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 3)

The safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilities
or do not have the correct tools for this installation, please consult a shop to have it done. Improper installation of this product
could result in injury or death to the rider.
Be sure to disconnect the battery of your motorcycle before starting on this procedure. Accidental starting of the motorcycle
could cause injury to you or others around you during the installation.
To avoid damage to motorcycle and installed parts follow the guidelines in your factory service manual when taking the
transmission and primary assemblies of your motorcycle apart.
DISASSEMBLY
1. Disconnect the negative cable from the battery.
2. Drain primary and transmission fluids.
3. Follow the guidelines in your factory service manual to remove the entire primary assembly. The cover, primary chain, clutch
and compensating sprocket components need to be removed. Additionally the starter, jackshaft and inner primary will need to
come off.
4. Remove any exhaust components that restrict access to the transmission side door.
5. On FLT models, the oil filler spout will also be removed at this time. NOTE: Mask opening in case to prevent debris from entering
oil tank. See Picture 2.
6. Remove clutch release cover and clutch cable.
7. Remove the neutral switch and transmission top cover. NOTE: Harley-Davidson ® Dyna TM models will require masking on the front
of the transmission case to prevent debris from entering the oil tank and oiling system. See Picture 3.
8. Remove the shift drum and support blocks.
9. Remove the shift shaft and forks.
10. Use an inner bearing race removal tool (S&S ® tool PN 56-5141) to remove the race from the transmission mainshaft.
11. After removing the transmission side door hardware, slide the gear set from the transmission case.
12. Remove the shifter shaft assembly and seal.
13. Consult your factory manual for the procedure necessary to remove the main drive gear and bearing.
14. Remove the countershaft needle bearing following the directions in your factory service manual.
Small metal chips and pieces can damage machined surfaces and block passageways. Be sure to thoroughly clean all metal chips
and pieces out to prevent premature failures.
Always wear eye protection while grinding and cleaning the transmission case to avoid eye injury.
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