8273 - Jims
Contents
1. gt 8 Install shifter shaft washer JIMS No 6497HW and retaining ring JIMS No 11150 supplied Refer to your late H D Service Manual 9 Install shifter shaft centering pin BOLT JIMS No 34978 00A supplied Torque to 10 ft Ib Refer to your Late H D Service Manual Caution Center shifter assembly return spring on each side of centering bolt NOTE This model will not require any gear engagement adjustments Refer to your Late H D Service Manual NOTE 2 of the 3 shift forks will need to be installed into their shift rings as indicated in Figure 3 FIGURE Al 10 Place 3rd gear fork JIMS No 8348 into 3rd gear shift ring JIMS No 8342 at the same time sliding both the fork and shift ring away from trap door so the fork will lay down towards countershaft as shown in Figure 3 11 Place 4th gear fork JIMS No 8349 into 4th and 5th gear shift ring JIMS No 8354 at the same time allowing fork to lay down towards countershaft as shown in Figure 3 Fetfotmance Fads fot Harley Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 5 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Note The last fork for 1st and 2nd gear JIMS No 8347 is installed after the Super Kit has been installed into case 12 Place trap door gasket JIMS No 8352 over the two dowel pins on the trans case Refer to your Late2. Retaining Ring Main Drive Gear 37075 87 Dipstick With O Ring 411132 8357 Tool Modification Case 1215 Washer Pillow Block 8273 15 No Qt Part No Description Qt Part No Description 1 1 8325 Shift Lever w springs 1 18350 Shift Drum 2 1 8326 Screw Adjuster Clutch Hub 1 8351 Gasket End Cover 3 3 8873 Ball Bearing Ramp 1 18352 Gasket Trap Door Stock Cover 4 1 8876A Split Bearing Mainshaft Countershaft 4 8353 Bearing Pack Mainshaft amp Countershaft 5 1 8327 Trap Door Fat 5 1 34091 85 Bearing Inner Race 6 1 8343 1 Spline Sleeve 4th amp 5th mainshaft 1 16003 Thrust Washer 7 1 8329 End Cover Chrome Fat 5 1 33904 00 Neutral Switch 8 1 8330 1 Mainshaft Fat 5 1 8354 Shift Ring 4th amp 5th Mainshaft 9 1 8331 1 Countershaft W 5th Gear 1 37088 85 Pushrod Center 10 2 8081 Thrust Washer Mainshaft amp Countershaft 2 35087 99 Retaining Ring Trap door 11 1 8332 1 Gear 2nd Mainshaft 1 33376 00 Screw Detent Arm 12 1 8333 1 Gear 1st Countershaft 1 33374 00 Spring Detent Arm 13 4 8334 1 Gear 1st Mainshaft 1 33375 00A Sleeve Detent Arm Spring 14 1 8335 1 Gear 2nd Countershaft 1 33364 00A Detent Follower Assy 15 1 8336 1 Gear 3rd Mainshaft 1 33304 00 Assy Right Pillow Block 16 1 8337 1 Gear 3rd Countershaft 1 33301 00A Assy Left Pillow Block W Bearing amp Retainer 17 1 8338 1 Gear 5th Mainshaft 1 111342 Retainer Shift Drum 18 1 8339
3. 1 Instruction Sheet CAUTION SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS Fetfotmance Fads fot Harley Davidson PHONE 805 482 6913 FAX 805 482 9224 555 DAWSON DRIVE CAMARILLO CA 93012 10 A Division of Thiessen Products Inc REV H 6 14 INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE 555 DAWSON DRIVE CAMARILLO CA 93012 Not used in Kit 8274 or 8275 29 8273 ONLY a me a d SSS C se 69 Ki 3 a E Ea I KO K 1 Not used in Kit i O N O r 8274 or 8275 1 1 1 1 Fetfotmance Fads fot Harley Davidson PHONE 805 482 6913 FAX 805 482 9224 11 No 8273 IS Rev H 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE 9219 8 95 om EE d CC l o o 1 Di R fw ji 61 62 L PR CAUTION WEAR SAFETY GLASSES
4. H D Service Manual 13 Apply a small amount of lube to the inside of the main drive gear NOTE If you have removed the mainshaft protective cover already install a lubed tool JIMS No 2256 2 main drive gear seal protector inside the main drive gear seal The mainshaft protective sleeve covering the clutch hub spline on the mainshaft can also be used as a seal protector as the mainshaft is being installed thru the main drive gear as shown in Figure 1 5 16 in screw 4 13 16 ft Ibs 17 6 21 7Nm 14 Gently place the gear set trap door assembly into the case by sliding the mainshaft through 4 408 the main drive gear bearing and slowly pushing the trap door assembly inward until the trap door makes contact with the two dowel pins in trans case A non marring hammer is helpful to tap the trap door assembly over the dowel pins without risking damage to the aluminum chrome of the trap door assembly Apply a small amount of Blue Loctite to each of the four 1 4 screws JIMS No 1258 and thread them into the top four 1 4 screw holes Torque to 84 108 in lbs in a criss cross pattern Apply a small amount of Blue Loctite to each of the four 5 16 screws JIMS No 1118 and thread them into the four 5 16 screw holes Torque to 13 16 ft lbs in a criss cross pattern as shown in Figure 5 Quad Seal No 11165 SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEE
5. 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 JIMS and a customer 4 JIMS parts are designed exclusively for use in Harley Davidson motorcycles JIMS shall have no warranty or liability obligation if a JIMS part is used in any other application DISCLAIMER The words Harley H D is a registered trademark and is for reference only Use of H D model designations and part numbers are for reference only JIMS has no associations with and makes no claims against these words trademarks or companies The installation of these parts may void or otherwise adversely affect your factory warranty It is the sole responsibility of the user to determine the suitability of this 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 CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Fads fot dange Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 14
6. 2 Gear 4th Mainshaft 4 2135 Screw Pillow Block 19 1 8340 1 Gear 4th Countershaft 1 34904 86 Gasket Top Cover 20 1 8341 1 Shift ring 1st amp 2nd Countershaft 1 125604 00 Ramp Inner 21 1 8342 1 Shift Ring 3rd Mainshaft 1 25605 00 Ramp Outer 22 1 8328 1 Spline Sleeve 1st amp 2nd C S 1 10998 Retaining Ring 23 1 18344 1 Spline Sleeve 3rd M S 1 34920 86 Coupler Clutch 24 2 35078 79 Locknut Mainshaft amp Countershaft 1 2226 Clutch Bearing 25 1 8996 Bearing Main Case 1 34977 02A Spring Ratchet Arm 26 2 8992 Bearing Trap Door 1 34064 00B Spring Shifter 27 5 11067 Retaining Ring 4 609 Roll Pin 28 1 7514 Sleeve Shifter Shaft H D No 34979 00 1 72405 98TN Assembly Tan Wire 29 1 34978 00A Centering Pin 8273 ONLY 1 72405 98BK Assembly Black Wire 30 1 8076 Pushrod Clutch Right 1 72241 94A Terminal 1 4 Ring 14 18 GA 31 1 8977 Crankshaft Bearing Closed End 1 70585 93 Connector 18 20 32 2 8345 Main Drive Needle Bearing 6 1121 Screw Chrome 33 4 1258 Screw Upper Trap Door 1 112045 Seal Shifter 34 4 1118 Screw Upper Trap Door 1 6497H Washer Shifter 36 1 8347 Shift Fork 1st amp 2nd Gear 1 11150 Retaining Ring Shifter 37 1 8348 Shift Fork 3rd Gear 1 12035B Seal Gear Main Drive 38 1 8349 Shift Fork 4th amp 5th Gear 6 8356 Pin Drum 39 1 12067A Seal Main Case 1 11165 Quad Seal 40 1 34088 87 haft Shift Fork 1 739A Drain Plug Magnetic 1 1 1 1 4
7. 7 9 ft Ibs 6 Fill trans with H D trans lube or equivalent to the same level as a 5 speed trans Refer to your H D Service Manual for reference In the unlikely event that you would need to disassemble this trans you will need a few of JIMS Service Tools For replacement parts see materials list on page 10 WARNING Always disconnect the battery ground cable at the battery to prevent injury Instructions for disassembly of your Fat 5 Speed Overdrive This kit is basically easy to disassemble but does require some special tools See tool list on page 2 1 Remove primary and clutch components as indicated in your H D Service Manual CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Fads fot dange Davidson 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 8 ER 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE 2 Drain oil from trans by removing drain plug from trap door JIMS No 739A or if your trans case has other means of oil drain use that Remove end cover Refer to your H D service manual gt w Remove top cover and shift drum slide all three forks into any gear this is to lock the trans to keep the gears from turning for removal of mainshaft and counter shaft nuts
8. CE No 40250 94A 3 Install mainshaft seal spacer JIMS No 33344 94 sup plied over mainshaft bearing boss on left side of trans with the chamfered side to the inside towards seal as shown in Figures 7 and 8 y 4 Install the drive pulley you will be using Refer to your H D Service Manual 5 To install Mega Nut JIMS No 1708 not supplied over the main drive gear Follow instruction sheet supplied with Mega Nut 6 Install center pushrod JIMS No 37088 85 supplied Lube both ends and slide pushrod into Mainshaft 7 Install primary drive refer to your H D Service Manual for the model your installing this kit into CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Fads fot Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 8273 IS REV H LER 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Instructions for installing shift drum pillow blocks and top lid 1 Place the shift drum assembly with pillow blocks over the 3 Pins of shift forks you may need to move forks as needed to line up with the tracks in the shift drum At the same time aligning the pillow blocks over and onto the 4 split dowel pins Refer to your Late H D Service Manual 2
9. D TO BUY CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS Fetfotmance Fads fot tfaeg Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 6 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Instructions for installing the 1st and 2nd Gear Shift Fork JIMS No 83 47 Aqa Chamfer towards seal 1 Place the final remaining shift fork for the 1st and 2nd gear iugo dm JIMS No 8347 into fork slot of 1st and 2nd shift ring JIMS Th Y No 8341 putting it down through the top cover opening and NI slide it into the shift ring 2 Slide shift fork shaft JIMS No 34088 87 supplied through the hole in the trap door all three shift forks and into the left side of trans case Refer to your late H D Service Manual t SECTION 3 Install shifter shaft set screw JIMS No 3784C supplied Tighten until you have about 020 end play on the shifter shaft Instructions for Installing Main Seal Spacer and Torquing Mainshaft Nuts on Primary Side 1 Slide all three shift rings so that they all three engage into mating gears this is to lock the trans to keep the gears from turning 2 Install mainshaft quad seal JIMS No 11165 supplied over the main drive gear on left side of trans as shown in Figure 6 NOTE Spacer 33344 94 is for late pulley only pulley REF EREN
10. E PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetpotmance Fads fot dange Davidson 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Instructions for preparing the Transmission Case to install JIMS Fat 5 Super Kit Refer to your Service Manual and parts book for the proper year and model you will be installing this kit into for reference Also use a Late H D 2002 05 Big Twin Service Manual and parts book for reference 1 Remove Old Gear set and all Case Bearings per H D Service Manual NOTE If Dowel Pin H D No 634 came out upon the Gear Set removal it will need to be reinstalled back into the Trans Case Refer to your H D Service Manual 2 Upgrade Shifter Shaft Bushing for 1990 99 Big Twins and 1999 2000 T C FLHT FXR amp FXD by removing the existing Shifter Shaft Bushing and installing a new longer Shifter Shaft Bushing H D No 34979 00 JIMS No 7514 supplied Follow the instruction Sheet provided with JIMS Tool No 1664 not included and refer to any 2000 to 2005 B T H D Service Manual for Shifter Shaft Assembly 3 Using masking tape cover all the trap door flat holes except for the top three The two threaded holes at the top of the trap door flange are used for Specia
11. ELS NOTE 2000 2006 FXST and 2001 2006 FLHT amp FXD models do not need modifying 1 Place new top cover gasket JIMS No 34904 86 on the trans top cover flange 2 Use 4 of your top cover screws to hold gasket in place by slipping screws thru the gasket and into the top cover 3 Mark the inside exposed portion of the flange as shown in Figure 2 The material to be removed is 060 wide by 1 80 Deep Remove top cover screws and gasket 4 With a die grinder tool remove the casting rib until it is the same height as the adjacent surface area Clean the top cover of all loose material including screw holes as shown in Figure 2 5 With shifter assembly installed in transmission Install top cover with gasket using only 2 screws so cover can move if shifter arm is making contact with top cover 6 While watching to see if the top cover moves for ward shift the transmission into first gear firmly holding the shift lever down If there is no forward movement of the top cover then the modification is complete If any forward movement of top cover is observed then more of the casting rib must be removed Repeat Step 4 as necessary Instructions for Installing JIMS Fat 5 Super Kit parts into case 1 Install main drive gear bearing JIMS No 8996 using JIMS Tool No 35316 80 Follow the instruc tion sheet provided with tool or refer to your H D Service Manual NOTE NEVER install any bearings into the case by applying pres
12. ER 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE we INSTRUCTIONS FOR THE FOLLOWING PART NO S 8280 8279 8282 8283 8284 8273 8274 8275 amp 8277 These instructions are for installation of the Super Kit complete transmission or rebuild kit for EVO or Twin Cam These instructions are also reference for disassembly Disassembly is the same as assembly but in reverse order READ ALL INSTRUCTIONS BEFORE PERFORMING WORK IF YOU DO NOT KNOW WHAT YOU ARE DOING DO NOT DO IT JIMS IS NOT RESPONSIBLE FOR THE QUALITY AND SAFETY OF YOUR WORK If you are not sure about any of the procedures in these instructions have a reputable H D repair shop perform these procedures for you WARNING Always disconnect the battery ground cable at the battery to prevent injury Your work area should be well lit Wear safety glasses over your eyes and protective clothing when working around power tools and compressed air Be careful with chemicals when cleaning parts Protect your skin from solvents and use only in a well ventilated area Degreasers are flammable and are a fire hazard Just use common sense and exercise good judgement If you have purchased a No 8277 FAT 5 Rebuilt Kit read these complete instructions before perform ing any work See page 13 of these instructions for a Parts List of items included in this kit CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAG
13. EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetpotmance Fads fot tfaeg Davidson 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 12 REV H 6 14 No 8273 IS A Division of Thiessen Products Inc PARTS LIST FOR REBUILD KIT No 8277 FOR ANY FAT 5 TRANSMISSIONS Item numbers may show where used on drawing bubble call out for reference on where used on pages 11 and 12 Some part numbers may not be shown in drawings NO QTY JIMS Mescripton __ 43 1 8352 GASKET TRAPDOOR FAR5 79 1 11165 QUAD SEAL MAIN DRIVE SPACER 1 1 809 62423 90 GASKET SPOUT ED 1 1 810 34917 90 GASKET LID COVER FXD __ 1 863 34917 99 GASKET TOP 39 1 12067A SEALMAINSHAFT CC 1 12045 SEALSHIFTERSHFT 59 1 34904 86 EARLY TRANS TOPLID LL 1 867 34904 86C GASKET LATE TRANS TOP LID 120358 SEAL MAINDRIVE GEAR 8873 BALLBEARINGCLUTCHRAMP 1 8876A BEARING MS amp C S SPLIT 11132 O RING DIPSTICK ORSPOUT 2 8081 THRUSTWASHER 2 3507879 C S amp M S JAMNUTLOCK NUT EN i 2 RSC Oi 34091 85 RACE MAINSHAFT 2 8345 BEARING MAIN DHIVEGEAR j 1 34088 87 SHIFT FOR
14. Install four 1 4 pillow block mounting washers JIMS No 1215 over the four 1 4 pillow block mounting screws JIMS No 2135 Apply a small amount of Blue Loctite to each screw and torque to 7 9 ft lbs in a criss cross pattern Refer to your late H D Service Manual 3 Install top cover gasket JIMS No 34904 86 supplied per your H D Service Manual 4 Install your top cover Lid with your mounting hardware refer to your H D Service Manual 5 Install vent hose H D part No 42533 91A not supplied to your top cover elbow fitting Refer to your H D Service Manual Instructions for installing end cover 1 Install right push rod for clutch JIMS No 8076 supplied 2 Install end cover JIMS No 8329 supplied with gasket JIMS No 8352 supplied Refer to your H D Service Manual 3 Install speed sensor into trap door if applicable NOTE If you will be running an electronic speed sensor you will need to place a sensor cover see special parts list over your sensor hole in trans case and install your electronic speed sensor into the trap door If you will not be using an electronic speed sensor in either location trap door or case you will need to order a speed sensor block off plate for the trap door 4 Install speedo block off plate JIMS No 8042K or No 8102 8103 Billet block off plate 5 Install speedo block off plate mounting screw JIMS No 1120 by applying a small amount of Blue Loctite to screw and torque to
15. K SHAFT 1 1 1 1 1 4 8353 _ BEARING ASSY SPLIT CAGE M S x C S FAT 5 50 2 35087 99 RETAINING RING TRAP DOOR BEARING 1 11342 RETAINING RING SHIFT DRUM 62 1 10998 RETAINING RING CLUTCHRAMP 1 2226 BEARING KIT CLUTCH PUSHROD 1 34064 00C SPRING SHIFTER SHAFT zo 1 11161 RETAINING RING MAIN DRIVE CASE BEARING 25 1 8996 BEARING MAIN DRIVE CASE 6 8356 DOWELPIN SHIFTDRUM 42 1 8351 GASKET END COVER FAT 5 1 6003 THRUSTWASHER C S zo 1 8041 GASKETSPEEDOCOVER 1 11179 O RING CLUTCHCABLE 75 1 11150 RETAINER SHIFTERSHAFT 1 811 62672 90 O RING LOWER SPOUTFXD 41 11289 O RING SPEEDO SENSOR 47 1 11290 O RING NEUTRAL SWITCH Fetfotmance Fads fot dange Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 13 ER 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Customer Support For any installation on service or Questions Please contact JIMS Technical Department 805 482 6913 WARRANTY PROVISIONS All JIMS parts are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 12 twelve months from the date of purchase Merchandise that fails to conform to these conditions will b
16. Remove shifter shaft set screw JIMS No 3784C Remove shifter shaft JIMS No 34088 87 Remove 1st and 2nd gear shift fork JIMS No 8347 Remove all trap door hardware holding door to trans case je We N m f Slide the 3rd gear shift fork amp shift ring and 4th 5th gear shift fork amp shift ring away from the trap door so that the forks will lay down towards the countershaft As shown in Figure 3 10 Install trap door puller Tool JIMS No 1077 by lubing all threads of tool and threading trap door puller tool onto trap door 11 Remove trap door slowly making sure shift forks clear case 12 Remove both trap door bearings as you would for any 5 speed rebuild 13 Remove all gears from main and counter shafts as you would for any 5 Speed trans following the parts list as laid out in this instruction sheet 14 Remove any other parts bearings and seals from trans case as you would for any 5 Speed 15 To service main drive gear use JIMS tool No 37842 91 EXHAUST MOUNTING BRACKET MODIFICATION You will most likely need to modify the original exhaust mounting bracket as needed This will vary per model FL FXD or FXST and manufacturer of exhaust as needed Mount exhaust to the bot tom 2 or 4 5 16 door mounting screws FLH OIL FILL SPOUT MODIFICATION 1 Super kits used on FLH models will need modification of oil fill spout cover to fit properly on transmission case You will need to provide clearance on your fill s
17. ducts Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Optional parts that may be needed to install JIMS Fat 5 4 Fasten drill plate JIMS No 8357 to the top of the laces biki E Ki Ser S trap door flange using old and new speed i Part No Description sensor mounting screws as shown in Figure 1 8102 8103 Billet speedo block off plate 5 Spread one or two clean shop cloths inside the Speedo Block Off Plate trans case to catch the metal shavings and debris Depending on application 6 Starting with a 3 8 inch drill bit alternately use 8126 Speedo Re Calibration Module progressively larger bits to enlarge the fork shaft Depending on year pulley amp tire size hole Finish the drilling operation with a 3 4 inch drill bit 7 Remove all remaining material up to the edge of the drill plate with a die grinder or similar tool Remove the drill plate once complete 8 Using emery cloth steel wool or a fine tooth file remove any burrs or ridges that may exist from the drilling or cutting operations Warning Abrasive particles can damage machined surfaces and result in premature failure 9 Carefully pull out shop cloths from inside the trans case Exercise care to keep any debris cap tured by the cloths from falling into the trans case 10 Place drain pan beneath trans case and remove tape from drain hole Thoroughly flush the trans case with a non volatile clean ing solution or solvent
18. e repaired or replaced at JIMS option if the parts are returned to us by the purchaser within the 12 twelve month warranty period or with in 10 ten days thereafter In the event warranty service is required the original purchaser must call or write JIMS immedi ately with the problem Some problems can be rectified by a telephone call and need no further course of action A part suspected of being defective must not be replaced by a Dealer without prior authorization from JIMS If it is deemed necessary for JIMS to make an evaluation to determine whether the part is defective it must be packaged properly to prevent further damage and be returned prepaid to JIMS with a copy of the original invoice of purchase and a detailed letter outlin ing 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 JIMS and the part was found to be defective repair replace ment or credit will be granted ADDITIONAL WARRANTY PROVISIONS 1 JIMS shall have no obligation in the event a JIMS part is modified by any other person or organization 2 JIMS shall have no obligation if a JIMS 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 part 3 IMS shall not be liable for any consequential or incidental damages resulting from the failure of a JIMS
19. l Tools Required to un install JIMS Fat 5 Super Kit mounting of the drill plate and the shift fork shaft Note Some tools are the same as any 5 speed installation hole center through hole is used as the pilot for tools you might already have the drill bits Part No Description 4 From inside the transmission case tape over all 1077 Deer Muller foll 5 speed Maindrive Gear Tool bores as follows Mainshaft Bearing Race Tool e Vehicle speed sensor and mounting screw bores 94660 37A Mainshaft Sprocket Locknut Wrench e Transmission top cover and shifter drum support 28515 90 Clutch Spring Compressor Tool 1990 1997 2260 Big Twin Sprocket Locker screw bores 2362 External Lock Ring Pliers e Transmission drain hole bore 2234 Primary drive Locking Tool e Main Drive gear bearina bore 1720 5 speed Main Bearing Remover 9 9 i 2189 Main and Counter Shaft Installer e Countershaft needle bearing bore Solvent 184 Valco e Shift Fork shaft bore 1080 Brass Hammer e Shifter shaft bore 1145 Modular Engine amp Transmission Stand Kit Warning Be sure drill plate is properly oriented before drilling Improper orientation will result in damage that requires replacement of the transmis sion case Fetfotmance Fads for Harley Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 2 No 8273 IS REV H LER 6 14 A Division of Thiessen Pro
20. pout to clear the trap door You will need to machine file or grind to get enough clearance This is so you can mount spout cover to the case in normal position without the cover touching the trap door On 2001 and earlier FLH models Mount the modified oil fill spout to trans case along with oil fill spout gasket JIMS No 866 provided Mount and torque four mounting screws per H D Service Manual On 2002 to present FLH models Along with performing instruction steps above you need to pur chase or make a spout spacer not provided For a spout spacer order JIMS No 8088 You will need to plug and relocate the vent fitting on the spout cover as needed to clear your speedo sen Fetfotmance Fads for dange Davidson Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 UJ No 8273 IS A A Division of Thiessen Products Inc REV H 6 14 INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE Parts list for Super Kits and reference for Transmission Assemblies See drawings on page 11 and 12 for item bubble call outs For No 8277 Rebuild Kit parts list see page 13 NOT INCLUDED IN SUPER KITS 3784C Plug Shifter Shaft 11161
21. sure to the inner race Doing so will destroy the bearing Do not remove the mainshaft protective cover Figure 4 on the clutch hub spline end of mainshaft It can be removed after Super Kit has been installed into the trans case 2 Install the new main drive gear retaining ring JIMS No 11061 supplied with the bevel facing out Refer to your H D Service Manual 3 Install new main seal JIMS No 12067A supplied with JIMS Tool No 95660 85 to use with JIMS Tool No 95660 42 Refer to your H D Service Manual 4 Install main drive gear JIMS No 8339 2 using JIMS Tool No 35316 80 Follow the instruction sheet provided with tool or refer to your H D Service Manual Fetfotmance Forda foe lau Davidson Motorajtes 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 No 8273 IS 7 JIMS REV H 6 14 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE SHIFT FORK 8348 3rd GEAR SHIFT FORK 8349 4th 5TH GEAR SHOWN WITH CAP amp SHRINK WRAP Tool No 2256 2 5 Install counter shaft end bearing JIMS No 8977 Refer to your H D Service Manual NOTE Install counter shaft bearing by apply ing pressure to the LETTER side of bear ing ONLY 6 Install shifter shaft seal JIMS No 12045 supplied Refer to your H D Service Manual 7 Install shifter assembly JIMS No 8325 sup plied Refer to your Late H D Service Manual
22. 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 trans top cover opening Repeat procedure as necessary draining excess solvent through the drain hole using low pressure compressed air to thoroughly blow out all solvent 11 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 12 Carefully inspect the transmission case for any metal shavings or debris Repeat step 11 if any debris is found 13 Remove the masking tape to uncover remaining holes and bores 14 Thoroughly inspect each bore for any metal shavings dust or debris Alternately direct com pressed air into each bore to be certain that it is clean and dry CAUTION WEAR SAFETY GLASSES EXCESSIVE FORCE MAY DAMAGE PARTS SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Fetfotmance Fads fot tHarley Vavidton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 3 REV H 6 14 No 8273 IS A Division of Thiessen Products Inc INSTRUCTION SHEET FOR JIMS FAT 5 SPEED OVERDRIVE INSTRUCTIONS FOR PREPARING THE TRANSMISSION TOP COVER TO CLEAR THE NEW SHIFTING LEVER WHEN INSTALLING JIMS FAT 5 SUPER KIT INTO ANY 1990 99 BIG TWINS AND 1999 2000 T C FLHT FXR amp FXD MOD
Download Pdf Manuals
Related Search