S&S Cycle All-Helical Transmission Complete Assembly for 1991-99 Harley-Davidson Softail and Custom Applications - Manual (Page 8)

Picture 12
Install .250” shims as shown.
Picture 10
8
8- Install the shift linkage.
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 10.
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 11. If there is
enough clearance move onto step 9. 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. Grind or machine away material to acquire .200” of clearance between belt and casting boss on the inner primary
housing. Use caution when grinding or machining so you don’t cut into the bolt hole. Clean thoroughly before installing.
2. Repeat step 8b to verify clearance.
9- Follow the recommended procedure in your service manual to install the inner primary, clutch, primary chain and outer cover.
Tighten starter mounting bolts.
10- Tighten components in the following order to prevent primary chain-case failure: inner primary bolts first, then transmission
mounting studs. Tightening the studs last will allow the transmission to align with the engine and primary chain-case.
11- Be sure to put some red threadlock on the five (four on some custom frames) transmission mounting studs and tighten the nuts
to 33-38 ft-lbs of torque. If you are using the fifth stud, be sure to shim it properly to avoid any case stress. Before tightening the
fifth stud, make sure there is no clearance between the stud mounting surface and the frame or mounting plate surface. If there
is a gap, the proper thickness shim must be determined and installed between the frame and the fifth case stud mounting surface.
12- Reinstall the shocks, tighten and align the drive belt to factory specifications.
13- Install exhaust system. Remember that the S&S transmission is .250” wider than a stock unit. If you find that the exhaust system is
too close to the side cover, you will need to shim the exhaust bracket as shown below in Picture 12.
14- Refill all drained fluids to specifications found in your factory service manual. Fill the S&S ® transmission with 24 ounces of 90 weight
gear oil or equivalent. Adjust the clutch per your manufacturers directions.
15- Reconnect battery, pump the rear brake, start the engine and shift through all six gears to ensure that the clutch engages correctly.
16- S&S recommends that the motorcycle be road tested to ensure proper function of all components.
Gear S&S ® Internal Transmission Ratio
1st 3.882
2nd 2.656
3rd 1.941
4th 1.475
5th 1.179
6th 1.000
GEAR RATIO CHART
RECOMMENDED FINAL BELT DRIVE GEARING
● S&S recommends that you use a 32- or 34-tooth output pulley with a
65-tooth rear pulley.
● S&S recommends the use of our 34-tooth output pulley with a 70-
tooth rear pulley.
NOTE: Installation of the 34-tooth pulley should not require a belt change.
Changing the rear pulley from a 70-to a 65-tooth will require a belt change.
TRANSMISSION SERVICE
NOTE: S&S recommends filling transmission with 20-24 ounces of
90 weight gear oil or equivalent.
1- Perform an initial fluid change at 500 miles.
2- Change fluid at 5,000 miles.
3- Service transmission fluid every 5,000 miles thereafter.
Picture 11
Belt
.200"