- S&S Cycle
Contents
1. can be rectified by a telephone call and need no further course of action A part that is suspect of being defective must not be replaced by a Dealer without prior authorization from S amp S If it is deemed necessary for S amp S to make an evaluation to determine whether the part was defective a return authorization number must be obtained from S amp S The parts must be packaged properly so as to not cause further damage and be returned prepaid to S amp S 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 S amp S and the part was found to be defective repair replacement or refund will be granted ADDITIONAL WARRANTY PROVISIONS 1 S amp S shall have no obligation in the event an S amp S part is modified by any other person or organization 2 S amp S shall have no obligation if an S amp S part becomes defective in whole or in part as a result of improper installation improper maintenance improper use abnormal operation or any other misuse or mistreatment of the S amp S part 3 S amp S shall not be liable for any consequential or incidental damages resulting from the failure of an S amp S 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 S amp S and a c2. Hydraulic Side Cover PN 56 4060 Complete Transmission nE MOVAL old transmission still in bike 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 8 Support the rear of the motorcycle with a scissors jack and then loosen the front mounting bolts on the shocks as shown in Picture 1 This will allow you to access the transmission mounting bolts and remove them Lift the old transmission out once the mountin
3. Instruction 51 1198 5 23 07 Copyright 2006 2007 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle Tac 235 Causeway Blvd La Crosse Wisconsin 54603 Phone 608 627 1497 Technical Service Phone 608 627 TECH 8324 Technical Service Email sstech sscycle com Website www sscycle com Fax 608 627 1488 Because every industry has a leader Installation Instructions for S amp S All Helical Transmission Complete Assembly for 1991 99 Harley Davidson Softail and Custom Applications DISCLAIMER S amp S parts are designed for high performance off road racing applications and are intended for the very experienced rider only The installation of S amp S parts may void or adversely effect your factory warranty In addition such installation and use may violate certain federal state and local laws rules and ordinances as well as other laws when used on motor vehicles used on public highways especially in states where pollution laws may apply Always check federal state and local laws before modifying your motorcycle It is the sole and exclusive responsibility of the user to determine the suitability of the product for his or her use and the user shall assume all legal personal injury risk and liability and all other obligations duties and risks associated therewith The words Harley Harley Davidson H D Sportster Evolution and all H D part numbers and model designations are us
4. Speed Transmission s s sesersesersesenseeeeee 56 5115 Switch neutral 56 5113 Shaft counter S amp S 6 speed with integral main gear 56 5114 Gear fifth countershaft S amp S G speed 56 5116 Assembly carrier drum LH 56 1294 Gear second countershaft S amp S G speed 56 5117 Gear first countershaft S amp S G speed 56 5118 Gear third fourth countershaft S amp S speed 56 3139 Nut bearing retainer trap door Te 20 UN 2B 50 8477 Collar SAIS E 56 5122 Assembly carrier drum BH 56 1295 Sleeve Shift collar cece cescssescssscssecssesssssessessesseesesseeseees 56 0010 Spacer thrust mainshaft S amp S G speed 56 1302 Gear fourth main S amp S 6 speed ceceeeeceseeeeeeeeeeeeeeeees 56 5126 Gear third mainshaft S amp S G speed EE 56 5127 Gear first mainshaft S amp S speed 56 5128 CONTINUED Replacement Parts for S amp S 6 Speed Transmissions 36 37 38 39 Gear second mainshaft S amp S 6 speed eceeceseteeeeeeeeee 56 5129 Gear fifth mainshaft S amp S G speed 56 5131 Gear main drive with bearings and seal S amp S 6 speed 56 5123 Case transmission S amp S 6 speed Natural sirni ia 56 1125 Black E NEEN 56 1126 POLISH OC EE 56 1127 40 Cover side S amp S 6 speed ransmisslon 41 Assembly dipstick 2 ccecccceseeeceseteeeeeeseeeeeeeceeeeeeeeeaeesereeeaeen 42 S amp S Inner primary bearing race optional Not shown Complete Transmission I
5. d of the black wire to a suitable ground using an eyelet or equivalent solderless connector Picture 7 Picture 8 5 Loosely install the starter oil tank and battery per the factory service manual DO NOT CONNECT THE BATTERY CABLES AT THIS TIME You will need to tighten the starter mounting bolts later in the procedure 6 Position the drive belt over the S amp S 34 tooth pulley This may require removing the rear axle to allow enough slack in the belt to fit over the pulley NOTE Use of the stock 32 tooth pulley with the S amp S transmission will result in an extremely low overall first gear ratio S amp S provides a 34 tooth pulley to counter act the lower internal first gear ratio by changing the final drive ratio with the provided pulley 7 Use the S amp S inner primary bearing race installation tool PN 56 5141 to press the race from the old transmission mainshaft onto the new mainshaft as shown in Picture 9 When using the stock H D bearing race press race onto shaft so inside edge is 0 100 from main drive gear NOTE S amp S recommends the use of S amp S race part number 56 5089 to eliminate race movement on the mainshaft preventing damage to the output gear seal Picture 9 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 Moc
6. e 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 amp 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 amp 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 amp S recommends that the motorcycle be road tested to ensure proper function of all components A119 SSS 250 shims as shown KE Picture 10 Picture 11 Picture 12 TRANSMISSION SERVICE NOTE S amp S recommends filling transmission with 20 24 ounces of GEAR RATIO CHART 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 RECOMMENDED FINAL BELT DRIVE GEARING S amp S recommends that you use a 32 o
7. ed in reference only S amp S Cycle is not associated with Harley Davidson Inc SAFE INSTALLATION AND OPERATION RULES Before installing your new S amp S part it is your responsibility to read and follow the installation and maintenance procedures in these instructions and follow the basic rules below for your personal safety Gasoline is extremely flammable and explosive under certain conditions and toxic when breathed Do not smoke Perform installation in a well ventilated area away from open flames or sparks If motorcycle has been running wait until engine and exhaust pipes have cooled down to avoid getting burned before performing any installation steps Before performing any installation steps disconnect battery to eliminate potential sparks and inadvertent engagement of starter while working on electrical components Read instructions thoroughly and carefully so all procedures are completely understood before performing any installation steps Contact S amp S with any questions you may have if any steps are unclear or any abnormalities occur during installation or operation of motorcycle with a S amp S part on it Consult an appropriate service manual for your motorcycle for correct disassembly and reassembly procedures for any parts that need to be removed to facilitate installation Use good judgement when performing installation and operating motorcycle Good judgement begins with a clear head Don t let alcoho
8. g hardware is removed NOTE Stock Harley Davidson frames have a removable transmission mounting plate that will need to be transferred to the new S amp S transmission for installation as an assembly in the frame Please refer to the factory service manual for your model motorcycle For further information refer to your factory service manual I i LKE Di ben Picture 1 INSTALLATION 1 Prior to placing the transmission in the chassis verify that the mounting plate is clean and free from any debris or paint chips Install the transmission onto the mounting plate See Picture 2 and thread your existing hardware on the five mounting studs See Picture 3 NOTE Stock Harley Davidson frames have a removable transmission mounting plate that will need to be transferred to the new S amp S transmission for installation as an assembly in the frame Please refer to the factory service manual for your model motorcycle Picture 2 Picture 3 NOTE If you are installing the S amp S transmission in a custom frame it is imperative that you verify that the fifth mounting stud Picture 4 will not interfere with the shocks when they are installed To do this position the transmission on the mounting plate and snug the four main mounting studs Position the shocks in their proper mounting place and confirm there will be no contact when the shock moves through its travel range If you do not have a fifth mounting position on your t
9. k 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 sur
10. l drugs or fatigue impair your judgement Start installation when you are fresh Be sure all federal state and local laws are obeyed with the installation For optimum performance and safety and to minimize potential damage to carb or other components use all mounting hardware that is provided and follow all installation instructions Motorcycle exhaust fumes are toxic and poisonous and must not be breathed Run motorcycle in a well ventilated area where fumes can dissipate IMPORTANT NOTICE Statements in this instruction sheet preceded by the following words are of special significance A WARNING Means there is the possibility of injury to yourself or others A CAUTION Means there is the possibility of damage to the part or motorcycle NOTE Other information of particular importance has been placed in italic type S amp S recommends you take special notice of these items WARRANTY All S amp S parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of twelve 12 months from the date of purchase Merchandise that fails to conform to these conditions will be repaired or replaced at S amp S s option if the parts are returned to us by the purchaser within the 12 month warranty period or within 10 days thereafter In the event warranty service is required the original purchaser must call or write S amp S immediately with the problem Some problems
11. nstallation 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 A CAUTION 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 amp 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 SPECIAL TOOL REQUIREMENTS Primary Locking Tool Inner Bearing Race Puller S amp S PN 56 5141 Inner Bearing Race Installer S amp 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 amp S Inner Bearing Race PN 56 5089 S amp S Speedometer Calibrator PN 55 1007 S amp S
12. r 34 tooth output pulley with a 65 tooth rear pulley S amp 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
13. ransmission plate remove the stud by affixing two hex nuts on it and turning it counterclockwise Coat a ie 14 x 4 bolt not included in kit with pipe sealant and install it in the hole the threads are a tight fit so go slow but be sure to bottom the bolt out on the transmission case Picture 4 2 Remove the S amp S billet end cover Use snap ring pliers to remove the snap ring and the S amp S 18 degree ball and ramp assembly as illustrated in Picture 5 Pass the clutch cable through the end cover and torque it to 3 5 ft lbs Attach the ramp mechanism to the cable install the three balls and reassemble the ramp mechanism and snap ring in the end cover Put blue threadlock on the six end cover mounting bolts and torque them to 7 9 ft lbs See Picture 6 NOTE If using S amp S hydraulic clutch side cover kit PN 56 4060 follow instructions included with the kit Picture 5 Picture 6 3 Transfer the breather hose from the stock unit to the S amp S transmission 4 Connect the neutral switch wires to the neutral switch as shown in Picture 7 If you are working on a 1991 1997 Harley Davidson you will need to convert it to a two wire system with H D part numbers 72405 98TN and 72405 98BK not included in kit See Picture 8 Convert the wiring by following the procedure below A Cut the existing single pin connector off and splice the tan wire in its place B Connect the black and tan wires to the neutral switch Attach the en
14. ustomer 4 S amp S parts are designed exclusively for use in Harley Davidson and other American v twin motorcycles S amp S shall have no warranty or liability obligation if an S amp S part is used in any other application REPLACEMENT PARTS FOR S amp S 6 SPEED TRANSMISSIONS 1 Trap Door 6 Speed Transmission sccccseeeeeseeeeeeeee 56 1221 2 Kit Gaskets and Sea 56 1226 3 Hardware Kit 6 Speed Transtrmtsslon 56 1227 4 Kit Ball and Ramp 6 Speed Transmisslon 56 1228 5 Kit Throwout Bearing eeccccseececeseteeeeeeeeeeeeeeeeeseeeeeaeeeee 56 1229 6 Kit Speed Sensor 56 1230 7 Kit Bearings Thrust Washers ANd Retaining Clips 56 1231 8 Mainshaft Nut jam hex nyloc 4 16 UNF 2B 2 Pack cccoxescecersevecsevescesevsencecetctssserseviecencheesetnstcset 56 1278 9 Kit Shift Pawl 6 Speed Transrmtsslon 56 1225 10 Shift Tork 5 6 ENEE 56 1275 11 Shift Tork E 56 1276 12 du fork 3 4 ipponin prunenn rican pinnien ican tiay 56 1277 13 Shaft shift rail 56 1274 14 Drum bt 56 1273 15 Nut hex 14 24 UNS 2B LH EE 56 3003 16 Sprocket 34 Tooth saguei s nia edane staasts iaa daae iaaiiai 56 5084 17 Hardware kit sprocket cccccsceseeseeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeee 56 1272 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Spacer Spro KEE aa e aaa aeaa raaa aeaa EnaA E aaas 56 1293 Ring retaining beveled internal 3 246 50 8469 Cover top 5 6
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