Ss-cycle All-Helical Transmission Gear Set Cassettes for Ha Manuel d'utilisateur télécharger pdf

S&S

Cycle, Inc.

235 Causeway Blvd.

La Crosse, Wisconsin 54603

Phone: 608-627-1497 • Fax: 608-627-1488

Technical Service Phone: 608-627-TECH (8324)

Technical Service Email: [email protected]

Website: www.sscycle.com

Because every industry has a leader

Installation Instructions for S&S

All-Helical Transmission

Gear Set Cassettes for Harley-Davidson

1991-’05 Dyna

1991-’06 FLT and Softail

models, and Custom Applications

Instruction 51-1232

7-12-07

2006, 2007

by S&S Cycle, Inc.

Printed in the U.S.A.

SAFE INSTALLATION AND OPERATION RULES:

Before installing your new S&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 perfor

ming 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&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&S part on it.

● Consult an appropriate service manual for your motorcycle for correct

disassembly and reassembly procedur

es 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 your judgement. Star

t 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 hardwar

e 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.

DISCLAIMER:

S&S parts are designed for high performance, off road, racing

applications and are intended for the very experienced rider only. The

installation of S&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 used in reference only.

S&S Cycle is not associated with Harley-Davidson, Inc.

IMPORTANT NOTICE:

Statements in this instruction sheet preceded by the following words

are of special significance.

WARNING

Means ther

e is the possibility of injury to yourself or others.

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&S recommends you take special notice of these items.

WARRANTY:

All S&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&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&S immediately with the problem. Some problems 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&S. If it is deemed necessary

for S&S to make an evaluation to determine whether the part was

defective, a return authorization number must be obtained from S&S.

The parts must be packaged properly so as to not cause further damage

and be returned prepaid to S&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&S and the part was found to be

defective, repair, replacement or refund will be granted.

ADDITIONAL WARRANTY PROVISIONS:

(1) S&S shall have no obligation in the event an S&S part is modified by

any other person or organization.

(2) S&S shall have no obligation if an S&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&S part.

(3) S&S shall not be liable for any consequential or incidental damages

resulting from the failure of an S&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&S and

a customer.

(4) S&S parts are designed exclusively for use in Harley-Davidson

and

other American v-twin motorcycles. S&S shall have no warranty or

liability obligation if an S&S part is used in any other application.

1 2 3 4 5 6 ... 19 20

Résumé du contenu

Page 1 - Cycle, Inc

1S&S®Cycle, Inc.235 Causeway Blvd.La Crosse, Wisconsin 54603Phone: 608-627-1497 • Fax: 608-627-1488Technical Service Phone: 608-627-TECH (83

Page 2 - & Softail

INSTALLATIONThe safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilitiesor do n

Page 3 - DISASSEMBLY

4. Align and install the S&S®shift forks and shaft on the gearset. The largest shift fork (3-4) is installed closest to the transmissiondoor. Next

Page 4 - 5-STEP MODIFICATION

8. Verify the clearance between the 3-4 shift fork and the modified portion of the case is a minimum of .030" to allow full travel ofthe shift fo

Page 5

NOTE: Due to a stack-up of tolerance in transmission cases that are machined by other manufacturers, it may be necessary to manuallyadjust the shift p

Page 6 - 2. Shift Linkage Clearance

NOTE: It is important that you pay special attention to shift pawl adjustment. The adjustment of the shift pawl is directly related toproper function

Page 7

18. Now install the new S&S neutral switch (3-5 ft-lbs) and speed sensor cover (6-8 ft-lbs) on the transmission case.NOTE: 1991-’97 models have a

Page 8 - 3. First Gear Clearance

NOTE: If using S&S®hydraulic clutch side cover kit PN 56-4060 follow instructions included with the kit.22. Fill the transmission with 20-24 ounce

Page 9 - 5. Clean Up

NOTE: Use of the stock 32-tooth pulley with the S&S®transmission will result in an extremely low overall first gear ratio. S&S providesa 34-to

Page 10 - INSTALLATION

18REPLACEMENT PARTS FOR S&S®6-SPEED TRANSMISSIONS34849203143302429397&4619218161734215211. Trap door, S&S 6-speed transmissionHarley-David

Page 11

19CONTINUED...Replacement Parts for S&S®6-Speed Transmissions35. Gear, first, mainshaft, S&S 6-speed ...

Page 12

S&S®Cycle Cassette Assembly Installation Instructions The S&S®six-speed gear sets are available for stock transmission cases of 1991-’05 Harle

Page 13

20TRANSMISSION SERVICENOTE: S&S recommends filling transmission with 20-24 ounces of 90 weight gear oil or equivalent.1. Perform an initial fluid

Page 14

The safety of the motorcycle rider is dependent on proper installation of this product. If you are not certain of your capabilitiesor do not have the

Page 15

5-STEP MODIFICATION1. 3-4 Shift Fork Clearance2. Shift Linkage Clearance3. First Gear Clearance4. 5-6 Shift Fork Clearance5. Clean Up1. 3-4 Shift For

Page 16

C. Position the clearance template on the side door uncovered holes using two 1⁄4 x 20 x 1” screws with the words THIS SIDEOUT facing you as shown in

Page 17 - .200"

F. Use a deburring tool, file or sandpaper to remove any rough edges or chips from the clearanced area as illustrated in Picture 8.2. Shift Linkage Cl

Page 18 - 6-SPEED TRANSMISSIONS

B. Follow the guidelines in your factory service manual to install the sleeve in the shifter shaft bore. NOTE: The new S&S®1.480”sleeve is a speci

Page 19 - 6-Speed Transmissions

4) Tighten the installer until the sleeve stops against the thrust washer. Remove the installation tool and verify the sleeve isflush with the counter

Page 20 - TRANSMISSION SERVICE

4. 5-6 Shift Fork ClearanceSome FLT models will require clearance for the 5-6 shift fork as indicated in Picture 20.A. Insert the 5-6 shift fork and s

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Ss-cycle All-Helical Transmission Gear Set Cassettes for Ha Manuel d'utilisateur

Résumé du contenu

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