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INSTRUCTIONS - Harley

1. 313 Mainshaft Race 34091 85A Oil Pan with Baffle Plain 26085 99A Main Case Seal 12067B Sleeve Spline 2 35140 03 Quad Seal 11165 Shifter Fork Shaft 34088 87A Vent Top Lid Fitting 62375 57A J03260 3 of 6 Part No 33034 03A Date 08 04 MOTOR e Service Parts 6 Speed Transmission Silver Item Description Qty Part No Item Description Qty Part No 31 Mainshaft 5th Gear 35237 03 59 Shifter Lever 33849 97 32 Speedo Sensor Plate Screw 4705 60 Clear Dip Stick 62853 99 33 Neutral Switch 33904 00A 61 Plug for Door 45853 99 34 Chrome Lid Top 34469 01 62 Door Roll Pin 634 35 Oil Pan Gasket 26072 99A 63 Main Case Bearing 8996A 36 Countershaft Bearing 8977 64 Harness Door Retaining Clip 38709 99 37 Trap Door Gasket 35147 03 65 Trap Door Screw Lower 3 3249 38 Clutch Release Cover Gasket 35148 03 66 Top Door Stud 16709 95 39 Lid Gasket 34917 99B 67 Bottom Door Stud 16708 95 40 Shifter Shaft Seal 12045 68 Motor Oil Hose 2 62726 99 41 Shifter Shaft Retaining Ring 11150 69 Hose Clamp Black 3 10249 42 Trap Door Screw Upper 4814A 70 Speedo Sensor O Ring 11289A 43 Pillow Block Screw 4 3909 71 Sensor Plate Gasket 35152 03 44 Shifter Centering Screw 34978 00A 72 Sensor Plate 35153 03 45 Chrome Dipstick 37075 87 73 Transmission Top Cover Vent Hose 42533 91A 46 Dipstick O Ring 11132 74 Elbow Motor Vent Fitting 16334 02 47 Countershaft Gear 5th 35238 03 75 Top Cover Vent Motor Hose 45795 02 48 Top Lid Screw 2 4740A 76 Cas
2. 4 03 Mainshaft Countershaft Mainshaft 6th Gear 35131 03 Locknut 2 35078 79 Mainshaft 1st Gear 35134 03 Clutch Release Cover Countershaft 3rd Gear Lower Screw 4 4718A Mainshaft 2nd Gear 2 35135 03 Shifter Lever Screw 856A Countershaft 4th Gear 35136 03 Mainshaft Countershaft Shift Ring 1 2 3 4 2 35137 03 Retaining Ring 8 11067 Shift Ring 5 6 35138 03 Mainshaft Thrust Washer 2 6003 Chrome Trapdoor with Ear 35139 0313 Sprocket Spacer 33344 94 Sleeve Spline 2 35140 03 Mainshaft Race 34091 85A Shifter Fork Shaft 34088 87A Main Case Seal 12067B Shifter Fork 1 2 Assembly 35143 03 Quad Seal 11165 Vent Top Lid Fitting 62375 57A J03260 5 of 6 Part No 33040 03A Date 08 04 SMOTOR Q Service Parts 6 Speed Transmission Black and Chome Item Description Qty Part No Item Description Qty Part No 31 Mainshaft 5th Gear 35237 03 59 Shifter Lever 33849 97 32 Speedo Sensor Plate Screw 4705 60 Clear Dip Stick 62853 99 33 Case Bearing Retaining Ring 11161 61 Shifter Shaft Set Screw 3784 34 Neutral Switch 33904 00A 62 Door Roll Pin 634 35 Chrome Lid Top 34469 01 63 Main Case Bearing 8996A 36 Oil Pan Gasket 26072 99A 64 Harness Door Retaining Clip 38709 99 37 Oil Pan with Black Baffle 26087 99A 65 Trap Door Screw Lower 3 3249 38 Trap Door Gasket 35147 03 66 Top Door Stud 16709 95 39 Clutch Release Cover Gasket 35148 03 67 Bottom Door Stud 16708 95 40 Lid Gasket 34917 99B 68 Motor Oil Hose 2 62726 99 41 Shifter S
3. MOTOR HARLEY DAVIDSON WY J03260 INSTRUCTIONS REV 10 13 2005 Kit Numbers 33034 03A 33040 03A DYNA 6 SPEED TRANSMISSION COMPLETE General These kits fit 2001 to 2005 FXD model motorcycles Requires separate purchase of cable Sidecover Release Kit or Hydraulic Sidecover Release Kit See retail catalog for parts numbers Refer to Instructions included in Sidecover Release Kits to complete installation of Screamin Eagle 6 Speed Transmission or Gearset Kits Kit 33034 03A is a complete 6 Speed Silver and Chrome transmission Kit 33040 03A is a complete 6 Speed Black and Chrome transmission STOCK 5 SPEED SE 6 SPEED Transmission Ratio Comparison WARNING The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have your Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00308a NOTE A Service Manual for your model motorcycle is available from any Harley Davidson dealer Removal of Original Transmission 1 Position motorcycle on a suitable lift WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a A WARNING Disconnect negative battery cable first If positive cable sh
4. chaincase cover Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a 7 Refer to the PRIMARY CHAINCASE HOUSING in the Service Manual and follow the instructions given to remove the primary chaincase housing 8 Refer to the REAR WHEEL REMOVAL in the Service Manual and follow the instructions given to remove the belt Remove the belt guard and debris deflector Remove spring clip Loosen axle nut enough to slide wheel forward Note the rear wheel does not need to be removed o a 0 co pw Remove the belt and set aside 1of6 10 11 12 13 14 15 16 17 See the VEHICLE SPEED SENSOR section and unplug the vehicle speedometer sensor connection and remove the mounting bolt Lift sensor from the trans mission case and set aside Refer to NEUTRAL SWITCH and disconnect the con nectors from the neutral switch Refer to the STARTER REMOVAL in the Service Manual and follow the instructions given to remove the the starter Position a jack with a wooden block under the engine and transmission oil pan Refer to the ENGINE MOUNTS in the Service Manual and follow the instructions given to remove the trans mission from the rear isolator Refer to the REAR FORK REMOVAL in the Service Manual and follow the instructions given to remove the plug screw an
5. d lockwasher from the rear fork Remove the screw and lockwasher and slide the pivot shaft with the attached nut out the right side Remove the four bolts and washers connecting the engine to the transmission The transmission is now loose from the frame and engine and resting on a support Slide the transmission toward the rear of the bike to clear the dowel pins and lift the transmission out the right side Installation of New Transmission 1 Refer to your Service Manual and follow the instructions given to install the new transmission into the motorcycle Slide the transmission from the right and align the four bolt holes on the transmission with the four holes on the engine Install the four bolts and washers removed in step 15 See Figure 1 Tighten the four transmission mounting bolts in a cross pattern sequence as follows a First tighten all four in turn to 15 ft lbs 20 3 Nm b Then tighten all four in turn to 30 35 ft lbs 40 7 47 5 Nm i06178 Dowel pins Figure 1 Transmission to Crankcase Torque Sequence Transmission viewed from front J03260 10 11 12 13 14 Slide fork assembly into position aligning with mounting boss of transmission case Install pivot shaft removed with attached nut Install washer and screw Tighten screw to 45 50 ft lbs 61 0 67 8 Nm Install the two screws washer and nuts
6. e Bearing Retaining Ring 11161 49 Clutch Release Cover Screw 77 Right Pillow Block 33304 00 Upper 6 4717A 78 Detent Spring Right Pillow Block 33375 00A 50 Top Lid Screw 4822A 79 Follower Detent Right Pillow Block 33364 00A 51 Transmission Pulley 40250 94C 80 Detent Arm Spring 52 Mega Nut 35236 03 Right Pillow Block 33374 00 53 Mega Nut Screw 2 4069A 81 Detent Arm Screw 54 Oil Pan Screw 10 4741A Left Pillow Block 33376 00 55 Shift Drum Assembly 35142 03 82 Cage Bearing Split 5 8876A 56 Shifter Shaft Assembly 35146 03 83 Shifter Shaft Set Screw 3784 57 Shift Drum Retainer 11342 84 Shifter Shaft Assembly 35146 03 58 Shifter Seal Washer 6497HW 85 Transmission Case Sub Assembly Silver 2001 and Up FXD 34791 03 J03260 4 of 6 Part No 33040 03A Date 08 04 MOTOR Q Service Parts 6 Speed Transmission Black and Chome i06778 24 25 24 25 24 AN 24242418 18 Description Qty Part No Description Qty Part No Mainshaft 35058 03 Shifter Fork 3 4 Assembly 35144 03 Countershaft 35059 03 Shifter Fork 5 6 Assembly 35145 03 Countershaft 1st Gear 35080 03 Cage Bearing Split 5 8876A Mainshaft 3rd Gear Door Retaining Ring 2 35087 99 Countershaft 2nd Gear 2 35083 03 Trap Door Bearing 2 8992A Mainshaft 4th Gear 3510
7. er and Release Pushrod Kit Part Number 38753 04 and in the Hydraulic Clutch Kit Part Number 45033 03 Black or 45383 03 Chrome 2 of 6 SMOTORZ Part No 33034 03A Date 08 04 ur Service Parts 6 Speed Transmission Silver and Chrome i06777 2425 24 AN RRA 17 16 18 76 229 36 44 H Tr 23 WA 4058 41 Description Qty Part No Description Qty Part No Mainshaft 35058 03 Shifter Fork 1 2 Assembly 35143 03 Countershaft 35059 03 Shifter Fork 3 4 Assembly 35144 03 Countershaft 1st Gear 35080 03 Shifter Fork 5 6 Assembly 35145 03 Mainshaft 3rd Gear Door Retaining Ring 2 35087 99 Countershaft 2nd Gear 2 35083 03 Trap Door Bearing 2 8992A Mainshaft 4th Gear 35104 03 Mainshaft Countershaft Mainshaft 6th Gear 35131 03 Locknut 2 35078 79 Mainshaft 1st Gear 35134 03 Clutch Release Cover Countershaft 3rd Gear Lower Screw 4 4718A Mainshaft 2nd Gear 2 35135 03 Shifter Lever Screw 856A Countershaft 4th Gear 35136 03 Pushrod Thrust Washer 37313 80 Shift Ring 1 2 3 4 2 35137 03 Mainshaft Thrust Washer 2 6003 Shift Ring 5 6 35138 03 Sprocket Spacer 33344 94 Chrome Trapdoor with Ear 35139 0
8. haft Seal 12045 69 Hose Clamp Black 3 10249 42 Shifter Shaft Retaining Ring 11150 70 Drain Plug 45830 48 43 Trap Door Screw Upper 4814A 70 Speedo Sensor O Ring 11289A 44 Pillow Block Screw 4 3909 71 Sensor Plate 35153 03 45 Shifter Centering Screw 34978 00A 72 Sensor Plate Gasket 35152 03 46 Chrome Dipstick 37075 87 73 Transmission Top Cover Vent Hose 42533 91A 47 Dipstick O Ring 11132 74 Elbow Motor Vent Fitting 16334 02 48 Top Lid Screw 2 4740A 75 Top Cover Vent Motor Hose 45795 02 49 Clutch Release Cover Screw 76 Countershaft Bearing 8977 Upper 6 4717A 77 Countershaft Gear 5th 35238 03 Top Lid Screw 4822A 78 Shifter Shaft Assembly 35146 03 Transmission Pulley 40250 94C 79 Right Pillow Block 33304 00 Mega Nut 35236 03 80 Detent Arm Screw 33376 00 Mega Nut Screw 2 4069A 81 Detent Sleeve 33375 00A Oil Pan Screw 10 4741A 82 Detent Follower 33364 00A Shift Drum Assembly 35142 03 83 Detent Arm Spring 33374 00 Left Pillow Block 33301 00A 84 Transmission Sub Assemby Case Shifter Shaft Assembly 35146 03 Black 2001 and UP FXD 34795 03 Shift Drum Retainer 11342 85 Speedo Sensor O Ring 11289A Shifter Seal Washer 6497HW J03260 6 of 6
9. ould contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 2 Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first 3 Refer to the TRANSMISSION CASE REMOVAL in the Service Manual and follow the instructions given to remove the components with the following steps 4 Refer to REMOVING ENGINE FROM THE CHASSIS in the Service Manual and follow the instructions given for the removal of the transmission with the following excep tions a The air cleaner fuel tank and carburetor need not be removed b The spark plugs do not need to be removed c Stabilizer link nut and horn bracket bolts do not need to be removed d MAP sensor does not have to be removed e The front downtubes do not need to be protected f A ratchet strap is not needed to secure the transmission 5 Refer to the CLUTCH CONTROL in the Service Manual and follow the instructions given to remove the clutch cover and disconnect the clutch cable end from the cover and set the cable aside NOTE Be sure to remove the inspection cover s top and rear screws or the inspection cover primary chaincase cover and the inner primary chaincase housing will be damaged 6 Refer to PRIMARY CHAINCASE REMOVAL in the Service Manual and follow the instructions given to remove the primary
10. to the rubber isolator mounting assembly at the rear lower boss of the transmission Tighten to 18 22 ft lbs 24 4 29 8 Nm Install the two socket head screws lockwashers and washer through the rear frame transmission mounting holes Tighten to 22 27 ft lbs 29 8 36 6 Nm Install belt over rear wheel sprocket and transmission sprocket Refer to REAR BELT DEFLECTION in the Service Manual and follow the instructions given to cor rectly install the belt to the proper deflection Refer to the PRIMARY CHAINCASE HOUSING in the Service Manual and follow the instructions given to install the chaincase housing Refer to NEUTRAL SWITCH in the Service Manual and fol low the instructions giver to install these connections Refer to VEHICLE SPEED SENSOR in the Service Manual and follow the instruction given to install the speedometer speed sensor and use the new o ring 85 provided in the kit Refer to the STARTER INSTALLATION in the Service Manual and follow instructions given to install starter from the right side Refer to the DRIVE COMPONENTS in the Service Manual and follow the instruction given to install the clutch assembly primary chain and compensating sprocket as a single assembly Install the 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 Clutch Side Cov

INSTRUCTIONS - Harley

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