No.8028C6-IS
Contents
1. tion sheets for inventory reference Use JIMS tool No 1008 TL trans holder for performing pre installation work Remove original transmission according to your Harley Davidson Service manual Clean and inspect all reusable parts and components and replace parts as needed Check all parts for correct fitment before installing transmission Remove the side cover No 2371C from trans assembly Lube and install three clutch pushrods H D 37089 79 right No 37088 79 center No 37090 79 left inside main shaft also attach clutch release bearing kit JIMS No2226 to right pushrod No 37089 79 Attach clutch cable o ring No 11179 and clutch cable to side cover No 2371C Also connect end of clutch cable to cable coupler No 34920 86 and attach to inner ramp inside side cover Now you are ready to mount gasket No 36801 87A and side cover No 2371C to trans assembly Lube and torque side cover screws to 10 12 ft Ibs 6 Optional Install JIMS No 74420 94 electronic speedo sensor into the trap door speedo hole NOTE Early transmissions used a mechanical drive from the trans case to drive the speedo while later 4 speed transmissions used a mechanical drive from the front wheel IMS new 4 6 speed was designed to be used with JIMS No 74420 94 electronic speedo sensor in conjunction with one of the many aftermarket electronic speedos with a built in calibrator 7 Optional If you decide not to use JIMS el2. No 9037 and H D No 12018 seal NOTE You must support the inner primary bearing bore as you install the new bear Continued on page 3 gt CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 2 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM REV 09 02 No 8028C6 IS ing and seal 2 Loosen transmission mounting nuts NOTE There must be enough play to position transmission inner primary cover and frame to prevent any binding 3 Align inner primary cover with transmission mounting studs and secure it with anchoring nuts and bolts to H D factory specs manual 4 Before continuing check the clearance between inner primary cover and the final drive sprocket with the chain on it should be with 0 05 0 06 NOTE Some chains require more room and you may need to make clearance Also check nut no 35211 36 to seal No 12018 for having at least 050 of clearance 5 Tighten transmission to transmission mount plate Torque to factory manual specs NOTE Check No 8049 mounting stud shim if needed to sit level on frame Shim between frame and 5th mount 6 Pre assemble clutch hub and mount on main shaft Check for clearance between clutch hub and inner pri mary cover and relieve a
3. 4TH GEAR 030 AS NEEDED COUNTER SHAFT 2 7 BEARING 10 No 8028C6 IS Shifter Fork Location FIGURE NO 14 REV 09 02 36 lt aZ S W al 6 920S N d eZ 1908 N d 4 5 2 v6908 N d 364 1617 N d CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 1OO OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 11 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM No 8028C6 IS Trap Door Assembly FIGURE NO 15 REV 09 02 2 SHCS Fastener 5 TITLE OR DESCRIPTION SET SCREW CHROME SPLIT PIN BRIDGE SUPPORT BEARING SIN OTR OY Oy m m m 2 PART NO 3784C 609 MAGNETIC DRAIN PLUG 739A SCREW BUTTON HEAD 8090 8091 8074 SCREW BUTTON HEAD RETAINER PLATE 8073 8998 4 5 6 CHROME BILLET TRAP DOOR 8095C CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 12 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM REV C 09 02 No
4. early 84 Super kit No Case ratio first gear 2 94 is precision machined from forged aerospace material and is matched to their corresponding gear 4 5 Speed Transmission Case JIMS Pro Cut gears provide smoother more positive shifting with Application Year PartNo Case their precision machined and matched mating gears Each Pro Cut amp 1970 early 84 8096 Plain Aluminum Gear utilizes a steeper back cut shift dog angle than Clean Cut gears Polished Aluminum for quicker engagement during high speed acceleration All gears are HOSP 8030P American made by JIMS under stringent tolerances Required but not included components for Note See page 3 for important case information complete transmissions amp Super kit 37088 79 Center clutch pushrod H D 9 38607 87A Clutch cable H D 9 45031 65 Clutch cable pivot pin H D 2226 Clutch release bearing kit 5 74420 94 Electronic Speedo Sensor Aftermarket Speedo with built in calibrator Aftermarket Forward controls H D 5 or equivalent 12018 Inner Primary Seal H D 37090 79 Left clutch pushrod H D9 35126 36 Lock washer MDG JIMS 72405 98BK Neutral switch connector H D 9 72405 98TN Neutral switch connector H D 9 35211 36 Nut main drive gear H D 37089 79 Right clutch pushrod H D 33715 85AC Shifter lever JIMS9 33336 83 Sprocket 23T or larger Aftermarket Additional required but not included components for Super kits 8101 amp
5. for proper 12067A Seal Main drive case JIMS case to gear clearances CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM No 8028C6 IS JIMS SPECIAL TOOLS 2234 Primary Drive Locking Tool 94660 37A Main shaft Sprocket Wrench 2260 Big Twin Sprocket Locker 35316 80 5 Transmission Main Drive 2189 5 Speed Shaft Installer 2362 Lock ring pliers 1078 Door Bearing Remover Installer WARNING NOTE Read all instructions before performing work Prior to installation of this kit please read and follow the procedures and safety precautions to reduce the risk of personal injury Refer to your bike s year and model H D Service Manual during installation of this kit Read these instructions completely so you understand before performing any steps Always dis connect battery cables to prevent injury Your work place should be clean and well lit Wear safety glass es and protective clothing when working around power tools and compressed air Be careful with chemicals when cleaning parts Protect your skin from solvents and use only in a well ventilated area Degreasers are flammable and are a fire hazard Just use common sense and exercise go
6. 2067A m5 T1179 zi 1230 1259 1261 2401 3390298 62375 57 10998 25452 87 25453 87 36801 87 34920 86 8873 37075 87 375 634 3311479 11165 8012 11016 6016 35086 79 35068 79 34087 79 8998 8073 8090 8074 8091 9115 8082 8079 2 739 35961 52 8904 8096 8096 8096 2384 2528 8071AL 8079A B999PK 2371CH 8058 3 8058 5 8058 7 BOGIP 8058 2 8063 8042 8041 Screw Speedo Block Off Plate 1120 15 REV 09 02 No 8028C6 IS NOTE Please see page 3 for transmission case application requirements Please use appropriate thread locking compounds and press fit lubes when installing these compo nents 8096 8096P 4 5 Transmission Case Part no Description Qty 5318053 Stud Primary cover 79 63 RolPin Fdoor Dowel Pin R door 56609 8054 Screws Bracket CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 1OO OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 16 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM
7. 8028C6 IS FIGURE NO 16 fe 13 Exploded View Pro Cut amp Clean Cut P 41 Jr 8 s T0 69 020 e 9 al S fas t 0 EACH PRO CUT GEAR IS IDENTIFIED BY 3 PIP MARKS DOTS AND LASERED WITH PART NUMBER mele e 7 CAUTION Pro cut gears are designed and manufactured different than clean cut gears Clean cut gears are not designed to work with pro cut gears Do not mix gears
8. 8101P only 8978 Bearing Main drive case JIMS 8996 Bearing Main drive case JIMS 2371CK Clutch release cover clutch mechanism and hardware JIMS 36801 87K Gasket Side cover 10pk JIMS 33902 98 Neutral switch JIMS 11057K Retaining ring 10pk JIMS 11161 Retaining ring 10pk JIMS 12067A Seal Main drive case JIMS 805 Seal Main drive case 5 33119 79A Shifter arm adjuster screw 10 pk JIMS 7515K Shifter arm adjuster nut JIMS 2384 Shifter pawl assembly JIMS 8089 Spacer Main drive JIMS 33334 79 Spacer Main drive JIMS 8999CK Top cover amp fasteners 5 8096 8096P Transmission Housing JIMS 11165 Quad seal JIMS Optional may be used with aftermarket equivalent 9037 Primary Bearing H D Optional may be used with aftermarket equivalent From the Track To the Street 1 555 DAWSON DRIVE CAMARILLO 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM REV 09 02 No 8028C6 IS TRANSMISSION INSTALLATION INSTRUCTIONS WARNING ALWAYS REMOVE NEGATIVE CABLE FROM BATTERY BEFORE PERFORMING ANY WORK Pre installation procedures Complete Transmission Assembly Read all Instructions before performing any work 1 Unpack and inspect all parts for damage or missing components Immediately notify the JIMS dealer you purchased this transmission from for appropriate actions Use the parts list on page 12 13 of these instruc
9. ENT SYSTEM PILLOW BLOCK INSTALLATION Install the shift drum assembly as detailed in the Adjustments Set Up and Checks section This time however you must be careful to make sure the fork pins are in the grooves in which they belong As mentioned before it is recommended that you tighten down the Allen bolts in a circular pattern Monitor closely the pins of the forks rela tive to the shift drum grooves Application of Thread locking compound No 242 to all four bolts is recommended Set the adjustment on the shifter pawl adjustment screw per H D Service Manual Section 7 SHIFTER LINKAGE Adjustment Clutch Rod End Right Side Refer to the Pre installation procedures on page 2 CLUTCH RELEASE COVER INSTALLATION Install clutch release cover onto the side door Note that two of the screw holes in the side door that receive two clutch cover screws have a threaded depth of 1 2 This means if you are using and O E M style clutch cover you must use CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 WWW JIMSUSA COM REV C 09 02 No 8028C6 IS REV C 09 02 the two 1 4 20x2 SHCS that are provided or any other SHCS with a 2 length The positions of these two s
10. Each pro cut gear is identified by 3 pip marks dots see figure 18 on each gear 6 speed pro cut gears sets must be assembled on the proper shaft with the dogs facing the correct mating gear Gears are lasered with part No Note Assemble pro cut gears on the main shaft and counter shaft using assembly figure No 18 Check part number before and after gears are assembled on shafts This step is essential for proper assembly of the transmission Improper placement of the gears will result in the malfunction of the transmission and damage Customer Support For any installation on service or Questions please contact JIMS technical Depart 805 482 6913 No 8028C6 IS 4 5 6 Speed transmission parts list Clean cut and Pro cut gears No CO NI ON Ca A Parts List Description S O 1 1 1 Gasket Lid Qty 28 1 DT ele REV 09 02 Part Number 8095C 8072 8094 8061 35026 79 35027 79 35028 79 35029 79 8062 8064 35626 79 8876A 8048 8996 6003 11067 11161 8089 8063 8065 35078 79 8081 8071 1L 2226 8079W 2528 1 8068A 8069A 8077 1 1118 1258 5075 1287 1260 1213 2393 8028C6 IS 12013A 1215 2135 34193 79E 34088 87 8096MP 34084 86A 12045 6497HW 11150 33119 79A 7515 8049 8054 8052 8053 60348 65B 3784C 609 2371C 35652 79 34904 86 09 02 No 8028C6 IS 4 5 6 Speed transmission parts list Clean cut and Pro cut gears 3999C 1
11. REV 09 02 No 8028C6 IS WARNING Read all instruction before performing work Application Requirements For use on FX amp FL style frames 1970 Early 1984 only Dry clutch as used on 4 speed tapered D clutch hubs 2 Chain final drive Transmission to rear wheel All 4 6 Speed transmissions come _ aad 3 5 Speed style clutch cable with close ratio 1st gear JIMS bil q 4 Electric start only No provisions for kickers let pillow blocks JIMS chrome 5 Designed to use OEM style forward controls and mid controls top and side covers chrome hard hi amp available through aftermarket ware and JIMS 7075T billet chrome 6 May be used with either primary belt or primary chain drive trapdoors JIMS 6 SPEED IN A 4 SPEED STYLE CASE Part No Case JIMS 4 6 speed transmission will deliver increased gas mileage 8028C6 prolonged engine life smoother shifting increased torque freed 8030C6 horsepower and smoother cruising speeds while still using a 4 speed style case JIMS 4 6 speed transmissions are assembled by JIMS with JIMS shafts and gears incased in a JIMS case All JIMS transmissions are Part No Case sealed with JIMS gaskets and seals 8028P6 Plain Aluminum JIMS Clean Cut gears feature back cut shift dogs with lead in ramp FX amp 1970 early 84 8030P6 Polished Aluminum ing on mating gears for smooth shifting Each gear in this kit Close amp FL 1970
12. blocks in place 3 of the bolts 1 4 20 x1 1 4 socket head Allen and one bolt is a 1 4 20 x1 1 4 button head Allen Also there are 3 A N type washers these are used on the socket head Allen The button head bolt does not use a washer The button head bolt is used on the right side pillow block in CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 WWW JIMSUSA COM No 8028C6 IS the forward position below the detent roller See Figure 11 Apply a small amount of assembly lube to dowels Put the Allen bolts into the pillow block holes and tighten down the shift drum pillow block assembly squarely Squarely means tight en down the bolt one turn each at a time to pull down the pillow blocks over the dowels A cir cular pattern for tightening the four bolts works best The right side pillow block may be stubborn in making its way over the dowels Tightening down the pillow block bolts in a circular pattern as speci fied above is usually sufficient to overcome this Measure the end play next to the right side pillow block as seen in figure 12 If the measured value is within spec discard the other shim and remove the shift drum pillow block asse
13. crew holes are shown in figure 15 If you are installing a JIMS billet cover the correct length screws are supplied with the cover kit If you are using any other custom cover check and make sure the screws do not bottom out in the side door holes SPEED SENSOR INSTALLATION If you have a transmission case with speed sensor provisions install one of the sensor block off plate kits No 8042K in the case Relocate the speed sensor to the provision in the side door If you are not running a speed sensor use another block off plate kit No 8042K in the side door You may require a speed sensor signal conver sion box to correctly calibrate the speedo head Dakota Digital speed recalibration units model SGI 6 avail able through Dakota Digital 3421 W Hovland Ave Sioux Falls SD 57107 Phone 605 332 6513 Fax 605 339 4106 Fluid Fill Fill the assembled gearbox with 20 24 oz of Torco 80W 90W oil JIMS No 1230 Change oil at 500 miles Refill case with Torco 75W 140 Synthetic JIMS amp No 1232 DISASSEMBLY In general disassembly of your JIMS 6 speed Overdrive is the reverse of content of the Installation Instructions with only one note to remove the auxiliary fork shaft No 8075 you may need a slide hammer with a 10 32 threaded tip WARRANTY All JIMS parts are guaranteed to the original purchaser to be free of manvfacturing defects in material and workman ship for a period of six 6 months from the date of purchase Me
14. d M S and 1st M S forks will ride on the primary fork rod like 5 speed The 4th C S fork rides on the auxiliary shaft that will be pushed through the door First install the 1st M S fork You must slide the 1st gear away from the door and engage the dogs of the adjacent gear 4th to allow room for the fork to slide see Figure 13 Next install the 4th C S fork Install the 3rd C S and 2nd M S forks in the positions specified Slide the primary fork rod through the 1st M S fork 3rd C S fork and 2nd M S fork Insert shift fork shaft No 8075 with a small amount of lube No 1226 on small end of shaft only through trap door and into shift fork No 8069A C S 4th fork NOTE While pushing the auxiliary fork shaft through hold onto the 4th C S gear fork and make sure the fork is positioned correctly to receive the aux iliary fork shaft that is simultaneously being pushed through Install set screw No 3784C with 2 drops of Thread locking compound No 242 on screw and in threaded hole To hold shaft No 8075 in place Torque to 2 4 Ft Lbs Function check With the 4 forks and the primary and sec ondary fork rods installed check to make sure that the forks slide freely on the fork rods by moving them back and forth with your fingers In particu lar if you experience any binding of the 4th C S fork you most likely need to go back and perform clearance check 2 in the case clearance checks section SHIFT DRUM DET
15. d carefully push it down to seat against the case gasket surface Apply some spray lube JIMS No 1226 or equivalent to the main drive gear seal and to the main shaft on the portion adjacent to the splines CAUTION MAKE SURE THE SEAL PROTECTOR IS STILL ON THE END OF THE MAIN SHAFT BEFORE SLIDING THROUGH THE MAIN DRIVE GEAR see figure 1 Install the gear set by sliding the main CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAx 805 482 7422 WWW JIMSUSA COM REV C 09 02 No 8028C6 IS shaft through the main drive gear and slowly pushing the whole trap door gear set assembly until the case dowel pins contact the dowel holes in the side door A rubber hammer is helpful to tap the side door over the case dowel pins without risking any damage to the aluminum chrome of the side door Install the four 5 16 SHCS socket head cap screws with lube on the threads in the lower 4 screw holes and torque them to 13 16 ft lbs Install the two 1 4 SHCS in the screw holes above each dowel and torque them to 7 9 ft lbs Shift Fork Installation Figure 1 details the names of the 4 shift forks that are provided with this kit Page 11 details where these forks belong on the gear set The 3rd C S 2n
16. damages resulting in the failure of a JIMS part the breach of any warranties the failure to deliver delay in delivery delivery in non conforming condition or for any other breach of contract or duty between JIMS and a customer 4 JIMS parts are designed exclusively for use in Harley Davidson motorcycles JIMS shall have no warranty or liability obligation if JIMS part is used in any other application 5 Any JIMS parts or tools that are returned and replaced become the property of JIMS and will not be returned under any circum stance CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 9 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 www JIMSUSA COM No 8028C6 IS REV C FIGURE NO 1 09 02 Super kit Assembly OF RUE che amp SCREW y S MAIN SHAFT SEAL PROTECTOR SHIFT DRUM SHORT BOLTS FOR TRANS SIDE COVER PILLOW BLOCK DETENT N EAR SET amp PILLOW RAP DOOR m 9 BLOCK SSEMBLY pe SCREWS l PILLOW CIO A WASHERS 1ST M S GEAR FORK SIDE DOOR FASTENER 3RD GEAR FORK X AUXILIARY SHAFT 2ND M S Shift Fork GEAR ATH GEAR Q Q GEAR FORK shaft FORK C S CLUTCH RELEASE SET SCREW BEARING KIT FORK SHAFT quite DRUM
17. e To accomplish this mark the area with a black felt pen and draw around the gasket as shown in figure 3 Remove the marked materi al 1 2 inward perpendicular to gasket surface from the gasket surface of the case A die grinder FIGURE NO 2 gasket FIGURE NO 3 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 www JIMSUSA COM No 8028C6 IS FIGURE NO 4 with a carbide burr tool for aluminum cutting can be used or a course flat file also works well Check No 2 Auxiliary fork shaft bridge clearance The auxiliary fork shaft bridge comes installed on the inside of the side door as shown in figure 4 The fork shaft bridge functions as the support for the 4th C S gear fork shaft Again with the gasket still in place on the dowels notice the upper right hand corner of the gasket and if any aluminum is present below the gasket as shown in figures 2 amp 3 remove the material inward perpendicular to gasket surface 1 3 8 from the gasket surface A large coarse round file works well Clearancing must also be done internally on the right rear mounting stud perch Note This is for the third gear counter shaft clearance You must maintain a 060 of
18. ectronic speedo sensor you must install JIMS No 8042 speedo sensor hole block off plate included in kit with gasket and screw or aftermarket equivalent Step 1 Mount Transmission With primary covers removed align transmission mounting studs with transmission plate mounting holes and anchor the transmission to the transmission mounting plate with nuts and washers Tighten nuts enough to lock transmission in place Do not tighten to proper torque CAUTION Protect mounting stud threads while mounting All JIMS transmissions are shipped with a main shaft spline protector this protector should be left in place until transmission is fully mounted and secured Step 2 Install main drive gear final drive sprocket 1 Place final drive sprocket No 33336 83 H D ref on main drive gear with convex side of sprocket Note must use 23 tooth or larger facing outward with lock washer H D No 35126 36 and nut H D No 35211 36 2 Lock sprocket with chain and JIMS tool no 2234 and tighten sprocket nut to 110 120 ft Ibs of torque Bend one tab on lock washer 3 Install shifter arm JIMS No 33715 85AC on to shifter spline shaft Tighten shifter arm bolt to 18 22 ft lbs of torque NOTE IMS suggest positioning the shifter arm slightly off center pointing up and forward 11 55 on a clock Step 3 Assemble inner primary cover to engine transmission 1 Replace old inner primary bearing and seal Install new bearing H D
19. gear to case clearance at all times Remove approximately a 625 radius perpendicular to the trap door See figure 5 and 6 FIGURE NO 6 Note The stud hole will become partially exposed while clearancing the above area Some contact with the steel stud may occur and it is important that you use a die grinder bit suitable for both aluminum and steel All base studs have been coated with locking compound prier to installation to prevent oil bypass ing through this expose stud hole Check No 3 Right side pillow block clearance The right side pillow block roller detent assembly needs to be checked for proper fit to the case The face of the pillow block to case clearance see figure 7 Minimum clearance 010 maxi mum clearance is 060 The pillow block detent assembly must also fit squarely down over the dowels Also check to make sure that some gap FIGURE NO 7 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR OVER 100 OTHER TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY From the Track To the Street 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 7422 WWW JIMSUSA COM REV C 09 02 REV 09 02 No 8028C6 IS FIGURE NO 8 exists approximately 1 16 1 8 between the torsion spring and the side of the case as shown in figure 8 Check 4 Primary fork rod boss clearance The boss in which t
20. he fork rod slides through must be checked for clearance for the main shaft 6th gear Once again use the side door gasket for this check Figure 2 amp 9 shows the area of concern If the material of the case is outside the profile of the gasket remove material below gaskets 1 2 inward perpendicular to gasket sur face A large coarse flat file works best CAUTION REMOVE ALL METAL FILINGS FROM INSIDE OF CASE BEFORE FINAL ASSEMBLY ADJUSTMENTS SET UP AND CHECKS FIGURE NO 9 NOTE See figure 1 for reference The JIMS 6 speed Overdrive has only two adjustments just like the 5 speed The first adjust ment required is the shift drum end play which is different than the 5 speed The second adjust ment is the shifter pawl adjusting screw which is identical to early 5 speed and is performed as one of the last steps in the installation In the 5 speed design axial thrust from the shift drum during shifting is controlled by the right side pillow block only Both pillow blocks left and right side control the axial thrust on the 6 speed Overdrive The shim to properly set up the end play is placed adjacent to the left side pil low block see figure 10 Two shims are provided a 030 and a 025 shim to set up this clearance end play spec is 005 003 Start by putting the 025 thick shim on the end of the shift drum Install the shift drum The kit includes 4 Allen Head bolts to hold the pillow
21. mbly If it is greater than 008 repeat procedure with the other thicker shim In the unlikely event it is less than the lower limit of 002 this is due to a variation in your housing tolerance stack up of the JIMS hardware or a combination of both Regardless of the cause it needs to be cor rected Please call JIMS and have some vernier calipers available to take measurements during your conversation to assist with diagnosis If we determine that the difficulty is with your case we will advise you how to remedy the situation If the difficulty is with our hardware we will ship replacement hardware to remedy the situation With the preceding checks and set ups out of the way you are now ready to begin instal lation GEAR SET INSTALLATION FOR CLEAN CUT amp PRO CUT GEARS 6 5PEEDS Note Apply assembly lube to all moving parts from your seals to your bearings Note Some aftermarket 4 5 transmissions cases may use other year main drive gear bearings See page 3 Super Kit note NEVER install the bearing into the case by applying pressure to the inner race you will destroy the bearing Install the new retaining ring JIMS 11067 with the bevel facing out For a new case install the main drive gear bearing with assembly lube and retaining ring as indicated Install the main drive gear into the main drive gear bearing using the same JIMS tool No 35316 80 Hang the side door gas ket onto the case dowel pins an
22. nding on the manufacturer of the case you are No 8096 amp 8096P Pre Assembly Procedures using you will need to measure the diameter of the 5 Speed transmission installation hole where the main drive gear bearing sits in the Note Some assembly required See pages 13 16 case If you have a dimension of approximately If you are building a 5 speed transmission using 2 95 diameter then you will need to use the fol JIMS 5 speed superkits No 8100 or No 8100P or lowing in the main drive gear area an aftermarket equivalent you will not need to modify this case However you should always check A 2 95 Main drive gear case bearing for running clearances when mixing products from 8978 bearing Main drive case JIMS other manufactures Refer to the super kit note to 11057 Retaining ring 10pk JIMS the left for main drive gear differences Refer to 805 Seal Main drive case JIMS pages 13 16 for the listing of all parts associated 33334 79 Spacer Main drive JIMS with the 8096 8096P transmission case kit B 3 345 Main drive gear bearing 8096 amp 6 Speed Transmission Installation 8096P Kits If you are installing JIMS 6 speed Super Kits 8996 Bearing Main drive case JIMS No 8101 or 8101P you will need to read and follow 11161 Retaining ring JIMS the entire instruction sheet No 8028C6 Please 8089 Spacer Main drive JIMS note that JIMS 6 speed super kits No 8101 and 11165 Quad seal JIMS No 8101P require case modifications
23. od judgment This kit is basically easy to install but does require some special tools See tool list Use a 5 speed Big Twin H D Service Manual and parts book for reference If you are not sure about the procedures in these instructions have a rep utable H D repair shop perform those procedures for you INSTALLATION INSTRUCTIONS Case Preparation Gear set Removal If Super kit is replacing or refreshing an existing 4 5 speed refer to your early 5 speed H D Service Manual for removal of your 5 speed gear set The JIMS 4 6 speed Super kit is designed to fit into JIMS and other 4 5 speed transmission cases with some modifications These modifica tions require that you remove case material in key clearance areas Please read all instructions completely before attempting modifications REV C 09 02 Note these modifications will not limit your abili ty to use a 4 5 speed gear set in the future CAUTION Before grinding or filing cover or remove all bearings and seals and any motor or transmission parts in the area Check No 1 Main shaft 6th gear clearance check Note You must maintain a 060 of gear to case clearance at all times Placed the side door gasket provided onto the dowel pins of the case Figures 2 5 shows the areas of concern that has to be checked If the material of the case around the 5 16 18 screw hole is above the profile of the gasket the material must be removed from the cas
24. rchandise that fails to conform to these conditions will be repaired or replaced at JIMS option if the parts are returned to us by the purchaser within the six 6 months warranty period or within ten 10 days thereafter In the event warranty service is required the original purchaser must call or write JIMS immediately with the problem Some problems can be rectified by a telephone call and need no further course of action part suspected of being defective must not be replaced by a dealer without prior authorization by JIMS If it is deemed necessary for JIMS to make an evalua tion to determine whether the part is defective it must be packaged properly to prevent further damage and be returned pre paid to JIMS with a copy of the original invoice of purchase and a detailed letter outlining the nature of the problem how the part was used and the circumstances at the time of failure If after an evaluation has been made by JIMS and the part was found to be defective repair replacement or credit will be granted ADDITIONAL WARRANTY PROVISIONS 1 JIMS shall have no obligation in the event a JIMS part is modified by person or organization 2 JIMS shall have no obligation if a JIMS part becomes defective in whole or in part as a result of improper instal lation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the part 3 5 shall not be liable for any consequential or incidental
25. s necessary to maintain a clearance of 020 to 050 Finish up assembly of clutch primary chain adjuster etc per H D service manual 7 Attach clutch cable to handle lever assembly using No 45031 65 clutch cable pivot pin Clutch cable length may vary per risers or handlebars Check clutch adjustment manual for 1987 and later 5 speed models 8 Use No 72405 98TN and No 72405 98BK connector and wiring for connecting neutral switch wiring to top of trans 9 For ease of installation and cost use front wheel drive units to drive Speedo or see your dealer for electronic Speedos and calibration units Some fabrication will be required 10 IMPORTANT Add approximately 20 24 oz Of 80W 90 transmissions gear oil Jims No 1230 to transmis sion through filler hole After running transmission allow bike to sit for a few minutes and double check oil level Fill as needed Change trans oil after 1st 500 miles of use and then change oil at normal H D service intervals Super Kit Pre installation procedures We have included the following instructions for the installing 5 8101 and No 8101P Super kits into JIMS No 8096 or 8096P transmission case If using another manufactures case please read super kit note below These instructions also apply to the disassembly and reassembly of JIMS No 8028C6 8028P6 8030C6 and 8030P6 complete transmissions SUPER KIT NOTE 8 TRANSMISSION CASE NOTE Depe
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No.8028C6 IS