1. Reverse Gear kit (Parts#MB002-003) for Harley-Davidson 6 Speed transmission.

 

2. Disconnect negative(-) battery cable.

 

 

3. Drain the transmission oil. Remove the exhaust pipe if it is necessary.

 

4. Remove the transmission side cover.

 

 

5. Remove the oil slinger assembly.

 

 

6. Remove two nuts from the mainshaft and countershaft.

 

7. Clean threads of the mainshaft and countershaft using a parts cleaner to remove oil.

 

8. Apply plenty of supplied Lock Tite#620(Green).

 

 

9. Install the main gear to the mainshaft. Tighten the main gear to 118ft-lbs (160Nm) using the supplied special tool. 

 

 

10. Using the drill and supplied 5mm bur, grind the mainshaft to the depth of 1.063"(27mm) from the main gear surface through two holes of the main gear.

 

 

11. Completely clean the holes. Use care to ensure debres does not enter transmission. Install Lock pin screws. Tighten the Lock pin screws to 8ft-lbs.

 

12. Apply plenty of the supplied Lock Tite#620 (Green) to the counter nut.

 

 

13. Install the counter nut to the countershaft. Tighten the counter nut to 118ft-lbs (160Nm) using the 32mm socket.

 

14. Apply grease on the counter nut.

 

 

 

15. Install the counter gear to the counter nut.

 

 

16. Align key grooves on the counter nut and counter gear. Install the two break-off keys into the grooves. 

 

17. Apply Lock Tite#271(Red) to the thread of bolt. Install the bolt and washer to the counter nut. Tighten the bolt to 56ft-lbs(75Nm).

 

18. Remove the thrust bearing from the oil slinger rod. Install the thrust bearing to 20mm extension rod.

 

 

19. Install the side cover gasket.

 

 

 

20. Install the Reverse gear housing, two supplied dowel pins, side cover gasket and 20mm extension rod..

 

 

21. Install the side cover using 4 of supplied bolts and 2 of longer stock bolts. Tighten the to 9ft-lbs(12Nm).

 

 

22. Fill the transmission with transmission lubricant. Install the exhaust pipe if it is necessary.

 

 

23. Turn cable adjuster until here ia a large amount of free play at clutch hand lever.

 

 

 

 

 

 

24. Remove the derby cover. Adjust clutch adjuster screw. To take up all free play, turn screw inward (clockwise) until gently seated. Activate the clutch lever to verify the balls of Ball & Ramp (in right side transmission) are seated in the ramps. Back out adjuster screw (counterclockwise) 1/2 to 1 turn. Tighten locknut while holding adjuster screw with an Allen wrench.

25. Install the derby cover.

 

 

 

26. Adjust the clutch cable. Ensure free play of 1/8" or more at the clutch lever pivot between the clutch holder and lever without pulling the cable.

27. Connect the battery.