1990 Harley Davidson ULTIMA 6 SPEED BUILDERS KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 09-04-2012

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For 2000 & later models removal of approximately 1/4 of an inch off of the shifter arm bushing is likely required. Doing so will allow installation of the retaining clip & washer onto the shifter arm. It is good practice to double check how much material should be removed before cutting the bushing. See fig. 1 & 2 Install supplied Main drive gear bearings & countershaft needle bearings using special tool # 97-164 NOTE: Lightly coat bearings with assembly lube or gear oil for easier installation. Install supplied Main drive gear retaining clip & verify that it is fully seated and cannot come out. Do not re-use old bearings or retaining clip. Install supplied Main drive gear into bearings using special tool # 97-166 See fig. 3 Install supplied trap door gasket & verify that it is on correctly. Install supplied 6 speed gear set making sure to align the countershaft with the needle bearing assembly. Slowly slide in gear set until the mainshaft & countershaft will not slide in any further. Lightly tapping on the trap door (while verifying that there is no interference) with a soft blow hammer will then fully seat the shafts & trap door. See fig. 4 Once gear set is installed use the supplied 5/16-18×1-1/2 & 1/4-20×1-1/2 bolts to secure the trap door. Torque the 5/16 bolts to 15 ft-lbs w/ red loctite (high strength) Torque the 1/4 bolts to 9 ft-lbs w/ red loctite (high strength) See fig. 5 FIG. 1 FIG. 2 FIG. 3 FIG. 4 FIG. 5 2 FIG. 6 At this time check to make sure all gears rotate freely & that all slider gears slide with no interference. Lightly lube & install supplied quad seal onto main drive gear. See fig. 6 Install Main seal using special tool # 97-164. See fig. 7 Install original spacer onto mainshaft. NOTE: Beveled side goes in towards quad seal. See fig. 8 Install supplied transmission drain plug & supplied speedo sensor plug with gasket. Install supplied shifter forks onto appropriate slider gears. See fig. 9 Lightly lube & install supplied shift fork shafts. NOTE: Short shaft is installed from the right side with the threaded hole facing out. Long shaft is installed from the left side & should not protrude from the right side of case. See fig. 10 Install supplied shift fork shaft allen head plugs. (Use red loctite to prevent movement of plug & to aid in sealing)

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ULTIMA 6 SPEED BUILDERS KIT INSTALLATION MANUAL

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Filed Under (Tips and Review) by admin on 03-03-2011

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DISASSEMBLY For 5 speed gear set removal refer to your factory service manual. You willneed to remove the main drive gear, main drive gear bearings, retaining clip & countershaft needle bearings. NOTE: Removal of the shifter arm is notnecessary for 99 & earlier transmissions. NOTE: Removal of the shifter arm isnecessary for 2000 & later transmissions. After trans. housing is disassembled thoroughly clean & inspect. ASSEMBLY For 2000 & later models removal of approximately 1/4 of an inch off of the shifter arm bushing is likely required. Doing so will allow installation of the retaining clip & washer onto the shifter arm. It is good practice to double check how much material should be removed before cutting the bushing. See fig. 1 & 2 Install supplied Main drive gear bearings & countershaft needle bearings using special tool # 97-164 NOTE: Lightly coat bearings with assembly lube or gear oil for easier installation. Install supplied Main drive gear retaining clip & verify that it is fully seated and cannot come out. Do not re-use old bearings or retaining clip. Install supplied Main drive gear into bearings using special tool # 97-166 See fig. 3 Install supplied trap door gasket & verify that it is on correctly. Install supplied 6 speed gear set making sure to align the countershaft with the needle bearing assembly. Slowly slide in gear set until the mainshaft & countershaft will not slide in any further. Lightly tapping on the trap door (while verifying that there is no interference) with a soft blow hammer will then fully seat the shafts & trap door. See fig. 4 Once gear set is installed use the supplied 5/16-18×1-1/2 & 1/4-20×1-1/2 bolts to secure the trap door. Torque the 5/16 bolts to 15 ft-lbs w/ red loctite (high strength) Torque the 1/4 bolts to 9 ft-lbs w/ red loctite (high strength) See fig. 5

Aprilia's Dorsoduro 750 Compare With Ducati's Hypermotard 796

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Filed Under (Tips and Review) by admin on 16-11-2010

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Mid-Size Italian Supermotos— Aprilia’s excellent Dorsoduro 750 vs. Ducati’sbrand-new Hypermotard 796 20 Japanese Rider Training Examined — Rigorous training & tiered licensing, because size matters 23 BMW Paralever Pivot Maintenance &Upgrade— Howto replace fragile needle bearings with Oilite bushings 26 Trail Tools— What to pack and how to carry it when you’re off the beaten path 30 Yamaha/Star’s New Stratoliner— 1st Impression: Astellar baggage handler 32 Mental Motorcycling— Highway Hypnosis 33 Medical Motorcycling— About Gout 34 Legends Of Motorcycling— Bill Werner, The Game Changer 36 Harl ey-Davidson’s Cross Bones— Aspringer fork and sprung seat make for a nostalgic Softail 37 Motorcycle Design— The YikeBike & Honda’s U3-X 38 Proficient Motorcycling— Corner Braking 48 Innovation Of The Month— PivotPeg

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