- S&S Cycle
Contents
1. 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 inhaled Do not smoke Perform installation in a well ventilated area away from open flames or sparks O 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 O 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 alcohol drugs or fatigue impair your2. to Harley Davidson Service Manual for appropriate model year Shift lever adjuster screw 56 1002 See Figure 2 will require adjustment after transmission assemblylinstallation and before operation of motorcycle See Harley Davidson Service Manual for further information After adjustment secure screw with hex head nut 50 5044 See Figure 2 Inspect all parts before installation in case Shifter forks are especially critical for proper operation of transmission Confirm shifting through all five gears before installing transmission Shifting will be stiff with transmission out of motorcycle and it will be necessary to rotate transmission sprocket back and forth to engage some gears Early style pre 1992 transmission sprockets use a sockethead screw as sprocket nut retainer S amp S recommends modifying early style sprocket to accept sprocket nut lockplate H D 40251 92 To modify early sprocket for lockplate install sprocket and torque sprocket nut to 110 120 ft lbs Place lockplate over nut and against sprocket Use one of four holes in lockplate as guide and drill and tap sprocket for 4 20 x sockethead screw H D 3594A Clean threads of screw with Loctite Primer or equivalent apply Loctite 242 blue to threads and install screw to secure lockplate Tighten to 50 60 in Ibs as explained in Harley Davidson Service Manual Remove metal chips before continuing installation A CAUTION Parts must be adequately supported
3. when using hydraulic press This is especially true when installing bearings in trap door Failure to support parts correctly may result in damage not covered under warranty A WARNING Proper assembly of transmission with correct parts in good condition is critical for safe operation of motorcycle Transmission malfunction can cause rear wheel to lock and tire to skid In some instances of transmission malfunction disengagement of clutch will not free wheel Never reuse transmission retaining rings Damaged retaining ring may permit engagement of two gears at once This can result in seized transmission and loss of control of motorcycle with severe personal injury to operator and others All reference to Harley Davidson part numbers is for identification purposes only We in no way implying that any of S amp S Cycle s products are original equipment parts or that they are equivalent to the corresponding Harley Davidson part number shown Replacement Parts for Part 56 1046 Starter Conversion Kit 1986 88 Conversion kit transmission case starter 1986 88 1 np yo SON Ou w N m m m WN 3 0 Spacer starter adapter Pin dowel 308 diameter x 70 H D 375 50 8029 Pin dowel diameter x H D 335 Pin roll 4 diameter x Seal oil H D 1205 1 0oooooococccccoconononcncnonononononnncnnnnnonnnns Replacement Parts for S amp S Transmission Cases and Accessori
4. 1046 INSTALLATION If required 1986 88 Starter Adapter Kit 56 1046 should be installed before assembling transmission To install Starter Adapter Kit 1 Carefully support starter area of transmission case on table of hydraulic press Apply thin film of Loctite 609 green to outer edge of starter adapter spacer 56 1066 and corresponding area of transmission case Press spacer into case until flush with starter mounting surface 2 Remove dowel pin 50 8171 Item 8 Figure 2 3 Apply thin film of oil to outside of dowel pin 50 8029 dowel pin 50 8172 and roll pin 50 8174 Items 2 3 and 4 Figure 1 and press into transmission case until flush with inner primary mounting surface 4 Install starter seal 56 1065 in adapter spacer Seal must be flush with outer surface of spacer NOTE Install seal with spring side toward primary cover Confirm fit of starter drive housing and inner primary cover on transmission case ASSEMBLY Assembly of transmission using S amp S case for Softail models and related parts is identical to assembly of transmission using stock components Refer to following notes and Harley Davidson Service Manual NOTES O Several differences exist between Harley Davidson 5 speed transmissions of certain year groups Most common differences are between shifter cams main drive gears sprockets spacers and seals Correct parts must be used for each year group and transmission must be assembled according
5. Instruction 51 1058 4 20 06 Copyright 1999 2002 2005 2006 by S amp S Cycle Inc All rights reserved Printed in the U S A SES Cycle me 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 S amp S 5 Speed Trasmission Case for 1986 99 Big Twin 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 Evolution and all H D part numbers and model designations are used in reference only S amp S Cycle is
6. eeseesseeeesee 56 3033 Door assembly trans access 5 speed rigid mount 1986 99 Dt u ae hehe 56 1027 Capscrew sockethead 4 20 x 1 H D 434824 50 0153 Capscrew sockethead s 18 x 1 H D 432104 50 0121 Washer flat 4 x s x Yo H D 6099 50 7013 Washer flat 6 x 545 x 042 aeeeeeennennsnsennnnneennenneennennen 50 7028 Ring internal retaining 2 072 OD x 062 tru arc H D 335021 80 rre nete Pin roll x 300 H D 609 K Pin roll Xs x 34 H D 634 essere Plug magnetic 27 H D 7394 50 8334 Door transmission access 5 speed rigid mount 1986 99 bt nee ea 56 1025 Gasket trans access door H D 435652 794 56 1026 Bearing trans access door H D 48998 56 3036 reference to Harley Davidson part numbers is for identification purposes only We in no way implying that any of S amp S Cycle s products are original equipment parts or that they are equivalent to the corresponding Harley Davidson part number shown
7. es Transmission case assembly 5 speed rigid mount 1986 U p Softall iii erkennen 56 1050 Case trans 5 speed rigid mount 1989 99 bt N A Screw socket buttonhead 20 x A oococccccccccnoccnncnananonnns 50 0229 Set screw sockethead 20 x 7 H D 43784 50 0203 Nut hex head 14 H D 87515 50 5044 Pin dowel 308 dia x 70 H D 4375 50 8029 Stud 24 s 14 x 1 300 H D 11733 50 8084 Pin dowel s dia x 1 H D 337 eene 50 8171 Pin roll x 300 H D 609 c ccccsssceeesseeeeeseeeeeeees 50 8173 Screw shift lever adjustment H D 33119 79B 56 1002 Cover speedo sensor hole 56 1061 Gasket speedo sensor hole cover sssssss 56 1062 Guide shifter shaft 5 speed rigid mount 1986 99 bt H D9 331 142 Did 56 1067 Kit transmission case bearings and seals 5 speed rigid mount 14 15 Ring internal retaining 3 734 OD x 109 tru arc H D 11161 50 8051 Seal oil 1984 up bt H D 12045 unenenneen 56 1064 Figure 2 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 All Bearing trans output shaft 1984 up bt H D 8996A 56 3035 Bearing trans countershaft H D 8977 56 3031 Seal oil H D 4120674 ccccccsscesscecsscesseceseeesee
8. hone 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 customer 4 S amp S parts a
9. judgement Start installation when you are fresh Be sure all federal state and local laws are obeyed with the installation O 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 inhaled 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 can be rectified by a telep
10. re 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 INTRODUCTION S amp S transmission cases are made from virgin 356T6 aluminum alloy and machined with state of the art CNC equipment S amp S Transmission Case 56 1050 fits 1986 1999 Harley Davidson Softail models 1986 1988 models require Starter Adapter Kit 56 1046 and custom applications S amp S 5 Speed Transmission Case includes shift lever adjustment screw shifter shaft guide and all studs and dowel pins required for assembly S amp S transmission case accepts stock and aftermarket 5 speed style trap doors gears shafts bearings and other parts designed for 1986 1999 Softail transmission NOTES O Starter Adapter Kit 56 1046 required for 1986 1988 models can be purchased separately through S amp S dealers or direct When building a transmission S amp S recommends using the 1987 up style trap door and end cover with ball and ramp clutch actuator Strength of lever type actuator is marginal for heavy duty clutch springs sometimes required in high performance applications Following options are available for S amp S Transmission Case Part 56 1050 Bearing and Seal Kit 56 1050B Trap Door Assembly 56 1027 Includes door bearings and miscellaneous hardware O Starter Adapter Kit for 1986 88 style starter 56
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