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 17)

NOTE: Use of the stock 32-tooth pulley with the S&S ® transmission will result in an extremely low overall first gear ratio. S&S provides
a 34-tooth pulley to counter-act the lower internal first gear ratio by changing the final drive ratio with the provided pulley.
Picture 40
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25. Position the drive belt over the S&S 34-tooth pulley. This may require removing the rear axle to allow enough slack in the belt to
fit over the pulley.
a. Due to the increased diameter of the 34-tooth pulley, some inner primary housing’s may require a minor clearance cut on the
inner primary to allow for belt clearance in the area pointed out in Picture 41.
b. Mock fit and check clearance between drive belt and inner primary housing mounting boss. You should have at least .200” of
clearance between the whole width of the belt and the mounting boss when the belt is adjusted. See Picture 42. If there is
enough clearance move onto step 26. If material needs to be removed for added clearance, remove primary housing and start
with step 1 below.
1.
Before removing any material tape up or remove bearings and seals to avoid any debris that could potentially cause
damage. Machine or grind away material to acquire .200” of clearance between belt and casting boss on the inner
primary housing. Use caution when grinding or machining that you don’t cut into the bolt hole. Clean thoroughly before
installing.
2. Repeat step 25b to verify clearance.
Picture 41
Picture 42
26. Assemble the primary drive following the factory manual
for your motorcycle. Also, fill primary with appropriate
amount of oil per your factory manual.
27. Adjust clutch cable per factory specification.
28. Connect battery cable and wipe down the vehicle.
29. Test drive motorcycle to verify clutch and transmission shift
pawl adjustments are appropriate.
30. Verify proper speedometer function and calibration. If you
do not have the parts to do this, you may want to purchase
an S&S Speedometer Calibrator PN 55-1007.
31. Verify proper neutral switch function.
Belt
.200"