slowly pushing the trap door assembly inward until the trap door makes contact with the two dowel pins in trans case 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 Apply a small amount of lube or Blue Loctite to each of the four 1 4 screws JIMS No 1258 and thread them into the top four 1 4 screw holes Torque to 84 108 in lbs in a criss cross pattern
5. 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 Feifotmance Fania for aeg Davidson date 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 5 No 8273 1IS REV B 8 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 9 Install shifter shaft centering pin BOLT JIMS No 34978 00A supplied in this kit Torque to 10 ft lb Refer to your Late H D Service Manual Caution Center shifter assembly return spring on each side of centering bolt NOTE This model will not require any gear engage ment adjustments Refer to your Late H D Service Manual NOTE 2 of the 3 shift forks will need to be installed into their shift rings as indicated in Figure 3 10 Place 3rd gear fork JIMS No 8348 into Kee SE 3rd gear shift ring JIMS No 8342 at the same time sliding both the fork and shift ring away from trap door so the fork will lay down towards countershaft as shown in Figure 3 11 Place 4th gear fork JIMS No 8349 into Ath and 5th gear shift ring JIMS No 8354 at the same time allowing fork to lay down towards countershaft as shown in Figure 3 Note The last fork for 1st and 2nd gear JIMS
6. on the shifter shaft Instructions for Installing Main Seal Spacer and Torquing Mainshaft Nuts on Primary Side 1 Slide all three shift rings so that they all three engage into matting gears this is to lock the trans to keep the gears from turning 2 Install mainshaft quad seal JIMS No 11165 supplied in this kit over the main drive gear on left side of trans as shown in Figure 6 NOTE Spacer 33344 94 is for late pulley only pulley REFERENCE No 40250 94A 3 Install mainshaft seal spacer JIMS No 33344 94 l IER ools you might already have supplied in this kit over mainshaft bearing boss on Bi f Part No Description left side of trans with the chamfered side to the inside towards seal as shown in Figures 7 and 8 34902 84 Mainshaft Bearing Race Tool 4 Install the drive pulley you will be using Refer to 94660 37A Mainshaft Sprocket Locknut Wrench your HD Service Manual 38515 90 Clutch Spring Compressor Tool 1990 1997 Big Twin Sprocket Locker 5 To install Mega Nut JIMS No 1708 not supplied small Lock Ring Pliers i N Large Lock Ring Pliers in this kit over the main drive gear Follow instruction sheet supplied with Mega Nut External Lock Ring Pliers Maindrive Gear Bearing Tool 6 Install center pushrod JIMS No 37088 85 supplied in this kit Lube both ends and slide pushrod into Mainshaft Special Tools Required to un install JIMS Fat 5 Super Kit Note Some t
7. 00 to 2005 B T H D Service Manual for Shifter Shaft Assembly 3 Using masking tape cover all the trap door flat holes except for the top three The two threaded holes at the top of the trap door flange are used for mounting of the drill plate and the shift fork shaft hole center thru hole is used as the pilot for the drill bits 4 From inside the transmission case tape over all bores as follows e Vehicle speed sensor and mounting screw bores e Transmission top cover and shifter drum support screw bores e Transmission drain hole bore REV B lt A 50 Over Stock Special Tools Required to install JIMS Fat 5 Super Kit Note Some tools are the same as any 5 speed installation tools you might already have Part No Description Mainshaft Sprocket Locknut Wrench 2260 Big Twin Sprocket Locker 1131 Small Lock Ring Pliers 1102 1080 Brass Hammer Main Drive Gear Seal Protector 1664 Shifter Sleeve 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 areg Davidsoni Nlorowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 2 No 8273 IS Warning Be sure drill plate is properly oriented e Main Drive gear bearing bore e Countershaft needle bearing bore e Fork shaft bore e Shifter shaft bore Part No 8042K befo
8. 3 Install top cover gasket JIMS No 34904 86 supplied in this kit per your HD Service Manual 4 Install your top cover Lid with your mounting hardware refer to your HD Service Manual 5 Install vent hose HD part No 42533 91A not supplied in this kit to your top cover elbow fitting Refer to your H D Service Manual Instructions for installing end cover iF Se Install right push rod for clutch JIMS No 8076 supplied in this kit Install end cover JIMS No 8329 supplied in this kit with gasket JIMS No 8352 supplied in this kit Refer to your H D Service Manual Install speed sensor into trap door if applicable NOTE If you will be running an electronic speed sensor you will need to place a sensor cover see special parts list over your sensor hole in trans case and install your electronic speed sensor into the trap door using your favorite gasket sealer If you will not be using an electronic speed sensor in either location trap door or case you will need to order a speed block off plate for the trap door Install speedo block off plate JIMS No 8042K 5 Install speedo block off plate mounting screw JIMS No 1120 by applying a small amount of lube or Blue Loctite to screw and torque to 7 9 ft lbs Fill trans with H D trans lube or equivalent to the same level as a 5 speed trans Refer to your H D Service Manual for reference In the unlikely event that you would nee
9. B J JNO Ell Les Mel ch 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 Fats for aey Davidson date 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 REV B 11 REV B 5 06 No 8273 IS Not used in Kit 8274 or 8275 e 54 II i e 9 De CH lel ees Lei 9 O _ 19 d l Not used in Kit r lt 8274 or 8275 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 Havley Vavidton Moiorcyclet 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 12 REV B 5 06 No 8273 IS S d dh 80 j
10. EAR SHOWN WITH CAP amp SHRINK WRAP Tool No 2256 2 bearing ONLY REV B Instructions for Installing JIMS Fat 5 Super Kit parts into case 1 Install main drive gear bearing JIMS No 8996 using JIMS Tool No 35316 80 Follow the instruction sheet provided with tool or refer to your H D Service Manual NOTE NEVER install any bearings into the case by applying pressure to the inner race Doing so will destroy the bearing Do not remove the mainshaft protective cover Figure 4 on the clutch hub spline end of mainshaft It can be removed after Super Kit has been installed into the trans case 2 Install the new main drive gear retaining ring JIMS No 11061 supplied in this Kit with the bevel facing out Refer to your H D Service Manual 3 Install new main seal JIMS No 12067A supplied in this kit with JIMS Tool No 95660 85 to use with JIMS Tool No 95660 42 Refer to your HD Service Manual Install main drive gear JIMS No 8339 2 using JIMS Tool No 35316 80 Follow the instruction sheet provided with tool or refer to your H D Service Manual Install counter shaft end bearing JIMS No 8977 Refer to your H D Service Manual NOTE Install counter shaft bearing by applying pressure to the LETTER side of 6 Install shifter shaft seal JIMS No 12045 supplied in this kit Refer to your H D Service Manual 7 Install shifter assembly JIMS No 8325 supplied
11. ace new top cover gasket JIMS No 34904 87 on the trans top cover flange 2 Use 4 of your top cover screws to hold gasket 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 1 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 the top cover of all loose material including screw holes as shown in Figure 1 5 With shifter assembly installed in transmission Install top cover with gasket using only 2 screws 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 modifi cation 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 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 Noiowycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 4 No 8273 1IS SHIFT FORK 8348 3rd GEAR SHIFT FORK 8349 4th 5TH G
12. 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 the 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 non conforming condition or for any other breach of contract or duty between JIMS and a customer 4 JIMS parts are designed exclusively for use in Harley Davidson motorcycles JIMS shall have no warranty o
13. d to disassemble this trans you will need a few of JIMS Service Tools For replacement parts see materials list on page 9 WARNING Always disconnect the battery ground cable at the battery to prevent injury Instructions for disassembly of your Fat 5 Speed Overdrive This kit is basically easy to disassemble but does require some special tools See tool list on page 8 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 Feifotmance Fats for Maeg Davidson date 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 9 No 8273 IS gt EC 11 12 de 14 15 REV B Remove primary s and clutch components as indicated in your H D Service Manual Drain oil from trans by removing drain plug from trap door JIMS No 739A or if your trans case has other means of oil drain use that Remove end cover Refer to your H D service manual Remove top cover and shift drum slide all three forks into any gear this is to lock the trans to keep the gears from turning for removal of mainshaft and counter shaft nuts Remove shifter shaft set screw JIMS No 3784C Remove shifter shaft JIMS No 34088 87 Remove 1st and 2nd gear shift fork JIMS No 8347 Remove all trap door hardware holding door to trans case Slide the 3rd gear shift fork amp shift ring a
14. en working around power tools and compressed air Be careful with chemicals when cleaning parts Protect your skin from solvents and use only in a well ventilated area Degreasers are flammable and are a fire hazard Just use common sense and exercise good judgement 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 Peifotmance faria for Maeg Davidson Notater 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 1 No 8273 IS Instructions for preparing the Transmission Case to install JIMS Fat 5 Super Kit Refer to your Service Manual and parts book for the proper year and model you will be installing this kit into for reference Also use a Late H D 2002 Present Big Twin Service Manual and parts book for reference 1 Remove Old Gear set and all Case Bearings per 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 HD 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 supplied in this kit Follow the instruction Sheet provided with JIMS Tool No 1664 not included and refer to any 20
15. knut Mainshaft amp Countershaft Bearing Main Case Bearing Trap Door Retaining Ring Sleeve Shifter Shaft Centering Pin Pushrod Clutch Right Crankshaft Bearing Closed End Main Drive Needle Bearing Screw Upper Trap Door Screw Upper Trap Door Shift Fork 1st amp 2nd Gear Shift Fork 3rd Gear Shift Fork 4th amp 5th Gear Seal Main Case Shaft Shift Fork NOT INCLUDED IN SUPER KITS WIWI Iw Www A IA Ai JNO JNO NO TNO INO NO NO ININ IN J XO 00 Ni JON B GW NO 1S JO 00 IN ON JO BR Je No MO OO IN CAUTION Qt Part No Description 44 Bearing Inner Race 6003 Thrust Washer 8354 Shift Ring 4th amp 5th Mainshaft Pushrod Center Retaining Ring Trap door 51 33304 00 Assy Right Pillow Block Assy Left Pillow Block W Bearing amp Retainer 11342 Retainer Shift Drum 58 Screw Pillow Block 59 Gasket Top Cover 60 25604 00 Ramp Inner Ramp Outer 64 68 Assembly Tan Wire 72405 98BK Assembly Black Wire Terminal 1 4 Ring 14 18 GA Connector 18 20 Screw Chrome Seal Shifter Washer Shifter Retaining Ring Shifter Seal Gear Main Drive Pin Drum 1165 Quad Seal 39A Drain Plug Magnetic 3784C Plug Shifter Shaft 1161 Retaining Ring Main Drive Gear 89 4 1215 Washer Pillow Block Cd 90 1 8273 IS__ Instruction Sheet S S 1 1 1 1 CS EA 1 Ka Ce afi el ESCH 1 esch ON o 1 OO OO NININININININININIO Alz XO OO JON J
16. lvent to remove any metal shavings dust or debris that might remain For best results use a squirt bottle to direct as stream of solvent through the trans top cover opening Repeat procedure as necessary draining excess solvent through the drain hole using low pressure compressed air to thoroughly blow out all solvent 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 arkey Davidsoni Noiowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 3 No 8273 IS REv B 11 Using a clean lightly oiled cloth thoroughly wipe the Inside of the transmission case Repeat this step with a new cloth until the cloth comes out clean 12 Carefully inspect the transmission case for any metal shavings or debris Repeat steps 11 through 13 if any debris is found 13 Remove the masking tape to uncover remaining holes and bores 14 Thoroughly inspect each bore for any metal shavings dust or debris Alternately direct com pressed air into each bore to be certain that it is clean and dry INSTRUCTIONS FOR PREPARING THE TRANSMISSION TOP COVER TO CLEAR THE NEW SHIFTING LEVER WHEN INSTALLING JIMS FAT 5 SUPER KIT INTO ANY 1990 99 BIG TWINS AND 1999 2000 T C FLHT FXR amp FXD MODELS NOTE 2000 Present FXST and 2001 Present FLHT amp FXD models do not need modifying 1 Pl
17. nd 4th 5th gear shift fork amp shift ring away from the trap door so that the forks will lay down towards the countershaft As shown in Figure 3 Install trap door puller Tool JIMS No 1077 by lubing zs all threads of tool and threading trap door puller tool onto trap door Remove trap door slowly making sure shift forks clear case Remove both trap door bearings as you would for any 5 speed rebuild Remove all gears from main and counter shafts as you would for any 5 Speed trans following the parts list as laid out in this instruction sheet Remove any other parts bearings and seals from trans case as you would for any 5 Speed To service main drive gear use JIMS tool No 997 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 Pefotmance Fats for aey Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAx 805 482 7422 10 No 8273 IS Part No Description End Cover Chrome Fat 5 8330 1 Mainshaft Fat 5 Gear 2nd Mainshaft Gear 1st Countershaft Gear 1st Mainshaft Gear 2nd Countershaft Gear 3rd Mainshaft Gear 3rd Countershaft Gear 5th Mainshaft DE es Js NV nid Gear 4th Mainshaft Gear 4th Countershaft Shift ring 1st amp 2nd Countershaft Shift Ring 3rd Mainshaft Spline Sleeve 1st amp 2nd C S Spline Sleeve 3rd M S Loc
18. ools are the same as any 5 speed installation Primary drive Locking Tool 5 speed Main Bearing Remover Main and Counter Shaft Installer Solvent 184 Brass Hammer f Trans Stand 7 Install primary drive refer to your H D Service Modular Engine amp Transmission Stand Kit Manual for the model your installing this kit into IN No Io No No NIO Je J IN IN IMO IA J eN CO 00 CH OO IN LA IN IO LA IU O O JNO O CO BR N IW O 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 laeg Davidson Moioicycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 8 No 8273 1S REV B Instructions for installing shift drum pillow blocks and top lid 1 Place the shift drum assembly with pillow blocks over the 3 Pins of shift forks you may need to move forks as needed to line up with the tracks in the shift drum At the same time aligning the pillow blocks over and onto the 4 split dowel pins Refer to your Late HD Service Manual Install four 1 4 pillow block mounting washers JIMS No 1215 over the four 1 4 pillow block mounting screws JIMS No 2135 Apply a small amount of lube or Blue Loctite to each screw and torque to 7 9 ft lbs in a criss cross pattern Refer to your late HD Service Manual
19. r liability obligation if a JIMS part is used in any other application DISCLAIMER The words Harley H D is a registered trademark and is for reference only Use of H D model designations and part numbers are for reference only JIMS has no associations with and makes no claims against these words trademarks or companies The installation of these parts may void or otherwise adversely affect your factory warranty It is the sole responsibility of the user to determine the suitability of this product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith 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 Feifotmance Fats for aleg Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 e FAX 805 482 7422 REV B 5 06 14
20. re drilling Improper orientation will result in damage that requires replacement of the trans 1708 mission case 8126 4 Fasten drill plate JIMS No 8357 to the top of the trap door flange using old and new speed sensor mounting screws as shown in Figure 1 Spread one or two clean shop cloths inside the trans case to catch the metal shavings and debris Starting with a 3 8 inch drill bit alternately use progressively larger bits to enlarge the fork shaft hole Finish the drilling operation with a 3 4 inch drill bit Remove all remaining material up to the edge of the drill plate with a die grinder or similar tool Remove the drill plate once complete Using emery cloth steel wool or a fine tooth file remove any burrs or ridges that may exist from the drilling or cutting operations Warning Abrasive particles can damage machined surfaces and result in premature failure 9 Carefully pull out shop cloths from inside the trans case Exercise care to keep any debris captured by the cloths from falling into the trans case REV B Special parts needed to install JIMS Fat 5 Super Kit Description Gear oil Speedo Block Off Plate Depending on application Mega Nut Speedo Re Calibration Module Depending on year pulley amp tire size 10 Place drain pan beneath trans case and remove tape from drain hole Thoroughly flush the trans case with a non volatile cleaning solution or so
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