Owner manual

ManualsBrandsS&S Cycle ManualsFor motorcyclesAll-Helical Transmission Gear Set Cassettes for Harley-Davidson 1991-05 Dyna, 1991-06 FLT and Softail models, and Custom Applications

S&S

Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603

Phone: 608-627-1497 • Fax: 608-627-1488

Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: sstech@sscycle.com

Website: www.sscycle.com

Because every industry has a leader

Installation Instructions for S&S

All-Helical Transmission

Gear Set Cassettes for Harley-Davidson

1991-’05 Dyna

1991-’06 FLT and Softail

models, and Custom Applications

Instruction 51-1232

7-12-07

2006, 2007

by S&S Cycle, Inc.

Printed in the U.S.A.

SAFE INSTALLATION AND OPERATION RULES:

Before installing your new S&S part it is your responsibility to read and

follow the installation and maintenance procedures in these

instructions and follow the basic rules below for your personal safety.

● Gasoline is extremely flammable and explosive under certain

conditions and toxic when breathed. Do not smoke. Perform

installation in a well ventilated area away from open flames or sparks.

● If motorcycle has been running, wait until engine and exhaust pipes

have cooled down to avoid getting burned before perfor

ming any

installation steps.

● Before performing any installation steps disconnect battery to

eliminate potential sparks and inadvertent engagement of starter while

working on electrical components.

● Read instructions thoroughly and carefully so all procedures are

completely understood before performing any installation steps.

Contact S&S with any questions you may have if any steps are unclear

or any abnormalities occur during installation or operation of

motorcycle with a S&S part on it.

● Consult an appropriate service manual for your motorcycle for correct

disassembly and reassembly procedur

es for any parts that need to be

removed to facilitate installation.

● Use good judgement when performing installation and operating

motorcycle. Good judgement begins with a clear head. Don't let

alcohol, drugs or fatigue impair your judgement. Star

t installation

when you are fresh.

● Be sure all federal, state and local laws are obeyed with the

installation.

● For optimum performance and safety and to minimize potential

damage to carb or other components, use all mounting hardwar

e that

is provided and follow all installation instructions.

● Motorcycle exhaust fumes are toxic and poisonous and must not

be breathed. Run motorcycle in a well ventilated area where fumes

can dissipate.

DISCLAIMER:

S&S parts are designed for high performance, off road, racing

applications and are intended for the very experienced rider only. The

installation of S&S parts may void or adversely effect your factory

warranty. In addition such installation and use may violate certain

federal, state, and local laws, rules and ordinances as well as other laws

when used on motor vehicles used on public highways, especially in

states where pollution laws may apply. Always check federal, state, and

local laws before modifying your motorcycle. It is the sole and exclusive

responsibility of the user to determine the suitability of the 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.

The words Harley

, Harley-Davidson

, H-D

, Sportster

, Evolution

, and

all H-D part numbers and model designations are used in reference only.

S&S Cycle is not associated with Harley-Davidson, Inc.

IMPORTANT NOTICE:

Statements in this instruction sheet preceded by the following words

are of special significance.

WARNING

Means ther

e is the possibility of injury to yourself or others.

CAUTION

Means there is the possibility of damage to the part or motorcycle.

NOTE

Other information of particular importance has been placed in italic type.

S&S recommends you take special notice of these items.

WARRANTY:

All S&S parts are guaranteed to the original purchaser to be free of

manufacturing defects in materials and workmanship for a period of

twelve (12) months from the date of purchase. Merchandise that fails

to conform to these conditions will be repaired or replaced at S&S’s

option if the parts are returned to us by the purchaser within the 12

month warranty period or within 10 days thereafter.

In the event warranty service is required, the original purchaser must

call or write S&S immediately with the problem. Some problems can be

rectified by a telephone call and need no further course of action.

A part that is suspect of being defective must not be replaced by a

Dealer without prior authorization from S&S. If it is deemed necessary

for S&S to make an evaluation to determine whether the part was

defective, a return authorization number must be obtained from S&S.

The parts must be packaged properly so as to not cause further damage

and be returned prepaid to S&S with a copy of the original invoice of

purchase and a detailed letter outlining 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 S&S and the part was found to be

defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS:

(1) S&S shall have no obligation in the event an S&S part is modified by

any other person or organization.

(2) S&S shall have no obligation if an S&S 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 S&S part.

(3) S&S shall not be liable for any consequential or incidental damages

resulting from the failure of an S&S 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 S&S and

a customer.

(4) S&S parts are designed exclusively for use in Harley-Davidson

and

other American v-twin motorcycles. S&S shall have no warranty or

liability obligation if an S&S part is used in any other application.

Summary of content (20 pages)

PAGE 1
S&S Cycle, Inc. ® Instruction 51-1232 7-12-07 Copyright © 235 Causeway Blvd. La Crosse, Wisconsin 54603 2006, 2007 by S&S Cycle, Inc. Phone: 608-627-1497 • Fax: 608-627-1488 All rights reserved. Printed in the U.S.A. Technical Service Phone: 608-627-TECH (8324) Technical Service Email: sstech@sscycle.com Website: www.sscycle.
PAGE 2
S&S® Cycle Cassette Assembly Installation Instructions SPECIAL TOOL REQUIREMENTS ● Inner Primary Bearing Race Puller, S&S PN 56-5141 ● Inner Primary Bearing Race Installer, S&S PN 56-5145 ● Main Drive Gear Remover/Installer & Bearing Installer ● Primary Drive Locking Tool ● Mainshaft Locknut Wrench ● Output Sprocket Locking Tool ● Shift Shaft Sleeve Remover/Installer CASSETTE CONTENTS For more information see exploded view on pages 14-15.
PAGE 3
WARNING The safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilities or do not have the correct tools for this installation, please consult a shop to have it done. Improper installation of this product could result in injury or death to the rider. WARNING Be sure to disconnect the battery of your motorcycle before starting on this procedure.
PAGE 4
5-STEP MODIFICATION 1. 3-4 Shift Fork Clearance 2. Shift Linkage Clearance 3. First Gear Clearance 4. 5-6 Shift Fork Clearance 5. Clean Up 1. 3-4 Shift Fork Clearance Due to the multiple transmission cases that the S&S® cassette fits, clearance will be required in several locations to facilitate a successful installation. See Picture 1 below for required clearance locations. As always, be sure to verify proper clearance has been created by mocking-up the affected components.
PAGE 5
C. Position the clearance template on the side door uncovered holes using two 1⁄4 x 20 x 1” screws with the words THIS SIDE OUT facing you as shown in Picture 5. Position the template so that it is flush with the top edge of the transmission housing. Use a scribe or fine-tip marking pen to trace the outline of the guide and then remove the template. Flush with this surface. Picture 4 D. E. Picture 5 Spread out a few shop rags to catch any metal shavings that fall during the clearancing process.
PAGE 6
F. Use a deburring tool, file or sandpaper to remove any rough edges or chips from the clearanced area as illustrated in Picture 8. Picture 8 2. Shift Linkage Clearance A. Remove shift shaft sleeve by using remover tool H-D® #35156-03 to drive the original sleeve out of the transmission case. See Picture 9.
PAGE 7
B. Follow the guidelines in your factory service manual to install the sleeve in the shifter shaft bore. NOTE: The new S&S® 1.480” sleeve is a special length for the S&S® transmission, so when you use the remover tool H-D® #35156-03, you will need to install a spacer of approximately 1⁄2” to the tool set. See Picture 10. 1) Install the shift-shaft sleeve as follows: Place the S&S® 1.480” sleeve over the installer.
PAGE 8
4) 5) 6) 7) 8) Tighten the installer until the sleeve stops against the thrust washer. Remove the installation tool and verify the sleeve is flush with the counter-bore surface on the outside of the case. Lubricate the inside of the sleeve and the outside of the new S&S shifter shaft pawl. Slide the new shifter shaft pawl into the sleeve. See Picture 12. Verify that the shift pawl has full rotation. If there is interference, grind the case surface until the shift pawl sweeps without binding.
PAGE 9
4. 5-6 Shift Fork Clearance Some FLT models will require clearance for the 5-6 shift fork as indicated in Picture 20. A. Insert the 5-6 shift fork and shift shaft into the case. B. Starting in the center of the shift shaft, sweep the fork toward the back of the case until it contacts the inside of the case. C. Slide the fork toward the main drive gear bearing bore and note the material that pushes the fork toward the front of the case.
PAGE 10
INSTALLATION WARNING The safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilities or do not have the correct tools for this installation, please consult a shop to have it done. Improper installation of this product could result in injury or death to the rider. 1. Install the provided S&S® shift pawl centering screw (PN 56-1002 adjuster, PN 50-5044 nut) as shown in bottom of Picture 17. It is eccentric to allow more precise adjustments.
PAGE 11
4. Align and install the S&S® shift forks and shaft on the gearset. The largest shift fork (3-4) is installed closest to the transmission door. Next, the small-notch fork (1-2) rides in the center and the flat notch fork (5-6) is installed closest to the primary as shown below. Note the direction of shift shaft installation shown below. 3-4 1-2 5-6 Stepped-end of shift shaft Picture 19 CAUTION Do not use bolts to draw trap door onto case. This may strip the case threads. 5.
PAGE 12
8. Verify the clearance between the 3-4 shift fork and the modified portion of the case is a minimum of .030" to allow full travel of the shift fork (Picture 21). If there is not enough clearance make sure to remove the cassette and cover all the bearings and surfaces again—before removing any material. Do not skip this operation as premature wear or failure could result from chips getting caught in the transmission. Verify .030" clearance between shift fork and case. Picture 21 9.
PAGE 13
NOTE: Due to a stack-up of tolerance in transmission cases that are machined by other manufacturers, it may be necessary to manually adjust the shift pawl linkage to prevent shift pawl from contacting the drum or the housing for the drum bearing support. 12. Shift pawl to shift drum and shift pawl to drum bearing support clearance: a. b. c. Sweep shift arm in an upshift direction and measure the clearance to the shift drum using a feeler gauge while pressing in on the end of the shift shaft.
PAGE 14
NOTE: It is important that you pay special attention to shift pawl adjustment. The adjustment of the shift pawl is directly related to proper function and smoothness of shifting. 17. FLT and Harley-Davidson® Softail® Transmission Top Cover Verify transmission top cover clearance to the shift pawl by using clay or machinists dye. Clearance as necessary. Then, install the top transmission cover with the supplied gasket. Use blue threadlock on the screws and torque them to 7-9 ft-lbs.
PAGE 15
18. Now install the new S&S neutral switch (3-5 ft-lbs) and speed sensor cover (6-8 ft-lbs) on the transmission case. NOTE: 1991-’97 models have a single-wire neutral switch which will not work with the S&S two-wire switch. Changing to the two-wire switch will require wiring harness part numbers: H-D #72405-98TN and H-D #72405-98BK. Convert the wiring by following the procedure below: a. Cut the existing single pin connector off and splice the tan wire in its place. b.
PAGE 16
NOTE: If using S&S® hydraulic clutch side cover kit PN 56-4060 follow instructions included with the kit. 22. Fill the transmission with 20-24 ounces of 90 weight gear oil or equivalent. NOTE: S&S offers an extension for the oil filler spout on FLT models—PN 56-1292 (not included in this kit). Be sure that the flat edge is up, directed toward the transmission side cover as shown in Picture 37.
PAGE 17
NOTE: Use of the stock 32-tooth pulley with the S&S® transmission will result in an extremely low overall first gear ratio. S&S provides a 34-tooth pulley to counter-act the lower internal first gear ratio by changing the final drive ratio with the provided pulley. Picture 40 25. Position the drive belt over the S&S 34-tooth pulley. This may require removing the rear axle to allow enough slack in the belt to fit over the pulley. a.
PAGE 18
REPLACEMENT PARTS FOR S&S® 6-SPEED TRANSMISSIONS 3 48 21 20 42 49 2 & 43 3 3 3 14 2 24 9 17 15 16 30 18 2 19 7 & 46 39 1. Trap door, S&S 6-speed transmission Harley-Davidson® 2000-’06 Softail®/ 1991-’06 FLT models .....56-1221 1991-’05 DynaTM, 1990-up FXR, 1991-’99 Softail .....................56-1253 2. Kit, gaskets and seals-1991-’06 Softail (S&S complete trans) ....56-1226 3. Hardware kit, 6-Speed transmission ........................................56-1227 4.
PAGE 19
CONTINUED... Replacement Parts for S&S® 6-Speed Transmissions 35. Gear, first, mainshaft, S&S 6-speed .............................................56-5128 42. S&S inner primary bearing race- optional .................................56-5089 36. Gear, second, mainshaft, S&S 6-speed........................................56-5129 43. Gasket top cover (10 pack) Softail®, FLT ....................................................................................56-5107 37. Gear, fifth, mainshaft, S&S 6-speed ..
PAGE 20
TRANSMISSION SERVICE NOTE: S&S recommends filling transmission with 20-24 ounces of 90 weight gear oil or equivalent. 1. Perform an initial fluid change at 500 miles. 2. Change fluid at 5,000 miles. 3. Service transmission fluid every 5,000 miles thereafter. Recommended Final Belt Drive Gearing ● S&S recommends that you use a 32- or 34-tooth output pulley with a 65-tooth rear pulley. ● S&S recommends the use of our 34-tooth output pulley with a 70-tooth rear pulley.