S&S Cycle All-Helical Transmission Gear Set Cassettes for Harley-Davidson 1991-05 Dyna, 1991-06 FLT and Softail models, and Custom Applications - Manual (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.
Do not use bolts to draw trap door onto case. This may strip the case threads.
5. Install the provided gasket on the transmission side door surface. Slide the gear set into place as one piece. You may need to rotate
the main drive gear to mesh with the countershaft gear and lightly tap the transmission door with a rubber mallet to seat it
completely over the alignment dowels. Install the supplied hardware—but do not put any threadlock on them at this time. There
are six fasteners, the top two are
1 ⁄
4
”-20 X 1.25” long and the bottom four are 5 ⁄
16
-18 X 1.25” long. Each chrome fastener has a
corresponding flat washer for installation.
6. Rotate main shaft to verify that there is no interference between the gears and the transmission case. If the mainshaft does not
rotate freely, determine the cause and correct the interference before moving on.
7. Check for adequate clearance between the shift fork (5-6) and the case area closest to the primary (Picture 20). This can be done
by sweeping the fork and collar into the adjacent gears, while using a .030" feeler gauge.
11
CAUTION
Picture 19
5-6
1-2
3-4
Stepped-end
of shift shaft
Picture 20