6 SPEED TRANSMISSION SUPER KIT - Harley

6 SPEED TRANSMISSION SUPER KIT - Harley
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REV. 2005-10-05
6 SPEED TRANSMISSION SUPER KIT
GENERAL
Kit Number
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
33103-03A
Models
This kit fits 2001 to 2005 Dyna™ model motorcycles.
Table 1. Gear Ratio
GEAR
STOCK 5-SPEED
SE 6-SPEED
First
3.210
3.210
Second
2.209
2.209
Third
1.572
1.572
Fourth
1.226
1.226
Fifth
1.000
1.000
Sixth
N/A
0.885
NOTES
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.
Detailed instructions on removing the main drive gear and
bearing can be found in the 2005 Touring Model Service
Manual (Part Number 99483-05), Section 7.7 MAIN DRIVE
GEAR/ BEARING
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.
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Additional Parts Required
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 Dyna 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.
A Service Manual for your model motorcycle is available at
any Harley-Davidson Dealer.
Figure 1. Install Drill Plate to Transmission Case
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 a HarleyDavidson dealer perform the installation. Improper installation of this kit could result in death or serious injury.
(00308a)
Kit Contents
See Figure 6 and Table 3.
REMOVAL
NOTE
Leave the transmission case in the frame unless the case itself
requires replacement. For ease of illustration, photographs
show the case removed.
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1.
Using the appropriate service manual, proceed as follows:
a.
Drain the primary chaincase and transmission lubricants.
b.
Unthread bolt and remove battery negative cable
(black) from battery negative (-) terminal.
c.
Remove the primary chaincase cover. Remove the
clutch assembly, primary chain, and compensating
sprocket components. Remove the starter jackshaft
assembly and primary chaincase.
d.
Remove the exhaust system as necessary to gain
complete access to the transmission side door.
e.
Remove the starter.
f.
See Figure 1. Obtain the drill plate (Part Number 3515503) 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.
Always wear proper eye protection when drilling. Flying
debris could cause serious eye injury. (00402c)
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.
Remove the clutch release cover. Remove the clutch
cable from the clutch release cover.
7.
Remove all remaining material up to the edge of the drill
plate with a die grinder or similar tool.
g.
Remove the vehicle speed sensor.
8.
h.
Remove the transmission top cover.
Using emery cloth, steel wool, or a fine tooth file, remove
any burrs or ridges that may exist from the drilling or cutting operation.
i.
Remove the drum support blocks and shift drum.
Remove the drum support block dowels from deck of
transmission case.
NOTE
Abrasive particles can damage machined surfaces and result
in premature failure.
j.
Remove the fork shaft and shifter fork assemblies.
9.
k.
Remove the bearing inner race from the transmission
mainshaft.
l.
Remove the transmission side door and the mainshaft/ countershaft assembly.
m. Remove the shifter shaft assembly and shifter seal.
n.
Remove the main drive gear and bearing.
o.
Remove the countershaft needle bearing.
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.
2.
4.
Using masking tape, cover all the side door flange holes
in the transmission case with the exception of the top
three.
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
NOTE
Be sure drill plate is properly oriented. Improper orientation will
result in damage that requires replacement of the transmission
case.
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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
NOTES
Detailed instructions on installing the main drive gear and
bearing can be found in the 2005 Touring Model Service
Manual (Part Number 99483-05), Section 7.7 MAIN DRIVE
GEAR/ BEARING
Prelube all bearings and shafts with clean transmission lubricant prior to installation.
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1.
Using the appropriate service manual, proceed as follows:
a.
Install the countershaft needle bearing.
b.
Install the main drive gear and bearing.
c.
Install the new shifter seal. Install shifter shaft
assembly from inside the transmission case. Install
new shifter seal washer and new retaining ring.
The 2005 Touring Models Service manual (Part Number 9948305) 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 .
3.
Using the appropriate service manual, proceed as follows:
a.
Install four new drum support block dowels in deck
of transmission case. Orient the dowels so that the
split line is aligned left to right. Install new drum support blocks with new shift drum.
b.
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.
c.
Install the mainshaft oil seal, quad seal, spacer
sleeve/sprocket spacer, sprocket, and sprocket nut.
d.
Install the new bearing inner race onto the transmission mainshaft.
Hang new side door gasket on dowels in side door
flange of transmission case.
e.
Install the transmission top cover with new gasket.
f.
Install the starter.
b.
Start side door and mainshaft/countershaft assembly
into transmission case, but stop so that all gears
remain on the outboard side.
g.
c.
Note that there are three shifter forks, each of which
are stamped for easy identification. Set aside the 56 shifter fork, the 3-4 shifter fork and the 1-2 shifter
fork in that order.
Install the primary chaincase and starter jackshaft
assembly. Install the clutch assembly, primary chain,
and compensating sprocket components. Install the
primary chaincase cover.
h.
Install drain plug and fill the primary chaincase with
the recommended lubricants.
NOTES
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.
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.
2.
NOTE
Install the transmission side door and mainshaft/countershaft assembly as follows:
a.
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 blind 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.
k.
Install new side door plug into side door.
l.
Remove shrink wrap from the mainshaft.
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Figure 2. Install 5-6 Shifter Fork Onto Shift Ring
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Figure 3. Install 3-4 Shifter Fork Onto Shift Ring
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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.
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
Figure 4. Install 1-2 Shifter Fork Onto Shift Ring
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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.
Figure 5. Orient Shift Drum Support Block Dowels
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SERVICE PARTS
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57
56
55
54
35
36 53 35
1213 14
36
63
62
49 52
44
36
47
16
35
15
35
17
36
34
43
60 61
21
33
5
32
20 18 19
39
10 4
6
8
7
11
45
41
37 46
40
41
39
20 18 19
59 42
9
8
58
50
32
10 4
3
51
23 24 22 22 23 23 2224
23
31
1
2
30 28 27 29 25
26
23 38
48
23 23 23
22
22
Figure 6. Service Parts: 6 Speed Transmission Super Kit
Table 2. Service Parts Table
Item
Description (Quantity)
Item
Description (Quantity)
1
Mainshaft
33
Chrome Trap Door with Ear
2
Countershaft
34
Shifter Shaft Assembly
3
Countershaft 1st Gear
35
Pillow Block Dowel (4)
4
Mainshaft 3rd Gear/Countershaft 2nd Gear (2)
36
Pillow Block Screw (4)
5
Mainshaft 4th Gear
37
Trap Door Plug
6
Mainshaft 6th Gear
38
Countershaft Bearing
7
Mainshaft 1th Gear
39
Lower Clutch RLS CVR Screw (4)
8
Countershaft 3rd Gear/Mainshaft 2nd Gear (2)
40
Upper Clutch RLS CVR Screw (2)
9
Countershaft 4th Gear
41
Lower Trap Door Screw (3)
10
Shift Ring, 1-2, 3-4 (2)
42
Upper Trap Door Screw
11
Shift Ring, 5-6
43
Shift Fork Shaft
12
Shift Drum Assembly
44
Case Modification Tool
13
Pillow Block, Left
45
Shifter Seal Washer
14
Shift Drum Retainer
46
Shift Fork Shaft Screw
15
Shifter Fork, 1-2 Assembly
47
Sensor Plate Gasket
16
Shifter Fork, 3-4 Assembly
48
Countershaft, 5th Gear
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Table 2. Service Parts Table
Item
Description (Quantity)
Item
Description (Quantity)
17
Shifter Fork, 5-6 Assembly
49
Speedo Sensor Plate Screw
18
Door Retainer Ring (2)
50
Dipstick O-Ring
19
Trap Door Bearing (2)
51
Chrome Dipstick
20
Mainshaft/Countershaft Locknut (2)
52
Sensor Plate
21
Speed Sensor O-Ring
53
Pillow Block, Right
22
Split Cage Bearing (5)
54
Sleeve Detent
23
Mainshaft/Countershaft Retaing Ring (8)
55
Detent Follower
24
Mainshaft Thrust Washer (2)
56
Spring Detent Arm
25
Spacer Sprocket
57
Screw Detent Arm
26
Mainshaft Race
58
Trap Door Gasket
27
Main Case Seal
59
Side Cover Gasket
28
Case Bearing Retaining Ring
60
Shifter Seal
29
Quad Seal
61
Shifter Retaining Ring
30
Main Case Bearing
62
Lower Trap Door Stud
31
Mainshaft 5th Gear
63
Upper Trap Door Stud
32
Spline Sleeve (2)
64
Lid Gasket, (FXD Models)
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Table 3. Service Parts: 6 Speed Transmission Super Kit
Item
Description (Quantity)
Part Number
Item
Description (Quantity)
Part Number
1
Mainshaft
35058-03
34
Shifter Shaft Assembly
35146-03
2
Countershaft
35059-03
35
Pillow Block Dowel (4)
609
3
Countershaft 1st Gear
35080-03
36
Pillow Block Screw (4)
3909
4
Mainshaft 3rd Gear/Countershaft 35083-03
2nd Gear (2)
37
Trap Door Plug
45830-48
5
Mainshaft 4th Gear
35104-03
38
Countershaft Bearing
8977
6
Mainshaft 6th Gear
35131-03
39
Lower Clutch RLS CVR Screw (4) 4718A
7
Mainshaft 1st Gear
35134-03
40
Upper Clutch RLS CVR Screw (2) 4717A
8
Countershaft 3rd Gear/ Mainshaft 35135-03
2nd Gear (2)
41
Lower Trap Door Screw (3)
3249
9
Countershaft 4th Gear
35136-03
42
Upper Trap Door Screw
4814A
10
Shift Ring, 1-2, 3-4 (2)
35137-03
43
Shift Fork Shaft (4)
34088-87A
11
Shift Ring, 5-6
35138-03
44
Case Modification Tool
35155-03
12
Shift Drum Assembly
35142-03
45
Shifter Seal Washer (4)
6497HW
13
Pillow Block, Left
33301-00A
46
Shift Fork Shaft Screw (2)
3784
14
Shift Drum Retainer
11342
47
Sensor Plate Gasket (3)
35152-03
15
Shifter Fork, 1-2 Assembly
35143-03
48
Countershaft, 5th Gear
35238-03
16
Shifter Fork, 3-4 Assembly
35144-03
49
Speedo Sensor Plate Screw
4705
17
Shifter Fork, 5-6 Assembly
35145-03
50
Dipstick O-Ring
11132
18
Trap Door Bearing (2)
35087-99
51
Chrome Dipstick
37075-87
19
Trap Door Bearing (2)
8992A
52
Sensor Plate
35153-03
20
Mainshaft/Countershaft Locknut
(2)
35078-79
53
Pillow Block, Right
33304-00
21
Speed Sensor O-Ring
11289A
54
Sleeve Detent
33375-00A
22
Split Cage Bearing (5)
8876A
55
Detent Follower
33364-00A
23
Mainshaft/Countershaft Retaing
Ring (8)
11067
56
Spring Detent Arm
33374-00
24
Mainshaft Thrust Washer (2)
6003
57
Screw Detent Arm
33376-00
25
Spacer Sprocket
33344-94
58
Trap Door Gasket
35147-03
26
Mainshaft Race
34091-85A
59
Side Cover Gasket
35148-03
27
Main Case Seal
12067B
60
Shifter Seal
12045
28
Case Bearing Retaining Ring
11161
61
Shifter Retaining Ring
11150
29
Quad Seal
11165
62
Lower Trap Door Stud
16708-95
30
Main Case Bearing
8996A
63
Upper Trap Door Stud
16709-95
31
Mainshaft 5th Gear
35237-03
Items Not Shown
32
Spline Sleeve (2)
35140-03
Lid Gasket, (FXD Models)
33
Chrome Trap Door with Ear
35139-03
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134917-99B
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