Screamin` Eagle 6-Speed Gearset Instruction Sheet - Harley

Screamin` Eagle 6-Speed Gearset Instruction Sheet - Harley
-J03482
REV. 2009-01-22
SCREAMIN' EAGLE 6-SPEED GEARSET
GENERAL
REMOVAL
Kit Number
NOTES
Leave the transmission case in the frame unless the case itself
requires replacement. For ease of illustration, photographs
show the case removed.
33101-03A
Models
For model fitment information, see the P&A Retail Catalog or
the Parts and Accessories section of www.harley-davidson.com
(English only).
Additional Parts Required
For Cable Actuated Clutch: SE 6-Speed Cable Clutch Side
Cover and Release Pushrod Kit Part Number 38752-04.
For Hydraulic Clutch: Hydraulic Cable Side Cover and Release
Pushrod Kit Part Number 38753-04A.
1990- mid 1994 models use a wider sprocket spacer Part
Number 33334-85 and mainshaft oil seal Part Number 12050.
These parts are not included with the kit and will need to be
purchased separately. If a newer model sprocket is used
40250-94C, the mainshaft oil seal and the sprocket spacer in
the kit may be used.
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
perform the installation. Improper installation of this kit
could result in death or serious injury. (00333a)
Use the appropriate service manual for the following procedures.
1.
Drain the primary chaincase and transmission lubricants.
2.
Remove battery negative cable (black) from battery negative (-) terminal.
3.
Remove the primary chaincase cover. Remove the clutch
assembly, primary chain and compensating sprocket
components. Remove the starter jackshaft assembly and
primary chaincase.
4.
Remove the exhaust system as necessary to gain complete access to the transmission side door.
5.
Remove the oil filler spout and starter.
6.
Remove the clutch release cover. Remove the clutch cable
from the clutch release cover.
7.
Remove the vehicle speed sensor.
8.
Remove the transmission top cover:
a.
Remove neutral switch from transmission top cover.
b.
Remove the drum support blocks and shift drum.
Remove the drum support block dowels from deck of
transmission case.
NOTE
c.
Remove the fork shaft and shifter fork assemblies.
This instruction sheet references service manual information.
A service manual for your model motorcycle is required for this
installation and is available from a Harley-Davidson Dealer.
d.
Remove the bearing inner race from the transmission
mainshaft.
e.
Remove the transmission side door and the mainshaft/countershaft assembly.
Kit Contents
See Figure 8 and Table 2.
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.
Table 1. Gear Ratios
STOCK 5-SPEED
SE 6-SPEED
First
GEAR
3.210
3.210
Second
2.209
2.209
NOTE
Third
1.572
1.572
Fourth
1.226
1.226
Use the appropriate service manual for the following procedures.
Fifth
1.000
1.000
9.
Sixth
N/A
0.885
10. Remove the countershaft needle bearing.
f.
Remove the shifter shaft assembly and shifter seal.
Remove the main drive gear and bearing.
11. Using masking tape, cover all the side door flange holes
in the transmission case with the exception of the top
three.
-J03482
1 of 8
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.
12. 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.
14. Spread one or two clean shop cloths inside the transmission case to catch the metal shavings and debris.
15. 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.
16. Remove all remaining material up to the edge of the drill
plate with a die grinder or similar tool. Remove the drill
plate.
•
Transmission drain hole bore.
17. Using emery cloth, steel wool, or a fine tooth file, remove
any burrs or ridges that may exist from the drilling or cutting operation.
•
Main drive gear bearing bore.
18. Remove sleeve from shifter shaft bore. Proceed as follows:
•
Countershaft needle bearing bore.
•
Fork shaft bore.
•
Shifter shaft bore.
a.
Obtain shifter shaft sleeve remover/installer tool
provided in kit.
b.
See Figure 2. From the outside of the transmission
case (left side), insert smaller diameter end of
remover into shifter shaft sleeve (knurled side out).
Using a 30 ounce brass hammer (minimum), tap the
end of the remover with light blows until the shifter
shaft sleeve is free of the transmission case.
c.
Carefully remove any burrs from in or around the
sleeve bore.
NOTE
Be sure drill plate is properly oriented. Improper orientation will
result in damage that requires replacement of the transmission
case.
is05780
NOTE
Abrasive particles can damage machined surfaces and result
in premature failure.
19. 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.
1
1. Drill plate
Figure 1. Install Drill Plate to Transmission Case
20. 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.
21. Using low pressure compressed air, thoroughly blow out
all solvent.
is05783
22. 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.
1
23. Carefully inspect the transmission case for any metal
shavings or debris. Repeat steps 19 through 21 if any
debris is found.
24. Remove the masking tape to uncover remaining holes and
bores.
25. Thoroughly inspect each bore for any metal shavings, dust
or debris. Alternately direct compressed air into each bore
to be certain that the transmission case is clean and dry.
1. Shifter shaft sleeve remover
Figure 2. Remove Shifter Shaft Sleeve
13. See Figure 1. Obtain the drill plate (1) provided in kit and
fasten to top of side door flange using old and new vehicle
speed sensor mounting screws.
-J03482
INSTALLATION
NOTE
Prelube all bearings and shafts with clean transmission lubricant prior to installation.
2 of 8
1.
Using the appropriate service manual, proceed as follows:
a.
Install the countershaft needle bearing.
b.
Install the main drive gear and bearing.
foam bits or other packaging material that might be clinging to
gears or splines.
is05786
is05784
1
1
1. Shifter fork
Figure 4. Install 5-6 Shifter Fork to Shift Ring
1. Shifter shaft sleeve installer
is05787
Figure 3. Install Shifter Shaft Sleeve
2.
Using the appropriate service manual, proceed as follows:
a.
Obtain shifter shaft sleeve remover/installer tool
provided in kit.
b.
See Figure 3. Place new sleeve over installer (1).
Place thrust washer, thrust bearing and then the
second thrust washer onto installer screw.
1
c.
Apply a very thin film of HD 20W50 engine oil to OD
of new sleeve, ID and OD installer threads and ID of
sleeve bore. Also apply a very thin film of HD 20W50
engine oil to the thrust bearing and thrust washers.
1. Shifter fork
d.
From inside the transmission case, hold the sleeve
and installer against the sleeve bore. From outside
the transmission case, thread the installer screw
assembly into the installer keeping the sleeve properly
aligned.
e.
Using a 3/4-inch box wrench, hold the hex on the
installer inside the transmission case.
f.
Using a 1/4-inch hex head, tighten the installer screw
until the sleeve stops against the first thrust washer.
g.
Remove the tool from the transmission case.
h.
Apply a very thin film of HD 20W50 engine oil to
sleeve ID and new shifter shaft. From outside the
transmission case, slide shaft through sleeve and
then rotate. Shaft must rotate freely a full 360
degrees. Remove shifter shaft assembly.
i.
Install the new shifter seal. Install shifter shaft
assembly from inside the transmission case. Install
new shifter seal washer and new retaining ring.
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.
Figure 5. Install 3-4 Shifter Fork to Shift Ring
3.
Install the transmission side door and mainshaft/countershaft assembly as follows:
a.
Hang 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.
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.
d.
See Figure 4. Install the 5-6 shifter fork (1) into the
shift ring outboard of the 6th gear on the mainshaft
(shift ring closest to the main drive gear).
e.
See Figure 5. Install the 3-4 shifter fork (1) 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
Be sure to remove the plastic cap and cable strap from the
mainshaft before side door installation. Blow away any styro-
-J03482
3 of 8
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.
4.
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.
See Figure 6. Through the transmission top cover
opening, install the 1-2 shifter fork (1) 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.
Install new side door plug into side door.
j.
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.
k.
5.
Using the appropriate service manual, proceed as follows:
a.
See Figure 7. Install four new drum support block
dowels (1) in deck of transmission case. Orient the
dowels so that the split line is aligned left to right.
b.
Install new 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.
e.
Install the new bearing inner race onto the transmission mainshaft.
Install the transmission top cover with new gasket. Verify
that the shifter pawl does not contact the inside of the top
cover during installation.
a.
See Figure 8. Install new neutral switch into the
transmission top cover. For 1998 or later models or
if you are replacing the stock top cover with a 1998
or later model top cover, DO NOT remove the O-ring.
For 1990- 1997 model years, remove the O-ring from
the neutral switch and install the aluminum washer
(67) with the chamfer side of washer away from the
switch body followed by the nylon washer (68) on the
neutral switch. These parts are included in the bag
with your neutral switch. Install the neutral switch into
top cover and tighten to 120-180 in-lbs (13.6-20.3
Nm).
b.
Install connectors on neutral switch studs. For 1990
thru 1997 model years, refer to the wiring diagram at
the back of the service manual. The wiring harness
for these years has a single cap connector (H-D part
number 9905) connected to the neutral switch.
Replace the single cap connector as follows in the
next four steps.
c.
Cut single cap connector off stock wire.
d.
Connect the supplied wire (56) to the cut wire with
the supplied connector (58) and attach onto either
pole of the neutral switch.
e.
Attach the other supplied new wire (55) to the
remaining pole.
f.
Attach the supplied ring terminal (57) to the other end
of the new wire and attach to a convenient grounding
location.
The fork shaft set screw is a lock-patch type set screw
and is designed to allow the fork shaft to have minimum endplay but still rotate freely. DO NOT tighten
fork shaft set screw against fork shaft. Damage could
result if set screw is tightened against fork shaft.
Install fork shaft set screw in transmission side door.
Tighten screw until the shaft has minimum endplay,
but still rotates freely.
l.
Remove shrink wrap from the mainshaft.
is05788
1
1. Shifter fork
Figure 6. Install 1-2 Shifter Fork to Fork Ring
is05790
1
1. Block dowels
Figure 7. Orient Shift Drum Support Block Dowels
-J03482
6.
Install the starter and oil filler spout.
7.
Install the exhaust system.
8.
Install the primary chaincase and starter jackshaft
assembly. Install the clutch assembly, primary chain, and
compensating sprocket components. Install the primary
chaincase cover.
9.
Install drain plugs and fill the transmission and primary
chaincase with the recommended lubricant.
10. Install plate with gasket over vehicle speed sensor bore
in transmission case using stock hardware.
11. Install vehicle speed sensor at top of transmission side
door using new O-ring.
4 of 8
12. 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).
-J03482
13. Install battery negative cable (black) to battery negative
(-) terminal.
Transmission Service
1.
Replace the transmission lubricant after the first 500 miles.
Thereafter, refer to the service manual and change the
lubricant at the recommended service intervals.
5 of 8
62
-J03482
39
21
48
21
51
2
20
19
46
24
43
43
23
17
8
4
15
23
15
3
14
16
7
50
24 23 25
24
53
9
14
5 10
40
12
44
24
25
22
66
51
20 44
19
52 49
63
33 34 35 36 37
24
6
42
10
1
8
59 60 61
15
4
15
40
32
11
18
13
56
68
31
58
57
45
41
29 26
28 30
38
67
54
55
27
47
64
65
SERVICE PARTS
is05782
Figure 8. Service Parts: 6-Speed Gearset
6 of 8
Table 2. Service Parts: 6-Speed Gearset
Item
Description (Quantity)
Part Number
1
Mainshaft
35058-03
2
Countershaft
35059-03
3
Countershaft 1st Gear
35080-03
4
Mainshaft 3rd Gear/Countershaft 2nd Gear (2)
35083-03
5
Mainshaft 4th Gear
35104-03
6
Mainshaft 6th Gear
35131-03
7
Mainshaft 1st Gear
35134-03
8
Countershaft 3rd Gear/Mainshaft 2nd Gear (2)
35135-03
9
Countershaft 4th Gear
35136-03
10
Shift Ring, 1-2, 3-4 (2)
35137-03
11
Shift Ring, 5-6
35138-03
12
Side Door
35158-03
13
Shifter Fork Shaft
34088-87A
14
Splined Sleeve (2)
35140-03
15
Drum Support Block Dowel (4)
609
16
Shifter Fork, 1-2
35143-03
17
Shifter Fork, 3-4
35144-03
18
Shifter Fork, 5-6
35145-03
19
Side Door Bearing Retaining Ring (2)
35087-99A
20
Side Door Bearing (2)
8992A
21
Mainshaft/Countershaft Locknut (2)
35078-79
22
Speed Sensor O-Ring
11289A
23
Split Cage Bearing (5)
8876A
24
Retaining Ring (8)
11067
25
Thrust Washer (2)
6003
26
Sprocket Spacer
33344-94
27
Mainshaft Inner Race
34091-85A
28
Oil Seal, Large
12067B
29
Bearing Retaining Ring
11161
30
Quad Seal
11165
31
Main Drive Gear Bearing
8996A
32
Main Drive Gear
35237-03
33
Right Drum Support Block
33304-00
34
Detent Arm Screw
33376-00
35
Detent Sleeve
33375-00A
36
Detent Follower
33364-00A
37
Detent Arm Spring
33374-00
38
Shifter Shaft Assembly
35146-03
39
Clutch Release Cover Gasket
35148-03
40
Drum Support Block Screw (4)
3909
41
Shifter Centering Screw
34978-00A
42
Countershaft Needle Bearing
8977
43
Lower Side Door Screw (4)
3249
44
Upper Side Door Screw (2)
4814A
45
Shifter Shaft Sleeve
34979-00
-J03482
7 of 8
Table 2. Service Parts: 6-Speed Gearset
Item
Description (Quantity)
Part Number
46
Side Door Plug
45830-48
47
Shifter Seal Washer
6497HW
48
Shifter Fork Shaft Set Screw
3784
49
Speed Sensor Plate Gasket (2)
35152-03
50
Countershaft 5th Gear
35238-03
51
Speed Sensor Plate Screw (2)
4705
52
Speed Sensor Plate (2)
35153-03
53
Side Door Gasket
35147-03
54
Neutral Switch
33904-00
55
Black Wire Assembly
72405-98BK
56
Tan Wire Assembly
72405-98TN
57
Ring Terminal, 1/4 Inch
72241-94A
58
Connector (18-20 Gauge)
70585-93
59
Shift Drum
35142-03
60
Left Drum Support Block
33301-00A
61
Shift Drum Retainer
11342
62
Drill Plate
35155-03
63
Shifter Shaft Sleeve Remover/Installer Tool
35156-03
64
Shifter Seal
12045
65
Shifter Retaining Ring
11150
66
Speed Sensor Plug
35239-03
67
Neutral Switch Washer, Aluminum
6288
68
Neutral Switch Washer, Nylon
33043-80
Items Not Shown
Top Cover Gasket, FLHT and FXST
34904-86D
Oil Fill Spout Gasket, FLHT 1993 and Later
62432-93B
-J03482
8 of 8
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement