Harley Davidson J03322 Handleiding

Harley Davidson J03322

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General

The Screamin’ Eagle FLHT 6-Speed Transmission kit fits

2002 and later Harley-Davidson®Touring model

motorcycles.

Kit No. Description

33136-04 Silver

33137-04 Black

An additional kit for the side cover will be required. The kit

number depends on if the motorcycle is using the existing

clutch cable or is being converted to a hydraulically actuated

clutch.

Kit No. Description

38752-04 SE 6-Speed Cable Clutch Side

Cover and Release Pushrod Kit

45033-03A Hydraulic Clutch Kit - black

45383-03A Hydraulic Clutch Kit - chrome

38753-04 SE 6-Speed Hydraulic Side Cover

& Release Kit

See the Service Parts illustration for a list of service parts in

this kit.

Required Service Parts and Tools

Installation of this kit will require additional service parts and

supplies. Specialized tools will include Hose Clamp Pliers

(HD-41137) and Hose Clamp Pliers (HD-97087-65B).

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

This instruction sheet references Service Manual instruc-

tions. A Service Manual for your model motorcycle is avail-

able from any Harley-Davidson dealer.

Installation

Prepare the Motorcycle for Service

1. Mount the motorcycle on a suitable lift.

2. Follow Service Manual instructions given to remove the

seat.

To prevent accidental vehicle start-up, which could

cause death or serious injury, disconnect battery cables

(negative (–) cable first) before proceeding. (00307a)

Disconnect negative (–) battery cable first. If positive (+)

cable should contact ground with negative (–) cable con-

nected, the resulting sparks can cause a battery explosion,

which could result in death or serious injury. (00049a)

3. Disconnect the battery cables, negative (-) cable first:

a. Remove bolt and negative (–) cable.

b. Remove bolt and positive (+) cable.

Access the 5-Speed Transmission

1. Place a container under the engine, remove the engine

and transmission lubricant drain plugs to drain engine

and transmission fluids.

2. To access the existing 5-speed transmission, follow the

Service Manual instructions in the following sections:

a. SADDLEBAGS, REMOVAL

b. EXHAUST SYSTEM, REMOVAL

NOTE

The right muffler and crossover pipe can be removed in 1

piece and the left muffler and the front and rear header

pipes can be removed in 1 piece. Refer to the Service

Manual Section REMOVING ENGINE FROM CHASSIS for

instructions.

c. REAR WHEEL. REMOVAL

NOTE

Position a jack with a wooden block under the engine and

transmission oil pan to support the weight of the 5-speed

transmission.

d. REAR SWINGARM, REMOVAL

e. STARTER, REMOVAL

f. CLUTCH RELEASE COVER

1WARNING

Gear 5-Speed 6-Speed

1st 3.210 3.210

2nd 2.109 2.209

3rd 1.572 1.572

4th 1.226 1.226

5th 1.000 1.000

6th NA 0.885

INSTRUCTIONS

-J03322 REV. 02-11-2005

SCREAMIN’ EAGLE®FLHT 6-SPEED TRANSMISSION

Kit Number 33136-04 and 33137-04

1 of 6

Table 1. Transmission Ratios

Remove the Primary Chaincase

Follow the Service Manual PRIMARY CHAINCASE,

REMOVAL instructions to remove the cover, the primary

chain, clutch, engine compensating sprocket, chain

tensioner assembly, alternator and starter drive mechanism,

and the primary chaincase.

Remove the 5-Speed Transmission

1. Remove the locknut, lockwasher and flat washer to

separate the the shift rod from the 5-speed transmis-

sion shifter arm.

2. Remove oil hose cover and oil hoses at the crankcase.

a. Remove screws and cover.

b. Use side cutters to remove clamps on crankcase end

of oil supply, return and crankcase breather hoses.

3. See Figure 1. Locate vehicle speed sensor and remove

screw and the sensor from the existing transmission

case.

4. See Figure 2. Remove connectors from neutral switch.

5. See Figure 3. Remove the fasteners from the transmis-

sion exhaust bracket.

6. Remove the 4 bolts and washers connecting the trans-

mission to the engine.

NOTE

After removing the bolts, the transmission is unattached to

the frame or the engine and is resting on the support jack.

7. See Figure 4. From the right side,

slide the transmission

toward the rear of the motorcycle (to clear the ring dow-

els) and lift the transmission out of the frame.

Install 6-Speed Transmission

Slide the 6-speed transmission with oil pan from the right

side of the frame into position.

a. Center the the transmission rear mounts between the

rear swingarm mounts.

b. See Figure 4. Move transmission forward to engage the

2 ring dowels in the lower flange of crankcase.

2. Align the bolt holes on the transmission to the engine by

threading in and finger tightening the 4 bolts and washers.

NOTE

Use OPEN End Crowfoot (Snap-On FC018) on the upper

left and upper right transmission housing to crankcase bolts.

3. See Figure 5. Tighten the transmission bolts in a cross

pattern torque sequence:

a. 1st pass tighten to 15 ft-lbs (20.3 Nm).

b. 2nd pass tighten to 30-35 ft-lbs (40.7-47.5 Nm).

4. Assemble the pivot shaft assembly (pivot shaft, locknut,

cup washer, rubber mount and outer spacer) and coat

the pivot shaft with Loctite®Anti-Seize.

2 of 6

-J03322

Figure 3. Exhaust Bracket on 5-Speed Side Door

(side cover removed)

i06771

Figure 1. Vehicle Speed Sensor

(behind engine oil fill plug/dipstick)

i06775

Figure 2. Neutral Indicator Switch Connector

i06782

5. Slide rear swingarm assembly into position aligning with

mounting boss of transmission case.

6. Follow the Service Manual REAR SWINGARM INSTAL-

LATION instructions to position the rubber mounts in

the rear swingarm bracket

7. Install pivot shaft and tighten locknut to 45-50 ft-lbs

(61.0-67.8 Nm).

8. Install the flat washer, lockwasher and locknut to fasten

shifter rod to the new 6-speed shift lever. tighten lock-

nuts to 80-120 in-lbs (9.0-13.6 Nm).

9. Install the exhaust bracket and tighten bolts to 13-16 ft-

lbs (18-22 Nm).

10. Install oil supply, return and breather hoses.

a. Fit new clamps onto ends of hoses.

b. Push and push hoses onto oil fittings

c. Crimp supply and return clamps with Hose Clamp

Pliers (HD-41137).

d. Crimp breather hose clamp with Hose Clamp Pliers

(HD-97087-65B).

11. Secure oil hose cover to transmission and alternately

tighten screws to 84-108 in-lbs (10-12 Nm).

12. Install the vehicle speed sensor and tighten to 84-132

in-lbs (9.5-14.9 Nm).

13. Push the neutral indicator light connectors onto the

neutral indicator switch.

Install Primary Chaincase

1. Follow the Service Manual PRIMARY CHAINCASE,

INSTALLATION instructions to install the primary chain-

case, primary chain, clutch, engine compensating

sprocket, chain tensioner assembly, the starter drive

mechanism and the chaincase cover.

2. Remove the inspection cover.

Install Side Cover Release Kit

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 No. 38752-04).

For hydraulic clutch: Follow the instructions in the

Hydraulic Clutch Side Cover and Release Pushrod Kit

(Part No. 38753-04) and in the Hydraulic Clutch Kit

(Part No. 45033-03 - black or 45388-03 - chrome).

Install Removed Components

1. To install the components removed to access the 5-

speed transmission, follow the Service Manual instruc-

tions in the following sections:

a. REAR SWINGARM, INSTALLATION

b. REAR WHEEL, INSTALLATION

c. STARTER, INSTALLATION

d. EXHAUST SYSTEM, INSTALLATION

e. SADDLEBAGS, INSTALLATION

Instructions continued on page 6.

3 of 6

-J03322

Figure 5. Transmission to Crankcase Torque Sequence

(transmission view from front)

i06779

Figure 4. Ring Dowels

(oil filler spout and side cover removed)

i06772

Product specificaties

Merk:	Harley Davidson
Categorie:
Model:	J03322

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