S&S Cycle All-Helical Transmission Complete Assembly for 1991-99 Harley-Davidson Softail and Custom Applications - Manual (Page 4)

Complete Transmission Installation Instructions for
1991-’99 Harley-Davidson ® Softail ® and Custom Applications
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.
The complete S&S ® Six-Speed Transmission will work in 1991-1999 Softail ® frames with no clearance issues. Installation into an
aftermarket frame will require additional clearance checks be performed to ensure safe installation is possible.
REMOVAL
(old transmission still in bike)
1- Disconnect negative battery cable
2- Drain fluids from transmission and primary. NOTE: depending on your particular motorcycle, the oil tank may need to be removed
to allow transmission access. If so, drain the engine oil at this point.
3- Refer to a factory service manual for the proper procedure to remove the primary assembly, including the clutch, primary chain,
inner primary and shift linkage.
4- Remove the belt from the rear pulley—you may have to take off the belt guards and, possibly loosen or remove the rear axle to
do this.
5- Remove the exhaust system.
6- Loosen the clutch cable adjuster completely, then remove the stock transmission end cover. Remove the snap ring from the cover
using snap-ring pliers, and lift out the ball and ramp assembly to disconnect the clutch cable. Unthread the clutch cable from the
end cover.
Always wear eye protection when working with spring loaded clips like snap rings.
7- Consult a factory service manual for the proper procedure to remove the starter assembly. If your oil tank must come out, follow
the steps outlined in the service manual.
4
WARNING
WARNING
CAUTION
Complete Transmission
SPECIAL TOOL REQUIREMENTS:
● Primary Locking Tool
● Inner Bearing Race Puller, S&S PN 56-5141
● Inner Bearing Race Installer, S&S PN 56-5145
ADDITIONAL PARTS REQUIRED:
● 1991-’97 H-D ® models will require H-D #72405-98TN
and H-D #72405-98BK, neutral switch wiring
● Clutch Center Pushrod H-D #37088-90
OPTIONAL PARTS:
● S&S Inner Bearing Race PN 56-5089
● S&S Speedometer Calibrator PN 55-1007
● S&S Hydraulic Side Cover PN 56-4060
WARNING