RevTech - Naioti
Contents
1. Sockethead Screw 5 16 18x5 8 Sockethead Screw 5 16 18x1 1 4 5 Sockethead Screw 5 16 18x1 1 2 High Performance by Custom Chrome Five Speed in a Four Speed Case with Kicker The Ultimate transmission for the retro look Get the classic look of a four speed kicker and the performance benefit of a smooth shifting 5 speed This transmission is a bolt in proposition for virtually any electric start or four speed Big Twin It combines a heavy duty kicker assembly with the early five speed end cover and clutch actuation lever with five speed shifting mechanism gears and top cover in a four speed sized case CCI 58 290i 1 20 99 cap GUSTOM CHROME _ Chrome RevTech 0 instructions 4 5 Speed Kick Starter Kit Assembly CCI 58 290 58 295 Copytight 1998 Custom Chrome Inc Main and Counter shaft gears not shown WEN dec o4 Nee 9 amp High Performance by Custom Chrom IMPORTANT NOTE Use Loctite 35 007 onto the first three threads of all hardware before the final assembly 1 Use your proper OEM service manual and remove the existing shifter assembly and gear set with trap door from the transmission case 2 IMPORTANT Note the order and position of each existing gear thrust washer and retaining clip for reassemble Remove all gears thrust washers bearings and retaining clips from the main shaft2. Bracket Battery mount OEM Bracket Mounting Plate Illustration 7 ii FXWG Battery mount Revised 10 5 98 0 1 2 3 inches 4 30f3 CUSTOM CHROME RevTech Electronic Speedometer Recalibration Unit ns t rut t 101 For use with CCI RevTech 5 Speed or 6 Speed Gear Sets and Transmissions CCI 58 318 Copyright 1998 Custom Chrome Inc High Performance by Custom Chrome Box Installation 1 Attach the female connector from the speed sender to the male connector from the speedometer calibrator 2 3 4 m Disconnect the connector between the speed sender and the speedometer gauge Attach the male connector from the speedometer gauge to the female connector from the speedometer calibrator Route the red wire from the speedometer calibrator to a switched ignition source recommends connecting the red wire to the instrument circuit breakers orange wire using the supplied scotch lock Wire tie the speedometer calibrator unit to a desired location on the motorcycle for a permanent mount Gauge Calibration quo o deco i cx Plug the push button switch assembly into the receptacle on the speedometer calibrator unit Press in and hold the button and turn the ignition on but DO NOT START THE ENGINE Determine what speed you would like to calibrate your speedometer at This will be your calibration speed Hold and or press the push button switch Approx
3. E 9 RevTech 5 Speed Transmission Sanaa Assembly Check List 0 58306X Polish Chrome FXR 2 94 Ratio C 56310X Polish Chrome FLT 2 94 Ratio 7 58317X Black Chrome FLT 3 24 Ratio 1 58307x Black Chrome Dyna 2 94 Ratio 7 58314X Polish Chrome Dyna 3 24 Ratio _ 58334X Polish Chrome Softail 3 24 Ratio 2 58308 Polish Chrome Dyna 2 94 Ratio 0 58315X Black Chrome Dyna 3 24 Ratio C 58335X Black Chrome Softail 3 24 Ratio 1 5 09 BlackChrome FLT 2 94 Ratio 58316X Polish Chrome FLT 3 24 Ratio 0 58351 Glossy Black Softail 3 24 Ratio 582953674 C 58301X Polish 4 5 Speed 2 94 Ratio 2 58302X Biack Chrome Softail 2 94 Ratio 58303 Black Chrome FXR 2 94 Ratio 0 58305X Polish Chrome Softail 2 94 Ratio TRANSMISSION SERIAL 1 STUD TRANSMISSION CASE IF NECESSARY 2 INSTALL COUNTER SHAFT NEEDLE BEARING 3 BALL BEARING MAIN DRIVE GEAR AND RETAINER CLIP NOTE RETAINER CLIP DIRECTION BEVEL FACING OUT 4 INSTALL TRANSMISSION OIL SEAL MAIN SHAFT LEVER SEAL 5 INSTALL SHIFT LEVER ASSEMBLY PREVIOUSLY ASSEMBLED 6 INSTALL ADJUSTING SCREW SHIFT ARM TO DESIRED DEPTH WITH LOCK NUT FINGER TIGHT 7 INSTALL FIFTH GEAR AND QUAD SEAL SPACER 8 INSTALL BALL BEARING IN SIDE DOOR WITH RETAINING CLIPS BEVELED SIDE FACING OUT IF APPLICABLE B INSTALL COUNTER AND MAIN SHAFT WITH INNER SPACERS NOTE SHOULDERED SPACER GOES ON MAINSHAFT PLACE OUTER SPACERS AND NYLOCK ON THE TWO SHAFTS TIGHTEN TO 45 55 F
4. TO PROTECT THE WARRANTY PLEASE SEND IN WARRANTY CARD WITH IN 30 DAYS OF PURCHASE 16100 Jacqueline Court Morgan Hill CA 95037 5598 E CUSTOM CHROME Instructions Copyright 1986 Custom Chrome inc BILL OF MATERIAL __ BILL OF MATERIAL DESCRIPTION PART NO NO Y DESCRIPTION PART NO TRANSMISSION ASSEMBLY 58 301 SPACER WASHER 375 x 8 x 188 93 616 2 3 8 SPIRAL LOCK WASHER 93 614 SPACER 312 x 62 x 455 93 608 3 8 24 UNF HEX NUT 25 184 SPACER 312 x 62 x 580 93 617 4 5 16 SAE FLAT WASHER 25 177 SPACER 312 x 62 x 770 93 609 5 5 16 SNAP CAPS 32 532 STUD 5 167 24 UNF TO 5 16 18UNC 1 3 4 LONG 93 613 6 5 16 SPIRAL LOCK WASHER 25 174 CHROMERODEND _ aN ee 19 299 7 5 16 18x1 1 2 HEX SOCKETHEAD SCREW 732117 BUTTON HEAD BOLT 5 16 24x1 CHR 10 PACK 8 5 16 18x1 1 4 HEX SOCKETHEAD SCREW 32 116 NYLOCK NUT 5 16 24 CHR 10 PACK 9 5 16 24 UNF HEX NUT 25 183 FUFXWG SHIFT ARM SPECIAL 0 CLUTCH CABLE EXTENSION 4 5 SPEED TRANS 93 610 FXE MID SHIFT ARM SPECIAL 1 SHIFT LINKAGE ROD 5 16 24x10 1 2 LONG 19 318 5 16 24x1 HEX HEAD BOLT CLUTCH CABLE IMPORTANT NOTES Disconnect negative battery cable from the frame There is NO OIL in this transmission This transmission requires 20 ounces of transmission lube CCH 35 055 Fill with tr
5. and counter shaft Remove both existing shafts from the trap door Set aside the main shaft and trap door these items will be replaced with a new main Note The supplied main shaft is pre installed into the kicker trap door Install your existing counter shaft with the existing space supplied nylock nut 61 Reassemble all gears onto main shaft and counter shaft accordingly using the existing thrust washers bearings and the new supplied retaining rings Refer to back page for gear assembly Install the complete gear set with trap door and gasket into transmission case using the supplied hardware Install the existing shift forks shift rod and shift cam Use your OEM service manual for adjusting the shift pawl if needed Before continuing remove nut 45 from the main shaft and apply Loctite onto threads then securely tighten nut to 40 45 ft Ibs Install kicker crank clutch gear assembly in the following order Place starter clutch spring Kick starter gear Starter clutch 3 with key onto the protruding main shaft then secure this assembly with a lock washer and nut Apply Loctite onto threads then securely tighten nut to 22 28 ft Ibs 9 Slide the clutch push rod assembly clutch push rod 87 with oil slinger and bearings into the main shaft 10 The kicker cover is pre assembled except for the kick pedal spring and kick pedal arm Slide the clutch push rod assembly out 2 3 inches then install the kicker cover with gasket
6. lbs of torque Mount battery tray support bracket to battery tray using existing hardware See illustration 5 NOTE Some models may require two 580 instead of 455 spacers to keep the support bracket parallel to the transmission side cover 16 FXE FXWG battery tray starter motor bracket mounting procedures Install bracket onto side cover of transmission using two 5 16 18x1 1 4 socket head bolts 8 5 16 lock washers 6 5 16 flat washers 4 and two 455 spacers Q3 Tighten bolts to 18 22 ft Ibs of torque Install bracket onto starter stud and battery tray lord mount using OEM lock washers and OEM nuts and tighten securely See illustration 6 or 7 NOTE Some models may require two 580 instead of 455 spacers to keep the support bracket parallel to the transmission side cover 17 FXE Brake Pedal Installation Install three studs 16 onto side of cover using Loctite on first three threads Place three 455 spacers E onto studs Mount bracket and pedal assembly onto studs using 5 16 hex nuts 9 and 5 16 lock washers 6 making sure the brake rod is in the master cylinder piston The brake rod must be adjusted for free play as per OEM manual 18 Adjust rear chain if necessary and check all current hardware for correct fit and torque 19 Reconnect battery cable You are now ready to test ride Illustration 5 OEM FL FLH OEM Bracket hardware hu Starter stud Illustration 6 FXE
7. 20 sec until the gauge reads your desired calibration speed Turn off the ignition Temporarily mount the push button switch assembly on the bike where it would be easily accessible while riding Start the engine Pace the bike behind another moving vehicle When your pace vehicle reaches your calibration speed press the push button switch Your speedometer is now calibrated When the bike is stopped turn off the ignition Unplug and remove the push button switch assembly and place into a Safe keeping The push button switch assembly is not needed for normal operation Do not remove the speedometer calibrator unit Gauge Re Calibration 1 2 If you remember your calibration speed follow the Gauge Calibration steps 6 thru 10 If you DO NOT remember your calibration speed follow Gauge Calibration steps 1 thru 10 Se c e c CC ERE LOU LP M CCI 58 318i 16100 Jacqueline Court Morgan Hill CA 95037 5598 Revised 4 14 00 CUSTOM CHROME Heavy Duty Kicker Cover Spacers Hardware Kit for use with 25 948 n S U D t 0 n Special spacing for battery tray and mid mount brake controls DESCRIPTION MES 5 16 18 UNC x 1 5 Socket Head Bolt NOTE USE WASHER AS REQUIRED FOR SPACING Oy PT IAE Duty Kicker Spacer e R3 Heavy Duty Kicker Washer TN 5 16 Split Lockwashers a D ele oe EXISTING c BR
8. 75 1 0 spacer washer 2 3 8 lock washer 2 and 3 8 24 hex nut 3 transmission to frame stud Tighten to 21 27 ft Ibs of torque 11 Reinstall clutch release lever on transmission Install clutch cable using clutch cable extender NOTE This transmission assembly uses Supplied stock 1986 FXST standard length clutch cable CCI 13 947 38607 87 12 Install starter housing bolt and torque to 10 ft Ibs install clutch primary drive and engine sprocket as per OEM manual 13 Install outer primary cover 14 Adjust clutch as per OEM manual for 1979 1984 5 speeds FXWG FL Illustration 3 Transmission shift lever Provided FXE illustration 4 Existing rod end assembly y Transmission shift lever Provided 2013 RIGHT SIDE 15 FL Starter motor bracket and battery tray support bracket mounting procedures Install starter support bracket onto side cover of transmission using two 5 16 18x1 1 2 sockethead bolts 7 two 5 16 lock washers 6 two 5 16 flat washers O and two 770 long spacers 19 Tighten to 18 20 ft Ibs of torque Mount starter stud to starter support bracket using OEM lock washer and OEM 1 4 20 nut Tighten to 9 11 ft Ibs of torque Install battery tray support bracket onto side of transmission using two 5 16 18x1 1 4 socket head bolts 8 5 16 lock washers 8 5 16 flat washers 4 and two 455 spacers 3 Tighten to 18 22 ft
9. Il i O 4 KiT 25 948 EXISTING C 4 wore USE WASHER FOR J SPACING ONLY IF REQUIRED HEAVY DUTY KICKER IKICK STARTER REMOVED FOR CLARITY 8 EXISTING v d go Y 25 998 ANO 25942 d SY N CONTROLS 7 WHERE APPLICABLE CCI 40 404 Inst Sheet 16100 Jacqueline Court Morgan Hill CA 95037 5598 712192 L o Chrome RevTech E gt 4 5 Speed Kick Starter Kit For CCI 58 301 RevTech 4 5 Speed Transmissions CCI 58 290 without 4 5 Speed Transmission CCI 58 295 with 4 5 Speed Transmission Copyright 1998 Custom Chrome Inc Part ck Starter Shaft not shown 12 082 12 249 zd Gasket Trap Door 15 075 O Ring Filler Plug _ 18 432 Clutch Pushrod 19 076 Flathead Screw 5 16 18x3 4 Flat Washer 1 4 ID x 7 16 OD Kicker Main Shaft 4 5 Nylock Nut 7 8 18 Main Shaft Clutch Pushrod Extension Bracket Battery Box Starter Clutch Release Shaft Short Clutch Release Arm Chrome Upper Bushing Starter Cover not shown Retaining Ring Trap Door Main Shaft n s Bearing Trap Door Main Shaft Flat Washer 5 16 Chrome Kicker Cover 25 947 w Short Upper Bushing Spring Starter Clutch Lock Washer Crank Gear Lock Washer Starter Clutch Gasket Kicker Cover Clutch Release Finger Stud Kicker Spring
10. T LBS C INSTALL ALL GEARS BEARINGS WASHERS AND SNAP RINGS ON COUNTER SHAFT AND MAINSHAFT 9 INSTALL SIDE DOOR ASSEMBLY INTO CASE WITH GASKET 10 INSTALL 5 16 INCH SIDE BOLTS TIGHTEN TO 13 16 LBS 1 4 INCH SIDE BOLTS TIGHTEN TO 7 9 FT LBS 11 PLACE SHIFT FORKS AND SHAFT IN CASE INSERT LEFT PLUG UNTIL SHIFT FORK ROD IS FLUSH WITH RIGHT SIDE OF CASE 12 A SHIFT DRUM ASSEMBLY PLACE SHIFT DRUM RIGHT SUPPORT AND PLACE OUTER SHIM AND SNAP RING ON OUTSIDE OF SUPPORT BLOCK END PLAY MUST BE 001 TO 004 B PLACE LEFT SUPPORT ON SHIFT DRUM INSTALL SHIFT DRUM AND SUPPORTS ON TRANSMISSION CASE WITH WASHER AND BOLTS TORQUE TO 7 TO 9 FT LBS 13 PLACE THROW OUT BEARING IN RIGHT END OF MAINSHAFT SIDE COVER GASKET AND OUTER SIDE COVER ON TRANSMISSION CASE SIDE DOOR INSTALL OUTER SIDE COVER HARDWARE SNUG NOTE HARDWARE WILL HAVE TO BE REMOVED AT LATER DATE TO INSTALL CLUTCH CABLE 14 INSTALL PRIMARY BEARING INNER RACE ON MAINSHAFT NOTE LEAVE 100 GAP BETWEEN INNER AND FIFTH GEAR 15 INSTALL TOP COVER AND HARDWARE TIGHTEN TOP BOLTS TO 7 9 FT LBS OF TORQUE 16 PLACE SPROCKET AND SPROCKET NUT ON FIFTH GEAR TORQUE NUT TO 110 120 FT LBS THEN TIGHTEN NUT AN ADDITIONAL 30 TO 40 TURN PLACE LOCK PLATE OVER NUT AND SECURE WITH THE TWO LOCK PLATE SCREWS USING RED LOCKTITE TORQUE SCREWS TO 50 60 IN LBS 17 ATTACH CCI WARRANTY STICKER ON BOTTOM OF TRANSMISSION CASE AND TRAP DOOR WARRANTY VOID IF SEAL IS BROKEN NOTE
11. ansmission lube after installation Do not use lock nuts on bottom case studs _ Use Blue Loctite CCI 35 007 on first three threads of all hardware before final assembly For relocation of a transmission speedo drive use speedodrive kit 26 737 for a 16 front wheel or CCI 26 738 for a 21 front wheel LEFT SIDE 1 Remove OEM inner and outer primary covers and 4 speed transmission if applicable 2 Remove transmission mounting plate from OEM transmission and clean 3 Loosely install the new RevTech transmission to the mounting plate using 375 1 D spacer washers 2 9 8 lock washers 2 and 3 8 hex nuts provided See illustration 5 6 or 7 4 Bolt inner primary cover securely to transmission assembly on bench Verify shift linkage and sprocket nut clearance BEFORE PROCEEDING READ REFERENCE NOTES BELOW NOTE 1 Cast Aluminum Inner Primary 1970 thru 1978 On the transmission side the four riser posts around the main shaft seal area must be machined down for sprocket nut lock screw clearance See illustration 1A NOTE 2 Cast Aluminum Inner Primary 1970 thru 1978 On the front side of the inner primary the bearing seal spigot must be machined down 050 for finger spool clearance See illustration 2 NOTE 3 OEM Die Cast Inner Primary 1979 thru 1984 This primary must be checked for clearance NOTE 4 CCI Inner Primary CCI 426 801 and 28 063 On the transmission side the bearing seal spigot mus
12. t be machined down 085 for proper clearance See illustration 1B illustration 1 Illustration 2 Remove all 4 post risers 1of 3 CCI 58 3011 16100 lacaueline Court Moraan Hill CA 95027 5598 Revised 10 5 98 5 Remove the clutch release arm from the transmission assembly This will allow clearance for installation Place the transmission assembly in the motorcycle frame Install mounting plate to frame hardware use Loctite on first three threads Tighten hardware to 30 33 ft Ibs of torque 6 Place the starter motor in position over the transmission Place rear chain over sprocket and install master link 7 FXWG and FL shift linkage installation Assemble shift linkage using shift rod two chrome rod ends and two 5 16 24 chrome nuts 9 Install front rod end linkage assembly onto shift arm using one buttonhead bolt and one nylock nut Install rear rod end assembly onto provided shift lever using hex bolt Tighten and secure bolts See illustration 3 8 FXE Mid shift linkage installation Using the existing rod end assembly install front rod end linkage assembly onto shift arm using button head bolt and nylock nut Install rear shift linkage assembly onto provided shift lever using hex head bolt G Tighten and secure bolts See illustration 4 9 Install the inner primary cover as described in the OEM manual 10 Tighten transmission to mounting plate bolts Torque to 21 27 ft Ibs Place 3
13. using the supplie hardware Slide the kick pedal spring 3 onto kicker shaft and attach Spring end onto stud 3 Install the kick pedal arm assembly onto kicker shaft using the supplied hardware Install the clutch release arm onto the top of kicker cover using the supplied hardware and place the clutch push rod extension into opposite side of main shaft Tighten all hardware securely shaft longer and your new kicker trap door r beveled side down into the kicker trap door using the S560 e 16100 Jacqueline Court Morgan Hill CA 95037 5598 _ m 1 20
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