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 14)

NOTE: It is important that you pay special attention to shift pawl adjustment. The adjustment of the shift pawl is directly related to
proper function and smoothness of shifting.
17. FLT and Harley-Davidson ® Softail ® Transmission Top Cover
Verify transmission top cover clearance to the shift pawl by using clay or machinists dye. Clearance as necessary. Then, install the
top transmission cover with the supplied gasket. Use blue threadlock on the screws and torque them to 7-9 ft-lbs. Rotate and shift
the transmission through all six gears again to confirm there is no binding.
NOTE: Stock top cover usually requires clearance operation to prevent shift linkage from binding. Use clay or machinists dye to identify
location of interference and correct the problem with a die grinder. Picture 29 illustrates a modified top cover for a FLT/Softail model.
1991-’98 Dyna Model Top Cover Hardware and Gasket Assembly.
When installing the S&S 6 speed transmission in 1991-’98 Dyna models, the supplied gaskets and hardware are required for shift
drum to top transmission cover clearance. Picture 30 illustrates supplied gaskets and hardware.
1- With the engine oil drained pull the dipstick cover out and place the 1.450” diameter gasket on the oil tank where the dipstick
cover pushes in. With the o-ring still in place on the dipstick cover push the dipstick cover back in the oil tank capturing the
gasket between the oil tank and the dipstick cover.
2- Now slide the supplied 1.170” diameter gasket over the top of the dipstick cover with the o-ring in place.
3- Install the new .120” thick transmission top cover gasket followed by the transmission top cover.
4- Install the supplied oil fill spout gasket followed by the oil fill spout. Picture 31 illustrates the assembly of gaskets that are
required for transmission top cover clearance.
14
Picture 29
Picture 30 Picture 31
Top cover clearance
for FLT/Softail model
NOTE: Verify transmission top cover clearance to shift detent arm and spring by using clay or machinist dye. Picture 32 illustrates the area
of the top cover that will be the closest. If clearance is required correct the problem area with a die grinder. Once clearance is verified
use blue threadlock on the supplied screws and torque to 7-9 ft-lbs. Picture 33 illustrates the assembly of the supplied hardware kit.
Top cover
clearance for
1991-’98 Dyna
model
Picture 32
Picture 33