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 8)

4) Tighten the installer until the sleeve stops against the thrust washer. Remove the installation tool and verify the sleeve is
flush with the counter-bore surface on the outside of the case.
5) Lubricate the inside of the sleeve and the outside of the new S&S shifter shaft pawl. Slide the new shifter shaft pawl into
the sleeve. See Picture 12.
6) Verify that the shift pawl has full rotation.
7) If there is interference, grind the case surface until the shift pawl sweeps without binding. See Picture 12.
8) When the appropriate clearance has been verified, slide the shifter shaft pawl into the case from the inside and install
the new shifter shaft seal, washer, retaining ring and shift linkage from outside the case.
NOTE: If shift shaft retaining ring groove is not in the appropriate location, something is wrong. Verify that the 1.480" sleeve was
installed flush with the bottom of the seal counterbore surface.
3. First Gear Clearance
A. Measure and mark on the inside bottom of the case at 1.250” and 2.200” from the trap door gasket surface in-line with the
countershaft. This is where first gear or the largest gear is located. See Picture 13.
B. Use a die grinder to blend the transition in the case casting by removing approximately .050” of material. See Picture 14.
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Picture 14 Picture 13
Picture 12
Common location for shift pawl interference.