I put a six speed gear set with a true overdrive into my 1985 FXRC, and got rid of the basterd 1985-1989 tapered main transmission shaft. I now have the splined shaft used 1991-2006. I used a 1993 fat boy primary, you can use a 1991-1993 primary with out having to change inner and outer primary covers in 1994 they changed the primary. I had to change the clutch release transmission cover and clutch cable. I used one for a FLH FXD FLS 1999-2006, again a better set up with the ramp and ball. I did have to some clearance on the top of the transmission housing toward the engine side for the shifter drum detent. Works great!! worth all the work, at 75mph dropped my rpms by 500, here are some pics

 

as you can see from the pics I had to tear it down anyway, it leaked a little

 

Time to take it on a nice long trip with the new OD. Nice work.

 

Nice! I bet you like how it shifts now also! No more “clunk”.

Who’s 6 speed did you use (brand)?

Enjoy! YD

 

Just a little... LOL....

Anyways well done, I did not know that the trans cases were the same through out the life of the 5 speed. Good to know. I have to say that the 91 up splined shafts are the way to go. Nothing like a 6 speed. I have a Baker. Who's did you use? Didn't see anything on top of the trap door.. What year clutch basket did you use?. I have a 98 basket and it can handle a lot of power..

 

Ya, found out a splined 5 speed gear set will replace the tapered set up in a 82 Shovel 5 speed, Harley's case machining workers knew the word repetition.

The OD6 in a light bike would be the catsazz, big bikes need some help.

 

I see you also went with a later model trap door, and upgraded to the ball and ramp clutch release (got rid of the old lever).

Nice job.

 

I got the gear set from a buddy of mine, he was going to put it in his newer bike but decided to go with a whole new tranny, so I told him Id buy it, he said for what? it wont work on your bike. I told him dont worry about it ill make it work lol, he believes me now, the gear set, shafts, shift drum and shift forks are baker od6, the trap door is just one i bought that would work because it was missing the trap door because a buddy of his has a baker and some how messed up the trap door, I dont know how he managed that one?? but the gears and shafts were new never installed and sold it to me for a couple hundred bucks, yeah it shift very smooth, tight and no clunk, its so nice out on the highway to hit that sixth gear. My bike the sweat spot is 3,000- 3,200 rpm which was about 65 mph which is cool but 70-75 she was running 3,500 rpm and above. Up close to 4,000 she just vibrates more and she dont feel happy for a long period time. Now at 75mph shes running 3,000 rpm and very happy. If Im running 60-65 mph I just leave her in fifth. Clutch basket I used was from a 1993 fat boy, 1994 and after they completely changed them and I didn't want to get into buying a new inner, outer primary covers and starter, even tho the newer starter set up is better!! My old starter set up has not really given much problem I guess because when I rebuilt my engine two years ago pretty much stock ".010" thats about it, so no big cu inch or high compression. If any of you guys are thinking about doing this, my advise is DO IT!!, not that bad, and there are a few different choices in gear sets for 1990- 2006 that will work, they say 1990 but in most cases its really "1991", 1990 was the "one year only" of the real bastard short spline main transmission shaft!, Ill be here for help or advise if needed, some special tools make it easier, but are not that expensive, Im a mechanic so I had them

 

An other mod I just done that I love is Signal Dynamics Self-Canceling Turn Signal Module 01501 for $70.00 bucks on amazon, no more trying to hold down the signal buttons while clutching and braking so easy to install just used it to replace my flasher and stuck it in my headlight bucket

• Perfect for custom builds or retrofitting models without self-canceling turn signals
• Features three turn signal timing modes: a one-second press of the turn signal button causes seven seconds of turn signal flash before self-cancel, a two-second press causes 20 seconds of flash before self-cancel and a four-second press causes 75 seconds of flash before self-cancel
• All flash modes can be canceled with a second push of the turn signal button
• Flash time is consistent whether using incandescent or LED lighting
• Simultaneous depression of right and left turn signal buttons for one second begins hazard mode; flash continues until manually canceled

 

Been running a Baker OD6 for roughly 7 years, changed the primary gear ratio to 3.34 putting gearing in the sweet spot. Pretty much stole a gear set like you mentioned with yours but Bakers would be worth the full price, no back seat to quality and ease of shifting makes HD's tranny's trash compactors.