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 5)

C. Position the clearance template on the side door uncovered holes using two 1 ⁄
4
x 20 x 1” screws with the words THIS SIDE
OUT facing you as shown in Picture 5. Position the template so that it is flush with the top edge of the transmission
housing. Use a scribe or fine-tip marking pen to trace the outline of the guide and then remove the template.
D. Spread out a few shop rags to catch any metal shavings that fall during the clearancing process.
E.
Drill the shaft hole out with increasingly larger drill bits until you get to 5 ⁄
8
” or 3 ⁄
4
”. Now use an air-powered grinder to remove
the rest of the material in the marked area. See Picture 6. Take your time and make sure that you remove the material evenly
across the front of the case. It is common to remove more material on the surface closest to you and have the cut dip down
a little in the back—do not allow this to happen.
NOTE: Use a combination square or equivalent to insure that the material removal is square to the gasket surface. The square
should only touch the inside of the case at the material closest to the gasket surface. See Picture 7.
5
Picture 4 Picture 5
Picture 7 Picture 6
Ideal clearancing should be
perpendicular to gasket surface.
Flush with this surface.