®
INSTRUCTIONS
-J03483
REV. 02-11-2005
Kit Number 33102-03A
6 SPEED TRANSMISSION SUPER KIT
General
This kit fits 2000 and later Softail and 2001 and later Touring model motorcycles. Requires separate purchase of Cable
Sidecover Release Kit or Hydraulic Sidecover Release kit.
See retail catalog for part numbers.
In addition to the above kits, the 2005 Touring Model Service
Manual (Part Number 99483-05) and Main Drive Gear
Remover & Installer Kit (Part Number 35316-B) must be purchased. See your Harley-Davidson dealer.
For a list of items contained in this kit, see the Service Parts illustration.
GEAR STOCK 5-SPEED
First 3.210
Second
Third
2.209
1.572
Fourth
Fifth
Sixth
1.226
1.000
N/A
SE 6-SPEED
3.210
2.209
1.572
1.226
1.000
0.885
b. Unthread bolt and remove battery negative cable
(black) from battery negative (-) terminal.
9449
Figure 1. Install Drill Plate to Transmission Case
1
WARNING
1
WARNING
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
A Service Manual for your model motorcycle is available at any Harley-Davidson Dealer.
Removal
NOTE
Leave the transmission case in the frame unless the case itself requires replacement. For ease of illustration, photographs show the case removed.
1.
Using the appropriate service manual, proceed as follows: a. Drain the primary chaincase and transmission lubricants.
1
WARNING
1
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
d. Remove the primary chaincase cover. Remove the clutch assembly, primary chain, and compensating sprocket components. Remove the starter jackshaft assembly. e. Remove the exhaust system as necessary to gain complete access to the transmission side door.
f. Remove the oil filler spout and starter. g. Remove the primary chaincase.
h. Remove the clutch release cover. Remove the clutch cable from the clutch release cover.
i. Remove the vehicle speed sensor. j. Remove the transmission top cover.
k. Remove the drum support blocks and shift drum.
Remove the drum support block dowels from deck of transmission case.
l. Remove the fork shaft and shifter fork assemblies. m. Remove the bearing inner race from the transmission mainshaft. n. Remove the transmission side door and the mainshaft/countershaft assembly.
NOTE
The front dowel pin may be stuck in the side door after removal. If this occurs, remove the dowel pin from the side door and install it back into the transmission case.
o. Remove the shifter shaft assembly and shifter seal. p. Remove the main drive gear and bearing.
-J03483 1 of 7
NOTE
Detailed instructions on removing the main drive gear and bearing can be found in the 2005 Touring Model Service Manual (Part No. 99483-05),
Section 7.7 MAIN DRIVE GEAR/
BEARING.
q. Remove the countershaft needle bearing.
2.
Using masking tape, cover all the side door flange holes in the transmission case with the exception of the top three.
NOTE
While the two threaded holes at the top of the flange are used for mounting of the drill plate, the fork shaft hole (center thru hole) is used as the pilot for the drill bits.
3.
From inside the transmission case, tape over all bores as follows:
• Vehicle speed sensor and mounting screw bores
• Transmission top cover and shift drum support block screw bores
• Transmission drain hole bore
• Main drive gear bearing bore
• Countershaft needle bearing bore
• Fork shaft bore
• Shifter shaft bore
CAUTION
Be sure drill plate is properly oriented. Improper orientation will result in damage that requires replacement of the transmission case.
4.
Obtain the drill plate (Part No. 35155-03) provided in kit and fasten to top of side door flange using old and new vehicle speed sensor mounting screws.
5.
Spread one or two clean shop cloths inside the transmission case to catch the metal shavings and debris.
6.
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.
7.
Remove all remaining material up to the edge of the drill plate with a die grinder or similar tool. Remove the drill plate.
8.
Using emery cloth, steel wool, or a fine tooth file, remove any burrs or ridges that may exist from the drilling or cutting operation.
CAUTION
Abrasive particles can damage machined surfaces and result in premature failure.
9.
Carefully pull out shop cloths from inside the transmission case. Exercise care to keep any debris captured by the cloths from falling into the transmission case.
10. Place drain pan beneath transmission case and remove tape from drain hole. Thoroughly flush the transmission case with a non-volatile cleaning solution or solvent to remove any metal shavings, dust or debris that might remain. For best results, use a squirt bottle to direct a stream of solvent through the transmission top cover opening. Repeat procedure as necessary draining excess solvent through the drain hole.
11. Using low pressure compressed air, thoroughly blow out all solvent.
12. 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.
13. Carefully inspect the transmission case for any metal shavings or debris. Repeat steps 10 through 12 if any debris is found.
14. Remove the masking tape to uncover remaining holes and bores.
15. Thoroughly inspect each bore for any metal shavings, dust or debris. Alternately direct compressed air into each bore to be certain that it is clean and dry.
Installation
NOTE
Prelube all bearings and shafts with clean transmission or
SYN-3 lubricant prior to installation.
1.
Using the appropriate service manual, proceed as follows: a. Install the countershaft needle bearing.
b. Install the main drive gear and bearing.
NOTE
Detailed instructions on installing the main drive gear and bearing can be found in the 2005 Touring Model Service Manual (Part No. 99483-05),
Section 7.7 MAIN DRIVE GEAR/
BEARING.
c. Install shifter shaft assembly from inside the transmission case. Cover splines of shaft with tape to protect seal. Install the new shifter shaft seal.
Remove tape and install new shifter seal washer and new retaining ring.
2.
Install the transmission side door and mainshaft/countershaft assembly as follows:
Leave the shrink wrap on the mainshaft until side door installation is complete. Installation of the side door with the shrink wrap removed may result in damage to the main drive gear seal.
CAUTION
CAUTION
Be sure to remove the plastic cap and cable strap from the mainshaft before side door installation. Blow away any styrofoam bits or other packaging material that might be clinging to gears or splines.
new
side door gasket on dowels in side door flange of transmission case.
b. Start side door and mainshaft/countershaft assembly into transmission case, but stop so that all gears remain on the outboard side.
-J03483 2 of 7
c. Note that there are three shifter forks, each of which are stamped for easy identification. Set aside the 5-
6 shifter fork, the 3-4 shifter fork and the 1-2 shifter fork in that order.
d. Install the 5-6 shifter fork into the shift ring outboard of the 6th gear on the mainshaft (shift ring closest to the main drive gear). e. Install the 3-4 shifter fork into the shift ring between the 4th and 3rd gears on the mainshaft (shift ring closest to the side door). Be sure the dogs on the shift ring are engaged with mainshaft 3rd gear and then rotate shifter fork toward the countershaft until the slot in the fork engages the edge of the shift ring between 1st and 2nd gears on the countershaft.
This engagement is necessary to obtain the proper clearance for side door installation. f. Slide side door assembly further into transmission case stopping about one inch before mating flanges make contact.
g. Start fork shaft through hole in side door.
h. Through the transmission top cover opening, install the 1-2 shifter fork into the shift ring between 1st and
2nd gears on the countershaft. For proper clearance, be sure the dogs on the 3-4 shift ring (closest to side door on the mainshaft) are fully engaged with mainshaft 4th gear. i. Slide fork shaft through holes in shifter forks and then fully install side door. Be sure that end of fork shaft engages plugged hole on left side of transmission case. j. Install fork shaft set screw in transmission side door.
Tighten screw until the shaft has minimum endplay, but still rotates freely.
side door plug into side door. l. Remove shrink wrap from the mainshaft.
9450
Figure 2. Install 5-6 Shifter Fork Onto Shift Ring
9451
Figure 3. Install 3-4 Shifter Fork Onto Shift Ring
9452
3.
Using the appropriate service manual, proceed as follows:
drum support block dowels in deck of transmission case. Orient the dowels so that the split line is aligned left to right.
drum support blocks with
new
shift drum.
c. Rotating output shaft by hand, shift through all six gears to verify proper operation. Input shaft may need to be rocked back and forth to get all gears to shift. d. Install the mainshaft oil seal, quad seal, spacer sleeve/sprocket spacer, sprocket, and sprocket nut.
NOTE
The 2005 Touring Models Service Manual (Part Number
99483-05) includes detailed instructions on installing the mainshaft oil seal, quad seal, spacer sleeve, sprocket and sprocket nut in
Section 7.7, MAIN DRIVE GEAR/BEARING
.
Figure 4. Install 1-2 Shifter Fork Onto Shift Ring new
bearing inner race onto the transmission mainshaft. f. Install the transmission top cover with
new
gasket.
g. Install primary chaincase.
h. Install the starter and oil filler spout.
-J03483 3 of 7
NOTE
If vehicle is equipped with a shotgun style exhaust system
(FLSTF/I or FXSTD/I), re-use or install new Part Number
3300 longer screws for mounting exhaust bracket to transmission side door. Torque screws to 13-16 ft-lbs (17.6 -21.7 Nm).
i. Install the starter jackshaft assembly. Install the clutch assembly, primary chain, and compensating sprocket components. Install the primary chaincase cover. j. Install drain plug and fill the primary chaincase with the recommended lubricants.
9455
Figure 5. Orient Shift Drum Support Block Dowels
4.
Install plate with gasket over vehicle speed sensor bore in transmission case using existing hardware.
5.
Install vehicle speed sensor at top of transmission side door using
new
O-ring.
1
WARNING
1
WARNING
Pull up on seat to verify that it is properly secured, front and rear. A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury.
6.
Install side cover.
For
Cable Actuated Clutch
: Follow the instructions in the SE 6-Speed Cable Clutch Side Cover and Release
Pushrod Kit (Part Number 38752-04).
For
Hydraulic Clutch
: Follow the instructions in the
Hydraulic Cable Side Cover and Release Pushrod Kit
(Part Number 38753-04), and in the Hydraulic Clutch Kit
(Part Number 45033-03, Black or 45383-03, Chrome).
TRANSMISSION SERVICE
7.
Replace the transmission lubricant after the first 500 miles. Thereafter, refer to the Service Manual and change the lubricant at the recommended service intervals.
-J03483 4 of 7
®
Service Parts
i06794
13 53
34
33
Part No. 33102-03A
Date 02/05
6 Speed Transmission Super Kit
1 5
19
48
24 18
23
18 24
23
27
29
1. Mainshaft
2. Countershaft
3. Countershaft 1st Gear
4. Mainshaft 3rd Gear/
Countershaft 2nd Gear (2)
5. Mainshaft 4th Gear
6. Mainshaft 6th Gear
7. Mainshaft 1st Gear
8. Countershaft 3rd Gear/
Mainshaft 2nd Gear (2)
9. Countershaft 4th Gear
10. Shift Ring, 1-2, 3-4 (2)
11. Shift Ring, 5-6
12. Chrome Trap Door, No Ear
13. Plate Sensor
14. Shift Fork Shaft
15. Shift Fork, 1-2 Assembly
16. Shift Fork, 3-4 Assembly
17. Shift Fork, 5-6 Assembly
18. Split Cage Bearing (5)
19. Door Retaining Ring (2)
20. Trap Door Bearing (2)
21. Mainshaft/Countershaft
Locknut (2)
22. Speedo Sensor O-Ring
23. Mainshaft/Countershaft
Retaining Ring (8)
24. Mainshaft Thrust Washer (2)
25. Sprocket Spacer
26. Mainshaft Race
27. Main Case Seal
28. Case Bearing Retaining Ring
29. Qual Seal
30. Main Case Bearing
31. Mainshaft 5th Gear
32. Pillow Block, Right
33. Sleeve Detent
34. Spring Detent Arm
35. Detent Arm Screw
36. Detent Follower
37. Trap Door Gasket
38. Side Cover Gasket
39. Pushrod Thrust Washer (2)
40. Shifter Seal
41. Shifter Retaining Ring
42. Pillow Block Screw (4)
43. Shift Fork Shaft Screw
44. Countershaft Bearing
45. Clutch Release Cover
Lower Screw (4)
46. Clutch Release Cover
Upper Screw (2)
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.)
48. Upper Trap Door Screw (2)
49. Spline Sleeve (2)
50. Case Modification Tool
51. Shifter Seal Washer
52. Trap Door Plug
53. Sensor Plate Gasket
54. Countershaft Gear, 5th
55. Speedo Sensor Plate Screw
56. Dipstick O-Ring
57. Chrome Dipstick
58. Pillow Block Dowel (4)
59. Shift Drum Assembly
60. Left Pillow Block
61. Shift Drum Retainer
62. Shifter Shaft Assembly
Items Not Shown:
Top Cover Gasket, FLHT and FXST
Oil Fill Spout Gasket, FLHT
-J03483 5 of 7
Part No. 33102-03A
Date 08/04
®
Service Parts
6 Speed Transmission Super Kit
Item Quantity
1.
2.
Mainshaft
Countershaft
3.
Countershaft 1st Gear
4.
Mainshaft 3rd Gear/Countershaft 2nd Gear
5.
Mainshaft 4th Gear
6.
Mainshaft 6th Gear
7.
Mainshaft 1st Gear
8.
Countershaft 3rd Gear/ Mainshaft 2nd Gear
9.
Countershaft 4th Gear
10. Shift Ring, 1-2, 3-4
11. Shift Ring, 5-6
12. Chrome Trap Door, No Ear
13. Plate Sensor
14. Shift Fork Shaft
15. Shift Fork, 1-2 Assembly
16. Shift Fork, 3-4 Assembly
17. Shift Fork, 5-6 Assembly
18. Split Cage Bearing
19. Door Retaining Ring
20. Trap Door Bearing
21. Mainshaft/Countershaft Locknut
22. Speedo Sensor O-Ring
23. Mainshaft/Countershaft
Retaining Ring
24. Mainshaft Thrust Washer
25. Sprocket Spacer
26. Mainshaft Race
27. Main Case Seal
28. Case Bearing Retaining Ring
29. Qual Seal
30. Main Case Bearing
31. Mainshaft 5th Gear
32. Pillow Block, Right
33. Sleeve Detent
34. Spring Detent Arm
35. Detent Arm Screw
36. Detent Follower
37. Trap Door Gasket
38. Side Cover Gasket
39. Pushrod Thrust Washer
40. Shifter Seal
41. Shifter Retaining Ring
42. Pillow Block Screw
43. Shift Fork Shaft Screw
44. Countershaft Bearing
45. Clutch Release Cover
Lower Screw
46. Clutch Release Cover
Upper Screw
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.)
48. Upper Trap Door Screw
49. Spline Sleeve
50. Case Modification Tool
51. Shifter Seal Washer
52. Trap Door Plug
53. Sensor Plate Gasket
1
1
2
1
1
1
2
1
1
1
1
1
1
2
2
2
1
1
5
1
1
2
4
2
1
1
1
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
8
2
1
4
1
1
1
1
1
2
11067
6003
33344-94
34091-85A
12067B
11161
11165
8996A
35237-03
33304-00
33375-00A
33374-00
33376-00
33364-00A
35147-03
35148-03
37313-80
12045
11150
3909
3784
8977
35058-03
35059-03
35080-03
35083-03
35104-03
35131-03
35134-03
35135-03
35136-03
35137-03
35138-03
35158-03
35153-03
34088-87A
35143-03
35144-03
35145-03
8876A
35087-99
8992A
35078-79
11289A
4718A
4717A
3249
4814A
35140-03
35155-03
6497HW
45830-48
35152-03
-J03483 6 of 7
Part No. 33102-03A
Date 08/04
®
Service Parts
6 Speed Transmission Super Kit
Item Quantity
54. Countershaft Gear, 5th
55. Speedo Sensor Plate Screw
56. Dipstick O-Ring
57. Chrome Dipstick
58. Pillow Block Dowel
59. Shift Drum Assembly
60. Left Pillow Block
61. Shift Drum Retainer
62. Shifter Shaft Assembly
1
1
1
4
1
1
1
1
1
35238-03
3594
11132
37075-87
609
35142-03
33301-00A
11342
35146-03
Items Not Shown:
Oil Fill Spout Gasket, FLHT
Top Cover Gasket, FLHT and FXST
1
1
62432-93B
34904-86D
-J03483 7 of 7
®
INSTRUCTIONS
-J03483
REV. 02-11-2005
Kit Number 33102-03A
6 SPEED TRANSMISSION SUPER KIT
General
This kit fits 2000 and later Softail and 2001 and later Touring model motorcycles. Requires separate purchase of Cable
Sidecover Release Kit or Hydraulic Sidecover Release kit.
See retail catalog for part numbers.
In addition to the above kits, the 2005 Touring Model Service
Manual (Part Number 99483-05) and Main Drive Gear
Remover & Installer Kit (Part Number 35316-B) must be purchased. See your Harley-Davidson dealer.
For a list of items contained in this kit, see the Service Parts illustration.
GEAR STOCK 5-SPEED
First 3.210
Second
Third
2.209
1.572
Fourth
Fifth
Sixth
1.226
1.000
N/A
SE 6-SPEED
3.210
2.209
1.572
1.226
1.000
0.885
b. Unthread bolt and remove battery negative cable
(black) from battery negative (-) terminal.
9449
Figure 1. Install Drill Plate to Transmission Case
1
WARNING
1
WARNING
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
A Service Manual for your model motorcycle is available at any Harley-Davidson Dealer.
Removal
NOTE
Leave the transmission case in the frame unless the case itself requires replacement. For ease of illustration, photographs show the case removed.
1.
Using the appropriate service manual, proceed as follows: a. Drain the primary chaincase and transmission lubricants.
1
WARNING
1
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
d. Remove the primary chaincase cover. Remove the clutch assembly, primary chain, and compensating sprocket components. Remove the starter jackshaft assembly. e. Remove the exhaust system as necessary to gain complete access to the transmission side door.
f. Remove the oil filler spout and starter. g. Remove the primary chaincase.
h. Remove the clutch release cover. Remove the clutch cable from the clutch release cover.
i. Remove the vehicle speed sensor. j. Remove the transmission top cover.
k. Remove the drum support blocks and shift drum.
Remove the drum support block dowels from deck of transmission case.
l. Remove the fork shaft and shifter fork assemblies. m. Remove the bearing inner race from the transmission mainshaft. n. Remove the transmission side door and the mainshaft/countershaft assembly.
NOTE
The front dowel pin may be stuck in the side door after removal. If this occurs, remove the dowel pin from the side door and install it back into the transmission case.
o. Remove the shifter shaft assembly and shifter seal. p. Remove the main drive gear and bearing.
-J03483 1 of 7
NOTE
Detailed instructions on removing the main drive gear and bearing can be found in the 2005 Touring Model Service Manual (Part No. 99483-05),
Section 7.7 MAIN DRIVE GEAR/
BEARING.
q. Remove the countershaft needle bearing.
2.
Using masking tape, cover all the side door flange holes in the transmission case with the exception of the top three.
NOTE
While the two threaded holes at the top of the flange are used for mounting of the drill plate, the fork shaft hole (center thru hole) is used as the pilot for the drill bits.
3.
From inside the transmission case, tape over all bores as follows:
• Vehicle speed sensor and mounting screw bores
• Transmission top cover and shift drum support block screw bores
• Transmission drain hole bore
• Main drive gear bearing bore
• Countershaft needle bearing bore
• Fork shaft bore
• Shifter shaft bore
CAUTION
Be sure drill plate is properly oriented. Improper orientation will result in damage that requires replacement of the transmission case.
4.
Obtain the drill plate (Part No. 35155-03) provided in kit and fasten to top of side door flange using old and new vehicle speed sensor mounting screws.
5.
Spread one or two clean shop cloths inside the transmission case to catch the metal shavings and debris.
6.
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.
7.
Remove all remaining material up to the edge of the drill plate with a die grinder or similar tool. Remove the drill plate.
8.
Using emery cloth, steel wool, or a fine tooth file, remove any burrs or ridges that may exist from the drilling or cutting operation.
CAUTION
Abrasive particles can damage machined surfaces and result in premature failure.
9.
Carefully pull out shop cloths from inside the transmission case. Exercise care to keep any debris captured by the cloths from falling into the transmission case.
10. Place drain pan beneath transmission case and remove tape from drain hole. Thoroughly flush the transmission case with a non-volatile cleaning solution or solvent to remove any metal shavings, dust or debris that might remain. For best results, use a squirt bottle to direct a stream of solvent through the transmission top cover opening. Repeat procedure as necessary draining excess solvent through the drain hole.
11. Using low pressure compressed air, thoroughly blow out all solvent.
12. 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.
13. Carefully inspect the transmission case for any metal shavings or debris. Repeat steps 10 through 12 if any debris is found.
14. Remove the masking tape to uncover remaining holes and bores.
15. Thoroughly inspect each bore for any metal shavings, dust or debris. Alternately direct compressed air into each bore to be certain that it is clean and dry.
Installation
NOTE
Prelube all bearings and shafts with clean transmission or
SYN-3 lubricant prior to installation.
1.
Using the appropriate service manual, proceed as follows: a. Install the countershaft needle bearing.
b. Install the main drive gear and bearing.
NOTE
Detailed instructions on installing the main drive gear and bearing can be found in the 2005 Touring Model Service Manual (Part No. 99483-05),
Section 7.7 MAIN DRIVE GEAR/
BEARING.
c. Install shifter shaft assembly from inside the transmission case. Cover splines of shaft with tape to protect seal. Install the new shifter shaft seal.
Remove tape and install new shifter seal washer and new retaining ring.
2.
Install the transmission side door and mainshaft/countershaft assembly as follows:
Leave the shrink wrap on the mainshaft until side door installation is complete. Installation of the side door with the shrink wrap removed may result in damage to the main drive gear seal.
CAUTION
CAUTION
Be sure to remove the plastic cap and cable strap from the mainshaft before side door installation. Blow away any styrofoam bits or other packaging material that might be clinging to gears or splines.
new
side door gasket on dowels in side door flange of transmission case.
b. Start side door and mainshaft/countershaft assembly into transmission case, but stop so that all gears remain on the outboard side.
-J03483 2 of 7
c. Note that there are three shifter forks, each of which are stamped for easy identification. Set aside the 5-
6 shifter fork, the 3-4 shifter fork and the 1-2 shifter fork in that order.
d. Install the 5-6 shifter fork into the shift ring outboard of the 6th gear on the mainshaft (shift ring closest to the main drive gear). e. Install the 3-4 shifter fork into the shift ring between the 4th and 3rd gears on the mainshaft (shift ring closest to the side door). Be sure the dogs on the shift ring are engaged with mainshaft 3rd gear and then rotate shifter fork toward the countershaft until the slot in the fork engages the edge of the shift ring between 1st and 2nd gears on the countershaft.
This engagement is necessary to obtain the proper clearance for side door installation. f. Slide side door assembly further into transmission case stopping about one inch before mating flanges make contact.
g. Start fork shaft through hole in side door.
h. Through the transmission top cover opening, install the 1-2 shifter fork into the shift ring between 1st and
2nd gears on the countershaft. For proper clearance, be sure the dogs on the 3-4 shift ring (closest to side door on the mainshaft) are fully engaged with mainshaft 4th gear. i. Slide fork shaft through holes in shifter forks and then fully install side door. Be sure that end of fork shaft engages plugged hole on left side of transmission case. j. Install fork shaft set screw in transmission side door.
Tighten screw until the shaft has minimum endplay, but still rotates freely.
side door plug into side door. l. Remove shrink wrap from the mainshaft.
9450
Figure 2. Install 5-6 Shifter Fork Onto Shift Ring
9451
Figure 3. Install 3-4 Shifter Fork Onto Shift Ring
9452
3.
Using the appropriate service manual, proceed as follows: of transmission case. Orient the dowels so that the split line is aligned left to right. drum.
c. Rotating output shaft by hand, shift through all six gears to verify proper operation. Input shaft may need to be rocked back and forth to get all gears to shift. d. Install the mainshaft oil seal, quad seal, spacer sleeve/sprocket spacer, sprocket, and sprocket nut.
NOTE
The 2005 Touring Models Service Manual (Part Number
99483-05) includes detailed instructions on installing the mainshaft oil seal, quad seal, spacer sleeve, sprocket and sprocket nut in Section 7.7, MAIN DRIVE GEAR/BEARING.
Figure 4. Install 1-2 Shifter Fork Onto Shift Ring
f. g. h. sion mainshaft.
Install the transmission top cover with new gasket.
Install primary chaincase.
Install the starter and oil filler spout.
-J03483 3 of 7
NOTE
If vehicle is equipped with a shotgun style exhaust system
(FLSTF/I or FXSTD/I), re-use or install new Part Number
3300 longer screws for mounting exhaust bracket to transmission side door. Torque screws to 13-16 ft-lbs (17.6 -21.7 Nm).
i. Install the starter jackshaft assembly. Install the clutch assembly, primary chain, and compensating sprocket components. Install the primary chaincase cover. j. Install drain plug and fill the primary chaincase with the recommended lubricants.
9455
Figure 5. Orient Shift Drum Support Block Dowels
4.
Install plate with gasket over vehicle speed sensor bore in transmission case using existing hardware.
5.
Install vehicle speed sensor at top of transmission side door using new O-ring.
1
WARNING
1
WARNING
Pull up on seat to verify that it is properly secured, front and rear. A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury.
6.
Install side cover.
For Cable Actuated Clutch: Follow the instructions in the SE 6-Speed Cable Clutch Side Cover and Release
Pushrod Kit (Part Number 38752-04).
For Hydraulic Clutch: Follow the instructions in the
Hydraulic Cable Side Cover and Release Pushrod Kit
(Part Number 38753-04), and in the Hydraulic Clutch Kit
(Part Number 45033-03, Black or 45383-03, Chrome).
TRANSMISSION SERVICE
7.
Replace the transmission lubricant after the first 500 miles. Thereafter, refer to the Service Manual and change the lubricant at the recommended service intervals.
-J03483 4 of 7
®
Service Parts
i06794
13 53
34
33
Part No. 33102-03A
Date 02/05
6 Speed Transmission Super Kit
1 5
19
48
24 18
23
18 24
23
27
29
1. Mainshaft
2. Countershaft
3. Countershaft 1st Gear
4. Mainshaft 3rd Gear/
Countershaft 2nd Gear (2)
5. Mainshaft 4th Gear
6. Mainshaft 6th Gear
7. Mainshaft 1st Gear
8. Countershaft 3rd Gear/
Mainshaft 2nd Gear (2)
9. Countershaft 4th Gear
10. Shift Ring, 1-2, 3-4 (2)
11. Shift Ring, 5-6
12. Chrome Trap Door, No Ear
13. Plate Sensor
14. Shift Fork Shaft
15. Shift Fork, 1-2 Assembly
16. Shift Fork, 3-4 Assembly
17. Shift Fork, 5-6 Assembly
18. Split Cage Bearing (5)
19. Door Retaining Ring (2)
20. Trap Door Bearing (2)
21. Mainshaft/Countershaft
Locknut (2)
22. Speedo Sensor O-Ring
23. Mainshaft/Countershaft
Retaining Ring (8)
24. Mainshaft Thrust Washer (2)
25. Sprocket Spacer
26. Mainshaft Race
27. Main Case Seal
28. Case Bearing Retaining Ring
29. Qual Seal
30. Main Case Bearing
31. Mainshaft 5th Gear
32. Pillow Block, Right
33. Sleeve Detent
34. Spring Detent Arm
35. Detent Arm Screw
36. Detent Follower
37. Trap Door Gasket
38. Side Cover Gasket
39. Pushrod Thrust Washer (2)
40. Shifter Seal
41. Shifter Retaining Ring
42. Pillow Block Screw (4)
43. Shift Fork Shaft Screw
44. Countershaft Bearing
45. Clutch Release Cover
Lower Screw (4)
46. Clutch Release Cover
Upper Screw (2)
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.)
48. Upper Trap Door Screw (2)
49. Spline Sleeve (2)
50. Case Modification Tool
51. Shifter Seal Washer
52. Trap Door Plug
53. Sensor Plate Gasket
54. Countershaft Gear, 5th
55. Speedo Sensor Plate Screw
56. Dipstick O-Ring
57. Chrome Dipstick
58. Pillow Block Dowel (4)
59. Shift Drum Assembly
60. Left Pillow Block
61. Shift Drum Retainer
62. Shifter Shaft Assembly
Items Not Shown:
Top Cover Gasket, FLHT and FXST
Oil Fill Spout Gasket, FLHT
-J03483 5 of 7
Part No. 33102-03A
Date 08/04
®
Service Parts
6 Speed Transmission Super Kit
Item Quantity
1.
2.
Mainshaft
Countershaft
3.
Countershaft 1st Gear
4.
Mainshaft 3rd Gear/Countershaft 2nd Gear
5.
Mainshaft 4th Gear
6.
Mainshaft 6th Gear
7.
Mainshaft 1st Gear
8.
Countershaft 3rd Gear/ Mainshaft 2nd Gear
9.
Countershaft 4th Gear
10. Shift Ring, 1-2, 3-4
11. Shift Ring, 5-6
12. Chrome Trap Door, No Ear
13. Plate Sensor
14. Shift Fork Shaft
15. Shift Fork, 1-2 Assembly
16. Shift Fork, 3-4 Assembly
17. Shift Fork, 5-6 Assembly
18. Split Cage Bearing
19. Door Retaining Ring
20. Trap Door Bearing
21. Mainshaft/Countershaft Locknut
22. Speedo Sensor O-Ring
23. Mainshaft/Countershaft
Retaining Ring
24. Mainshaft Thrust Washer
25. Sprocket Spacer
26. Mainshaft Race
27. Main Case Seal
28. Case Bearing Retaining Ring
29. Qual Seal
30. Main Case Bearing
31. Mainshaft 5th Gear
32. Pillow Block, Right
33. Sleeve Detent
34. Spring Detent Arm
35. Detent Arm Screw
36. Detent Follower
37. Trap Door Gasket
38. Side Cover Gasket
39. Pushrod Thrust Washer
40. Shifter Seal
41. Shifter Retaining Ring
42. Pillow Block Screw
43. Shift Fork Shaft Screw
44. Countershaft Bearing
45. Clutch Release Cover
Lower Screw
46. Clutch Release Cover
Upper Screw
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.)
48. Upper Trap Door Screw
49. Spline Sleeve
50. Case Modification Tool
51. Shifter Seal Washer
52. Trap Door Plug
53. Sensor Plate Gasket
1
1
2
1
1
1
2
1
1
1
1
1
1
2
2
2
1
1
5
1
1
2
4
2
1
1
1
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
8
2
1
4
1
1
1
1
1
2
11067
6003
33344-94
34091-85A
12067B
11161
11165
8996A
35237-03
33304-00
33375-00A
33374-00
33376-00
33364-00A
35147-03
35148-03
37313-80
12045
11150
3909
3784
8977
35058-03
35059-03
35080-03
35083-03
35104-03
35131-03
35134-03
35135-03
35136-03
35137-03
35138-03
35158-03
35153-03
34088-87A
35143-03
35144-03
35145-03
8876A
35087-99
8992A
35078-79
11289A
4718A
4717A
3249
4814A
35140-03
35155-03
6497HW
45830-48
35152-03
-J03483 6 of 7
Part No. 33102-03A
Date 08/04
®
Service Parts
6 Speed Transmission Super Kit
Item Quantity
54. Countershaft Gear, 5th
55. Speedo Sensor Plate Screw
56. Dipstick O-Ring
57. Chrome Dipstick
58. Pillow Block Dowel
59. Shift Drum Assembly
60. Left Pillow Block
61. Shift Drum Retainer
62. Shifter Shaft Assembly
1
1
1
4
1
1
1
1
1
35238-03
3594
11132
37075-87
609
35142-03
33301-00A
11342
35146-03
Items Not Shown:
Oil Fill Spout Gasket, FLHT
Top Cover Gasket, FLHT and FXST
1
1
62432-93B
34904-86D
-J03483 7 of 7
