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 4)

5-STEP MODIFICATION
1. 3-4 Shift Fork Clearance
2. Shift Linkage Clearance
3. First Gear Clearance
4. 5-6 Shift Fork Clearance
5. Clean Up
1. 3-4 Shift Fork Clearance
Due to the multiple transmission cases that the S&S ® cassette fits, clearance will be required in several locations to facilitate a
successful installation. See Picture 1 below for required clearance locations. As always, be sure to verify proper clearance has been
created by mocking-up the affected components.
A. You will need to use tape to cover all of the transmission side door holes except the top two, these will be used to support
the clearance template in step 3.
B. Use tape to cover the following components: speed sensor and screw holes, top cover and shift drum support block screw
holes, fluid drain hole, shifter shaft bore, main drive gear opening, countershaft needle bearing bore and the fork shaft bore.
Installation on FLT models must seal off the oil filler spacer with tape. See Picture 2. Installation on Harley-Davidson
® Dyna TM
models will require sealing off the oil tank cavity at the top cover surface. See Picture 3.
4
Picture 2 Picture 3
Picture 1
5-6 shift fork clearance.
Shift lever clearance.
Countershaft 1st gear clearance.
3-4 shift fork clearance.