Screamin` Eagle 6-Speed Gearset Instruction Sheet - Harley
Contents
1. J03482 8 of 82. The wiring harness for these years has a single cap connector H D part number 9905 connected to the neutral switch Replace the single cap connector as follows in the next four steps c Cut single cap connector off stock wire d Connect the supplied wire 56 to the cut wire with the supplied connector 58 and attach onto either pole of the neutral switch e Attach the other supplied new wire 55 to the remaining pole f Attach the supplied ring terminal 57 to the other end of the new wire and attach to a convenient grounding location Install the starter and oil filler spout Install the exhaust system Install the primary chaincase and starter jackshaft assembly Install the clutch assembly primary chain and compensating sprocket components Install the primary chaincase cover Install drain plugs and fill the transmission and primary chaincase with the recommended lubricant Install plate with gasket over vehicle speed sensor bore in transmission case using stock hardware Install vehicle speed sensor at top of transmission side door using new O ring 4of8 12 Install side cover For Cable Actuated Clutch Follow the instructions in the SE 6 Speed Cable Clutch Side Cover and Release Pushrod Kit Part Number 38752 04 For Hydraulic Clutch Follow the instructions in the Hydraulic Cable Side Cover and Release Pushrod Kit Part Number 38753 04 and in the Hydraulic Clutch Kit Part Number 45033 03
3. tape from drain hole Thoroughly flush the transmission case with a non volatile cleaning solution or solvent to remove any metal shavings dust or debris that might remain For best results use a squirt bottle to direct a stream of solvent through the transmission top cover opening Repeat procedure as necessary draining excess solvent through the drain hole 21 Using low pressure compressed air thoroughly blow out all solvent 22 Using a clean lightly oiled cloth thoroughly wipe the inside of the transmission case Repeat this step with a new cloth until the cloth comes out clean 23 Carefully inspect the transmission case for any metal shavings or debris Repeat steps 19 through 21 if any debris is found 24 Remove the masking tape to uncover remaining holes and bores 25 Thoroughly inspect each bore for any metal shavings dust or debris Alternately direct compressed air into each bore to be certain that the transmission case is clean and dry INSTALLATION NOTE Prelube all bearings and shafts with clean transmission lub ricant prior to installation 2of8 1 Using the appropriate service manual proceed as follows a Install the countershaft needle bearing b Install the main drive gear and bearing is05784 1 Shifter shaft sleeve installer Figure 3 Install Shifter Shaft Sleeve 2 Using the appropriate service manual proceed as follows a Obtain shifter shaft sleeve remover
4. Black or 45383 03 Chrome J03482 13 Install battery negative cable black to battery negative terminal Transmission Service 1 Replace the transmission lubricant after the first 500 miles Thereafter refer to the service manual and change the lubricant at the recommended service intervals 5 of 8 SERVICE PARTS Ss o Out gt o Os all ie mo H RE of
5. door flange using old and new vehicle speed sensor mounting screws J03482 14 Spread one or two clean shop cloths inside the transmis sion case to catch the metal shavings and debris 15 Starting with a 3 8 inch drill bit alternately use progress ively larger bits to enlarge the fork shaft hole Finish the drilling operation with a 3 4 inch drill bit 16 Remove all remaining material up to the edge of the drill plate with a die grinder or similar tool Remove the drill plate 17 Using emery cloth steel wool or a fine tooth file remove any burrs or ridges that may exist from the drilling or cut ting operation 18 Remove sleeve from shifter shaft bore Proceed as follows a Obtain shifter shaft sleeve remover installer tool provided in kit b See Figure 2 From the outside of the transmission case left side insert smaller diameter end of remover into shifter shaft sleeve knurled side out Using a 30 ounce brass hammer minimum tap the end of the remover with light blows until the shifter shaft sleeve is free of the transmission case c Carefully remove any burrs from in or around the sleeve bore NOTE Abrasive particles can damage machined surfaces and result in premature failure 19 Carefully pull out shop cloths from inside the transmission case Exercise care to keep any debris captured by the cloths from falling into the transmission case 20 Place drain pan beneath transmission case and remove
6. installer tool provided in kit b See Figure 3 Place new sleeve over installer 1 Place thrust washer thrust bearing and then the second thrust washer onto installer screw c Apply avery thin film of HD 20W50 engine oil to OD of new sleeve ID and OD installer threads and ID of sleeve bore Also apply a very thin film of HD 20W50 engine oil to the thrust bearing and thrust washers d From inside the transmission case hold the sleeve and installer against the sleeve bore From outside the transmission case thread the installer screw assembly into the installer keeping the sleeve properly aligned e Using a 3 4 inch box wrench hold the hex on the installer inside the transmission case f Using a 1 4 inch hex head tighten the installer screw until the sleeve stops against the first thrust washer g Remove the tool from the transmission case Apply a very thin film of HD 20W50 engine oil to sleeve ID and new shifter shaft From outside the transmission case slide shaft through sleeve and then rotate Shaft must rotate freely a full 360 degrees Remove shifter shaft assembly i Install the new shifter seal Install shifter shaft assembly from inside the transmission case Install new shifter seal washer and new retaining ring NOTES Leave the shrink wrap on the mainshaft until side door install ation is complete Installation of the side door with the shrink wrap removed may result in damage to the main drive gear
7. 8 Figure 8 Service Parts 6 Speed Gearset J03482 Table 2 Service Parts 6 Speed Gearset Item Description Quantity Part Number 1 Mainshaft 35058 03 2 Countershaft 35059 03 3 Countershaft 1st Gear 35080 03 4 Mainshaft 3rd Gear Countershaft 2nd Gear 2 35083 03 5 _ Mainshaft 4th Gear 35104 03 6 Mainshaft 6th Gear 35131 03 7 Mainshaft 1st Gear 35134 03 8 Countershaft 3rd Gear Mainshaft 2nd Gear 2 35135 03 9 Countershaft 4th Gear 35136 03 10 Shift Ring 1 2 3 4 2 35137 03 11 Shift Ring 5 6 35138 03 12 Side Door 35158 03 13 Shifter Fork Shaft 34088 87A 14 Splined Sleeve 2 35140 03 15 Drum Support Block Dowel 4 609 16 Shifter Fork 1 2 35143 03 17 Shifter Fork 3 4 35144 03 18 Shifter Fork 5 6 35145 03 19 Side Door Bearing Retaining Ring 2 35087 99A 20 Side Door Bearing 2 8992A 21 Mainshaft Countershaft Locknut 2 35078 79 22 Speed Sensor O Ring 11289A 23 Split Cage Bearing 5 8876A 24 Retaining Ring 8 11067 25 Thrust Washer 2 6003 26 Sprocket Spacer 33344 94 27 Mainshaft Inner Race 34091 85A 28 Oil Seal Large 12067B 29 Bearing Retaining Ring 11161 30 Quad Seal 11165 31 Main Drive Gear Bearing 8996A 32 Main Drive Gear 35237 03 33 Right Drum Support Block 33304 00 34 Detent Arm Screw 33376 00 35 Detent Sleeve 33375 00A 36 Detent
8. Follower 33364 00A 37 Detent Arm Spring 33374 00 38 Shifter Shaft Assembly 35146 03 39 Clutch Release Cover Gasket 35148 03 40 Drum Support Block Screw 4 3909 41 Shifter Centering Screw 34978 00A 42 Countershaft Needle Bearing 8977 43 Lower Side Door Screw 4 3249 44 Upper Side Door Screw 2 4814A 45 Shifter Shaft Sleeve 34979 00 J03482 70f8 Table 2 Service Parts 6 Speed Gearset Item Description Quantity Part Number 46 Side Door Plug 45830 48 47 Shifter Seal Washer 6497HW 48 Shifter Fork Shaft Set Screw 3784 49 Speed Sensor Plate Gasket 2 35152 03 50 Countershaft 5th Gear 35238 03 51 Speed Sensor Plate Screw 2 4705 52 Speed Sensor Plate 2 35153 03 53 Side Door Gasket 35147 03 54 Neutral Switch 33904 00 55 Black Wire Assembly 72405 98BK 56 Tan Wire Assembly 72405 98TN 57 Ring Terminal 1 4 Inch 72241 94A 58 Connector 18 20 Gauge 70585 93 59 Shift Drum 35142 03 60 Left Drum Support Block 33301 00A 61 Shift Drum Retainer 11342 62 Drill Plate 35155 03 63 Shifter Shaft Sleeve Remover Installer Tool 35156 03 64 Shifter Seal 12045 65 Shifter Retaining Ring 11150 66 Speed Sensor Plug 35239 03 67 Neutral Switch Washer Aluminum 6288 68 Neutral Switch Washer Nylon 33043 80 Items Not Shown Top Cover Gasket FLHT and FXST 34904 86D Oil Fill Spout Gasket FLHT 1993 and Later 62432 93B
9. MOTOR HARLEY DAVIDSON WY J03482 INSTRUCTIONS REV 2009 01 22 SCREAMIN EAGLE 6 SPEED GEARSET GENERAL Kit Number 33101 03A Models For model fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only Additional Parts Required For Cable Actuated Clutch SE 6 Speed Cable Clutch Side Cover and Release Pushrod Kit Part Number 38752 04 For Hydraulic Clutch Hydraulic Cable Side Cover and Release Pushrod Kit Part Number 38753 04A 1990 mid 1994 models use a wider sprocket spacer Part Number 33334 85 and mainshaft oil seal Part Number 12050 These parts are not included with the kit and will need to be purchased separately If a newer model sprocket is used 40250 94C the mainshaft oil seal and the sprocket spacer in the kit may be used WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 8 and Table 2 Table 1 Gear R
10. atios GEAR STOCK 5 SPEED SE 6 SPEED First 3 210 3 210 Second 2 209 2 209 Third 1 572 1 572 Fourth 1 226 1 226 Fifth 1 000 1 000 Sixth N A 0 885 J03482 REMOVAL NOTES Leave the transmission case in the frame unless the case itself requires replacement For ease of illustration photographs show the case removed Use the appropriate service manual for the following proced ures 1 Drain the primary chaincase and transmission lubricants 2 Remove battery negative cable black from battery neg ative terminal 3 Remove the primary chaincase cover Remove the clutch assembly primary chain and compensating sprocket components Remove the starter jackshaft assembly and primary chaincase 4 Remove the exhaust system as necessary to gain com plete access to the transmission side door 5 Remove the oil filler spout and starter 6 Remove the clutch release cover Remove the clutch cable from the clutch release cover 7 Remove the vehicle speed sensor 8 Remove the transmission top cover a Remove neutral switch from transmission top cover b Remove the drum support blocks and shift drum Remove the drum support block dowels from deck of transmission case c Remove the fork shaft and shifter fork assemblies d Remove the bearing inner race from the transmission mainshaft e Remove the transmission side door and the main shaft countershaft assembly The fro
11. he countershaft This engagement is necessary to obtain the proper clearance for side door installation f Slide side door assembly further into transmission case stopping about one inch before mating flanges make contact Start fork shaft through hole in side door See Figure 6 Through the transmission top cover opening install the 1 2 shifter fork 1 into the shift ring between 1st and 2nd gears on the countershaft For proper clearance be sure the dogs on the 3 4 shift ring closest to side door on the mainshaft are fully engaged with mainshaft 4th gear i Install new side door plug into side door j Slide fork shaft through holes in shifter forks and then fully install side door Be sure that end of fork shaft engages blind hole on left side of transmission case k The fork shaft set screw is a lock patch type set screw and is designed to allow the fork shaft to have min imum endplay but still rotate freely DO NOT tighten fork shaft set screw against fork shaft Damage could result if set screw is tightened against fork shaft Install fork shaft set screw in transmission side door Tighten screw until the shaft has minimum endplay but still rotates freely Remove shrink wrap from the mainshaft 1 Shifter fork Figure 6 Install 1 2 Shifter Fork to Fork Ring 1 Block dowels Figure 7 Orient Shift Drum Support Block Dowels J03482 10 11 Using the appropriate service man
12. nt dowel pin may be stuck in the side door after removal If this occurs remove the dowel pin from the side door and install it back into the transmis sion case f Remove the shifter shaft assembly and shifter seal NOTE Use the appropriate service manual for the following proced ures 9 Remove the main drive gear and bearing 10 Remove the countershaft needle bearing 11 Using masking tape cover all the side door flange holes in the transmission case with the exception of the top three 1 of 8 NOTE While the two threaded holes at the top of the flange are used for mounting of the drill plate the fork shaft hole center thru hole is used as the pilot for the drill bits 12 From inside the transmission case tape over all bores as follows e Vehicle speed sensor and mounting screw bores e Transmission top cover and shift drum support block screw bores e Transmission drain hole bore e Main drive gear bearing bore Countershaft needle bearing bore e Fork shaft bore e Shifter shaft bore NOTE Be sure drill plate is properly oriented Improper orientation will result in damage that requires replacement of the transmission case is05780 t 1 Drill plate Figure 1 Install Drill Plate to Transmission Case 1 Shifter shaft sleeve remover Figure 2 Remove Shifter Shaft Sleeve 13 See Figure 1 Obtain the drill plate 1 provided in kit and fasten to top of side
13. seal Be sure to remove the plastic cap and cable strap from the mainshaft before side door installation Blow away any styro J03482 foam bits or other packaging material that might be clinging to gears or splines is05786 1 S hifter fork Figure 4 Install 5 6 Shifter Fork to Shift Ring Wl is05787 a gt 1 Shifter fork Figure 5 Install 3 4 Shifter Fork to Shift Ring 3 Install the transmission side door and mainshaft counter shaft assembly as follows a Hang new side door gasket on dowels in side door flange of transmission case Start side door and mainshaft countershaft assembly into transmission case but stop so that all gears remain on the outboard side Note that there are three shifter forks each of which are stamped for easy identification Set aside the 5 6 shifter fork the 3 4 shifter fork and the 1 2 shifter fork in that order See Figure 4 Install the 5 6 shifter fork 1 into the shift ring outboard of the 6th gear on the mainshaft shift ring closest to the main drive gear See Figure 5 Install the 3 4 shifter fork 1 into the shift ring between the 4th and 3rd gears on the mainshaft shift ring closest to the side door Be sure the dogs on the shift ring are engaged with mainshaft 3rd gear and then rotate shifter fork toward the 3of8 countershaft until the slot in the fork engages the edge of the shift ring between 1st and 2nd gears on t
14. ual proceed as follows a See Figure 7 Install four new drum support block dowels 1 in deck of transmission case Orient the dowels so that the split line is aligned left to right b Install new drum support blocks with new shift drum c Rotating output shaft by hand shift through all six gears to verify proper operation Input shaft may need to be rocked back and forth to get all gears to shift d Install the mainshaft oil seal quad seal spacer sleeve sprocket spacer sprocket and sprocket nut e Install the new bearing inner race onto the transmis sion mainshaft Install the transmission top cover with new gasket Verify that the shifter pawl does not contact the inside of the top cover during installation a See Figure 8 Install new neutral switch into the transmission top cover For 1998 or later models or if you are replacing the stock top cover with a 1998 or later model top cover DO NOT remove the O ring For 1990 1997 model years remove the O ring from the neutral switch and install the aluminum washer 67 with the chamfer side of washer away from the switch body followed by the nylon washer 68 on the neutral switch These parts are included in the bag with your neutral switch Install the neutral switch into top cover and tighten to 120 180 in los 13 6 20 3 Nm b Install connectors on neutral switch studs For 1990 thru 1997 model years refer to the wiring diagram at the back of the service manual
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