I have an 04 Fatboy bought last October with 6200 miles on it. Excellent condition, like new and runs very well with stage 1. Thinking of changing the 5 speed transmission to the SE 6 speed gearset. Would have the HD dealer do the work. I anticipate more roadtrips with the riding group I belong to and the 6 speed would make any highway travel easier on the bike. Some people I've talked to say why not just trade in for a 96 ci 6 speed, 2008 or later. Well, I like the older Fatboys. The bike is like new and thus has a long life ahead of it. One of the major reasons for moving to a 96 ci 6 speed is the 6 speed, not so much the 96 ci. I did buy this bike for a very nice price($9,500), I would say $3,000 below what a normal market would bring and my intention is that this would be my last bike (I'm up in years-66) and would ride the life out of it and reman it if I'm still riding. Given these facts I estimate I would have to spend $6-8,000 to get into a newer (08-09) 96 ci. The cost of adding the 6 speed gearset to the 04 would be about $2500, parts and labor.

Opinions wanted as to what you would do. Does this make sense or am I just throwing my money away? And, yeah, I know I say this would be my last bike. Maybe not but let's assume it really is.

 

Sound's like a reasonable upgrade since the bike is that nice. Can they tell what kind of rpm drop that sixth gear will give you?

 

With an 04 Fatboy you should spend the 2500 on upgrading the cams plate and tensioners first, go ahead and do a 95 inch top-end. You are eventually going to have to replace the tensioners anyway.
I am not sure your stock motor would handle the 6th gear, very well, without increasing the horsepower and torque a little bit.
I have read, on here, that there is only about a 300 rpm difference between the 5th gear on a stock 5 speed and 6th gear on the SE kit.

 

A service tech at one dealer said that I would maybe have to downshift if going up a hill or passing quickly but just on a flat land cruising would not be a problem. I will call my dealer today and see what they say. Yeah, I know the tensioner change is in my future. Do you loose much gas mileage with the 95 upgrade? Also, I understand if you go with a gear drive cams you pick up a few more HP.

 

I have not ridden my bike enough since I did the 95 upgrade kit, to know about the MPG. But, from reading on here many people actually get better gas mileage with the 95 upgrade kit.
I expect mine to go up because of a better ecm.

 

Ur money, But, don't know I'd spend than much just to get the 6 speed.

61 yrs here, so probably Ur not worried about racing as I am not either.

I also have read the diff is only 2-3 hundred rpms at 65 or so MPH's

I can vouch that the 6th gear needs at least some cams to make it really usable. Didn't use 6th much myself till I did that cams. The stg1 only 96'' engine just seemed to labor below 65 and she always lost 2-4 mpg if I did run her in 6th.

After the cams she now can be ridden in 6th, even 2up at 60mph and still has plenty of power to pass without having to downshift. The fuel mileage even went up.

Used to get best mileage (average 41mpg) riding 55 in 5th.
Now its (average 44) riding 60-65 in 6th..
Another good result was the cams lowered the oil temp about 15* too.

I ride with several TC 88's and don't notice that much diff, If U do a lot of 80 mph riding and feel U have to lower the revs, how about just a sprocket change. That along with some cams would still have pretty good get up and go.

Just thought of another,, the lops Elite 3 rear in the 160 size is about 1/2 inch taller than the HD lop 401 - 150 rear tire, so just putting on one of those tires would make up maybe 1/2 of those rpm's Ur looking to get. plus there supposed to wear better. several K more miles out of them are being reported in here vs the 401's

still Ur $$$. just my .02..

 

I was contemplating this a while back and ended just sticking with the 5 speed. I could not justify that amount of money to get the extra gear. If i were going to upgrade i would also check out the Baker DD6 as I think it is a nicer 6 speed unit. As said above, it is your money, get what you want. Cam plate and tensioner situation is a much more dire situation than a 6 speed ion your year bike.

Drew

Drew

 

I agree with the Dr, Tensioners are on your must do list sometime in the future so why not upgrade to a better cam at the same time. You may find that after the cam and tensioner upgrade you dont feel theneed as much for the 6sp.

I though about doing this a few years ago and ended up putting $ into the engine for miore Hp. I went with SE 204 cams and the SE hyd Cam Tensioner Kit and am veruy happy with the improvement. I

With my stock trans I easily pull 70 -75 for hours on the freeway and it great having the extra Hp for passing and hills etc.

I dont think I want or need a 6th gear

 

JMHO I find that 6th gear is not very usable. When I only had 5 gears I dreamed of another gear. Now that I have it, not so much. I have done nothing to the engine. At some point I may do a stage 1. At 70 MPH the bike is lugging in 6th gear. Only when I'm being "crazy" do I look for that 6th gear light. I too an getting up in years and have little interest in being "crazy". 96" and 5th gear is just fine.

 

Here's the deal. I have an '02 Fat Boy with a pretty hot 95" motor and a S.E. six speed. It's a great unit and I've run it for six years. It shifts smoothly and has better shift forks and bearings than the 5 speed. If you don't run 75 to 80 m.p.h. the 5 speed is fine. If you spend a lot of time at high speed the six speed great. It slows down the engine about 500 r.p.m. on the road. The .89 overdrive means 2500 rpm at 70 m.p.h. instead of 3000 with the 5 speed. At 80 your purring along at 3000 r.p.m. The first five gears are identical to you stock 5 speed and you get the overdrive sixth. As far as improving mileage, it didn't help mine a bit. It depends on how fast you ride if you are to get any benefit at all from the change. Twin Cams love 3000 r.p.m.s. I'm a chronic law breaker, so I get a lot of good from my sixer, you, maybe not so much.

Now about cam chain tensioners, with less than 7000 miles I wouldn't worry. At about 20,000 miles I'd change them to either gears or the new hydraulic set up. Parts and labor about half of what the 6 speed costs installed.