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 13)

NOTE: Due to a stack-up of tolerance in transmission cases that are machined by other manufacturers, it may be necessary to manually
adjust the shift pawl linkage to prevent shift pawl from contacting the drum or the housing for the drum bearing support.
12. Shift pawl to shift drum and shift pawl to drum bearing support clearance:
a. Sweep shift arm in an upshift direction and measure the clearance to the shift drum using a feeler gauge while pressing in on
the end of the shift shaft. It does not matter what gear is selected.
b. Measure the clearance on the opposite side of the shift arm to the bearing support using a feeler gauge while pulling out on
the shift arm.
c. If the clearance on both sides of shift arm is greater than .020”, no adjustment is required, move on to step 13. If either
clearance is less than .020”, move on to step d.
NOTE: A centered shift arm with little endplay will yield .040” clearance on both sides of the shift arm. Excessive endplay in shift arm
can be reduced by pressing the shift shaft sleeve toward the gearset. Endplay of shift arm should be a maximum of .020”.
d. Adjust shift pawl clearance by removing the spring from the shift pawl arm to allow free movement. Rotate pawl arm to
vertical and push arm in or out to achieve equal clearance to shift drum and bearing support. Repeat steps a-c until
appropriate clearance is achieved. See Pictur e 25 and 26.
13. Rotate the transmission by hand, shifting through all six gears to ensure there is no binding.
14. Once it has been verified that the transmission shifts properly and adequate clearance has been achieved remove and reinstall the
side-door fasteners using blue threadlock. Torque the 5 ⁄
16
” fasteners to 13-16 ft-lbs and the 1 ⁄
4
” to 7-10 ft-lbs.
NOTE: Harley-Davidson ® Dyna TM models will require use of stock stud fasteners for exhaust bracket. FLT models will require installation of
exhaust bracket at this time.
15. Install main drive gear seal PN 56-3033, slide the O-ring over the main drive gear splines until it contacts the inner bearing race of
the S&S main drive gear bearing. Follow the o-ring with the sprocket spacer PN 56-1293 by sliding it onto the main drive gear splines.
16. Install a new inner bearing race onto the transmission mainshaft—we recommend the S&S ® bearing race PN 56-5089 (Picture 28)
to eliminate the problematic movement of the stock bearing race which can potentially destroy the output gear seal in high HP
applications.
13
Picture 25 Picture 26
Manual adjustment.
Insert feeler gauge as
shown by arrows. Minimum
clearance of .020" per side.
Adjust the clearance by bending shift
arm in or out as shown by arrows.
Picture 28 Picture 27
Optional S&S ® Inner Bearing Race PN 56-5089 S&S ® Inner Bearing Race Installer shown, PN 56-5145