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 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.
9. Install the transmission drain plug 14-18 ft-lbs. Install 1 ⁄
2
”-20 set-screw in trap door on the end of the shift rail using blue threadlock,
do not tighten all the way, shift rail should be free to rotate with very little endplay.
10. Place the new S&S ® shift drum and cast pillow blocks on the top dowels. See Picture 22. Apply blue threadlock on the new S&S
hardware and torque to 7-9 ft-lbs. The four fasteners supplied are 1 ⁄
4
”-20 X 1.25” black oxide coated. They should be installed with
the supplied lock washers. See Picture 26.
11. Adjust the shifter pawl by selecting third gear. Next, rotate the centering screw adjuster with a 1 ⁄
4
” wrench until the pawl is centered
between the shift drum pins (Picture 23). Verify the adjustment by sweeping the shift lever in an up- and down-shift direction until
the pawl arm engages the pins on the shift drum. Do not rotate the shift drum. Once equal clearance is achieved upshifting and
downshifting, tighten the adjuster locknut to 20 ft-lbs and verify that the pawl is still centered. See Picture 24.
12
Picture 21
Verify .030" clearance between shift fork and case.
Picture 22
Picture 24 Picture 23
Adjust pawl to achieve equal clearance.
Adjuster locknut