Harley-Davidson J03322 Bedienungsanleitung
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
1WARNING
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
1.
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
2
4
1
3
Produktspezifikationen
| Marke: | Harley-Davidson |
| Kategorie: | |
| Modell: | J03322 |
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