Factory 6-Speed Kicker kit
Contents
1. 9 Using Blue thread lock install the six bolts Torque the four 4 20 x 34 pn 25C50KLHS to 7 9 ft lbs 84 108 in Ibs Torque the two 10 24 x 5 8 pn 10C50KL HS to 4 5 ft Ibs 54 60 in Ibs DS HYDRAULIC KICKER COVER INSTALLATION pn 678 H P R B K 1 Place the side cover gasket on the two 10mm dowels pn 16583 00 on the bearing door assembly Insure that the clutch throw out rod is installed in the ratchet gear quill 585 5 While making sure the ratchet gear is still retained by the kicker crank gear place the side cover on to the two 10mm dowels pn 16583 00 While holding the cover in place take the nine supplied 5 16 18 x 1 1 4 SHCS pn 73496 with 5 16 washers pn 6100 and apply blue thread lock to the threads Now torque the fasteners to 13 16 ft Ibs 156 192 in Ibs 4 Install your 3 8 24 banjo bolt and 3AN brake line at this time 2 3 PAGE 13 GEARSET INSTALLATION KICKER COVER INSTALLATION V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS KICK ARM INSTALLATION 1 Install the kick arm on to the kicker crank gear shaft 2 Tighten the pinch bolt on the kicker crank gear shaft so that there is no sloppy movement in the kicker arm assembly 3 Either with your hand or leg kick the kick arm and run it through its motion to make sure everything is working properly FINAL ASSEMBLY 1 Install your primary and adjust your clutch per your Factory Servi2. 13 0128 25C50KFC 585 5 292032 125 5R 45 9404 TWC411 TC411 10705 01149 73496 578 56 PAGE 6 EXPLODED VIEW DESCRIPTION Transmission bearing door Bearing door to case gasket Side cover gasket Crank gear assembly Lock Washer crank gear Nut Crank Gear Ratchet pinion gear Pinion gear spring 14 20 x 1 2 Flat Socket cap screws Pinion gear quill Filler plug Actuator Rod 14 28 Bleeder screw Throw out washer Throw out bearing C clip throw out assembly O Ring Hydraulic piston 5 16 Washer 5 16 18 x 1 SHCS SS Kicker cover hydraulic HYDRAULIC TYPE V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS OTY 1 1 1 1 1 1 1 2 1 1 6 1 1 1 1 1 1 8 HYDRAULIC TYPE pn s 678 H P R B K PN 292013 291222 292003 292016 9452K29 6391K269 51740 001 16583 00 6007 407 RV07 24050 137RRRE 31C150KCSS P PAGE 7 EXPLODED VIEW DESCRIPTION Kicker return spring bolt Spring kick arm return Shaft kicker Washer kick shaft O ring kicker shaft Bushing kicker shaft 3 8 24 Drain plug 10mm dowels Mainshaft bearing Retainer Plate Mainshaft 14 20 x 5 8 BHCS Ratchet hub CD6 Mainshaft lock nut Nut countershaft retainer Retainer Plate Countershaft Countershaft bearing External Snap ring ratchet hub 5 16 18 x 1 SHCS SS HYDRAULIC TYPE V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS GETTING STARTED The BAKER Factory 6 Kicker kit is designed
3. damage to property BAKER transmissions transmission kits and Wide Tire Kits are designed exclusively for use in Harley Davidson motorcycles BAKER shall have no warranty or liability obligation if a BAKER part is used in any other application If it is determined that a BAKER transmission assembly has been disassembled during the warranty period for any reason this limited warranty will no longer apply PAGE 15 TERMS AND CONDITIONS V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS DISCLAIMER The words Harley and H D are registered trademarks and are for reference only Use of H D model designations and part numbers are for reference only BAKER Drivetrain has no association with and makes no claim against these words trademarks or companies It is the sole responsibility of the user to determine the suitability of this product for his or her use and the user shall assume all legal personal injury risk and liability and all other as well as all other obligations duties and risks associated therewith CUSTOMER SUPPORT For any installation or service questions please contact our BAKER technical department toll free 1 877 640 2004 DRIVETRAIN PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES Baker Drivetrain 9804 E Saginaw Haslett MI 48840 On the web www bakerdrivetrain com PAGE 16 DISCLAIIMER
4. to be easily installed by any competent mechanic or dealership technician Having your H D factory service manual is required in this installation as it is referred to in many sections of the instructions While this kit is made to be as easy as possible to install there is no substitution for experience To install the F5K kit disassembly of the transmission down to the gearset is required We recommend reading through these instructions to the end before proceeding with installation process TOOLS RESOURCES REQUIRED PARTS e Factory Service Manual For Your Motorcycle e Factory Parts Manual For Your Motorcycle e Hand Tools Are All That Is Needed For This Installation e BAKER TOOLB 56 e Hydraulic Press e 6 Torque Wrench e Brake Bleeder Pump for hydraulic type FOR HYDRAULIC VERSION ONLY Hydraulic Fluid BAKER Recommends H D Dot 5 Brake Fluid pn 99902 77 e AN 3 Brake Line e 10mm Banjo Fitting for both ends of brake line e 3 8 24 Banjo Bolt for the side cover end of the brake line e Banjo Fitting Washers e 11 16 Diameter Bore Hydraulic Clutch Lever Assembly PAGE 8 GETTING STARTED V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS DISASSEMBLY TEAR DOWN Whereas it may seem we are skimming over many of the steps your factory service manual will lay out in detail the proper methods for removal and reassembly of the components listed out in the steps within these inst
5. V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS 678 HR K Shown TT PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS FEATURES 6061 T 6 Aluminum Billet Bearing Door in Show Polish Raw Finish Black Finish 6061 T 6 Aluminum Billet Side Cover in Show Polish Modern Clutch Actuation Available in Ball and Ramp Cable Type or Hydraulic Hardened 8620 Kicker Gears 4140 Pinion Gear Quill With Smooth Micro Finish For Superior Function Hardened 8620 Ratchet Hub Encapsulates Mainshaft To Prevent Breaking Straight Stainless steel kick arm with 5 8 4140 spindle and bronze kicker pedal PART NUMBERS DESCRIPTIONS 678 MR K F6K w silver door amp polished cover cable type 678 HR K F6K w silver door amp polished cover hydraulic type 678 MB K F6K w black door amp polished cover cable type 678 HB K F6K w black door amp polished cover hydraulic type 678 MP K F6K w polished door amp cover cable type 678 HP K F6K w polished door amp cover hydraulic type APPLICATION 2007 2009 Softails FLT FLH 2006 Dyna Models Factory Cruise Drive 6 Speeds NOTES BAKER Factor 6 Kicker will not clear stock exhaust systems due to the extended length of the transmission door and kicker Aftermarket systems with The kicker arm will not clear the stock right side passenger floor board on FLT FLH models Installation of foot pegs or s
6. ce Manual at this time 2 With the bike vertical fill your transmission with the supplied 320z bottle of Spectro 75W140 3 Follow your Factory Service Manual to finish assembly on your motorcycle 4 Your BAKER Factory 6 Kicker installation is complete PAGE 14 GEARSET INSTALLATION KICKER COVER INSTALLATION V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS TERMS SPECIALORDERS A minimum 500 deposit is required with all special orders Special orders include unique case finishes unique side door requests i e wrinkle black door or no logo ALL OTHER ORDERS Orders can be pre paid using VISA MasterCard or American Express Prices shown are F O B Haslett MI BAKER provides free UPS ground shipping on all retail orders for complete transmissions or transmission kit UPS air shipment is available upon request Customer is responsible for air shipment premiums LIMITED WARRANTY BAKER Inc transmission assemblies transmission kits and wide tire kits are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 2 years from the date of purchase If the product is found by BAKER to be defective such products will at the option of BAKER be replaced or repaired at cost to BAKERTM In the event warranty service is required the original purchaser must call or write BAKER immediately with the problem If it is deemed necessary
7. en the jam nuts with a breaker bar Now you can unbolt the trap door from the case Lightly tap on the end of the mainshaft on the primary side with a rubber mallet to loosen the entire gearset and trap door from the case and the 6 main needle bearings You do not need to loosen the drive sprocket or remove the 6 main bottle gear install this kit Boo NOT HIT THE END OF THE MAINSHAFT WILL A BALL PEEN HAMMER OR ANY OTHER METAL HEADED HAMMER HITTING THE MAINSHAFT WITH A GREAT AMOUNT FORCE IN ANY MANNER WITH ANY HAMMER WILL DAMAGE THE THREADS YOU MUST REUSE YOUR STOCK MAINSHAFT AND WANT TO TAKE GREAT CARE NOT TO DAMAGE IT IN ANYWAY IF YOU FEEL THAT YOU DO NEED TO USE A GREAT DEAL OF FORCE TO REMOVE THE GEARSET STOP AND LOOK OVER ALL OF YOUR PREVIOUS STEPS AS YOU MAY HAVE FORGOTTEN TO REMOVE A BOLT THE MAINSHAFT BEARING PAGE 9 DISASSEMBLY TEAR DOWN V1 021809 RACE MOVED THE SHIFTER PAWL OR SOME OTHER SOLID OBJECT IS IMPEDING THE PATH OF THE GEARSET BEFORE YOU PROCEED PAGE 9 DISASSEMBLY TEAR DOWN V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS DISASSEMBLY TEAR DOWN CONTINUED Once you have successfully removed the gearset from the case and have it sitting with the trap door on a workbench and the shafts pointing in the air refer to your factory service manual for the safe and efficient way to strip the assembly down to the trap door You will be reusing everything but the transmission bearing door The figu
8. for BAKER to make an evaluation to determine whether the transmission assembly or transmission kit is defective the entire transmission assembly whether originally purchased as an assembly or kit must be properly packaged and returned prepaid to BAKER with a copy of the original invoice of purchase If after an evaluation has been made by BAKER and a defect in materials and or workmanship is found BAKER will at BAKER option repair or replace the defective part of the assembly Warranty card must be returned within 45 days of purchase to be valid ADDITIONALWARRANTY PROVISIONS This limited warranty does not cover labor or other costs or expenses incidental to the repair and or replacement of BAKER products This warranty does not apply if one or more of the following situations is judged by BAKER to be relevant improper installation accident modification including but not limited to use of unauthorized parts racing high performance application mishandling misapplication neglect including but not limited to improper maintenance or improper repair BAKER shall not be liable for any consequential or incidental damages arising out of or in connection with a BAKER transmission assembly transmission kit swingarm fender component or part Consequential damages shall include without limitation loss of use income or profit or losses sustained as the result of injury including death to any person or loss of or
9. ft lock nut Ratchet pinion gear Pinion gear spring 14 20 x 1 2 Flat Socket cap screws Pinion gear quill Filler plug Side cover gasket 5 16 Washer 5 16 18 x 1 SHCS SS Actuator Rod Throw out washer Throw out bearing C clip throw out assembly Inner actuator ramp 3 8 Actuator ball bearing Actuator ferrule MECHANICAL CABLE TYPE V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS OO sch 0O ND Bae sch mn sch py A Sa PN WT3196 587 56M 25C50KLHS 10C50KLHS 584 56M 588 56M 292013 291222 292003 292016 9452K29 6391K269 51740 001 16583 00 31C150KCSS P PAGE 5 EXPLODED VIEW MECHANICAL CABLE TYPE 5 678 M P R B K DESCRIPTION Outer Actuator Ramp Ball ramp cover gasket 14 20 x 1 2 Low head cap screw 10 24 x Low head cap screw Ball ramp cover plate Actuator assembly bolt Kicker return spring bolt Spring kick arm return Shaft kicker Washer kick shaft O ring kicker shaft Bushing kicker shaft 3 8 24 Drain plug 10mm dowels Mainshaft bearing Retainer Plate Mainshaft 14 20 x 5 8 BHCS Retainer Plate Countershaft Nut countershaft retainer Countershaft bearing 5 16 18 x 1 1 2 SHCS SS MECHANICAL CABLE TYPE V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS Q TY 1 1 1 1 1 1 1 1 4 1 1 1 1 2 1 1 2 1 9 1 HYDRAULIC TYPE pn s 678 H P R B K PN F6K R P B 35654 06 F 6N4 Side 33350 56 292014 292015 310 56K
10. ly press the mainshaft into the bearing door making sure all the gears spin freely Once the mainshaft is seated clean the threads with lacquer thinner and blow dry completely Apply Red thread lock to the mainhaft retainer nut pn RV 7050 and torque to 45 55 ft lbs Your bearing door assembly is complete Kai Ach Mainshaft and Countershaft Assembly Pressed In PAGE 11 BEARING DOOR ASSEMBLY V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS BEARING DOOR ASSEMBLY CONTINUED 3 You need to refer to your Factory Service Manual to finish the door assembly Install the shift drum shift forks shift fork rods and detent pawl to the Factory Service Manual 4 Your gearset is now complete Now is a good time to give your gearset a once over to make sure all the gears spin freely and are seated properly Completed F6K bearing Door Assembly PAGE 12 BEARING DOOR ASSEMBLY V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS GEARSET INSTALLATION 1 Refer to your Factory Service Manual for proper gearset installation Replace the bearing door assembly with the supplied gasket pn 35654 06 F Once the gearset is in the transmission case Use the eight supplied 5 16 18 x 1 1 2 SHCS pn 31C150KCSS P and eight 5 16 washers pn 6100 in the eight holes of the bearing door Using Blue thread lock torque the bolts to 13 16 ft lbs 156 192 in lbs 4 Install your top cover per yo
11. maller footboards are required Twin Cam models require installation of a cam based ignition See BAKER 2008 2009 Supplement for ignition alternatives or consult a BAKER sales tech Fuel injected models require retrofit to carburetor retrofit PAGE 2 OVERVIEW V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS TABLE OF CONTENTS 2 Overview Part Numbers and Application 3 Table Of Contents 4 F6K exploded view amp parts list Cable type 5 F6K exploded view amp parts list Cable type continued 6 F6K exploded view amp parts list Hydraulic type 7 F6K exploded view amp parts list Hydraulic type continued 8 Getting Started Tools and Resources 9 Gearset Removal Bearing Door Disassembly 10 Bearing Door Disassembly Continued 11 Bearing Door Assembly 12 Bearing Door Assembly Continued 13 Gearset Installation Side Cover Installation 14 Kick arm Installation Final Assembly 15 Terms and Warranty Conditions 16 Disclaimer and Customer Support PAGE 3 TABLE OF CONTENTS V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS MECHANICAL CABLE TYPE pn s 678 56M P R B K Q PN F6K R P B 35654 06 F 137RRRE 33350 56 13 0128 10705 01149 WT3096 987687 3094 DSSC PAGE 4 EXPLODED VIEW DESCRIPTION Transmission bearing door Bearing door to case gasket External Snap ring ratchet hub Crank gear assembly Lock Washer crank gear Nut Crank Gear Ratchet Hub Mainsha
12. re below shows the parts needed to rebuild your new F6K assembly Re used Factory Parts PAGE 10 DISASSEMBLY TEAR DOWN CONTINUED V1 021809 BAKER FACTORY 6 KICKER INSTALLATION INSTRUCTIONS BEARING DOOR ASSEMBLY 1 Remove the Factory 6 Kicker bearing door F6K P R B from the package Clean your mainshaft and counter shaft threads with lacquer thinner and dry completely before pressing Now take your countershaft assembly and support it vertically in the press with the threaded end facing up Insure that the split securing segments are still in place Now take your Factory 6 Kicker pn F6K P R B bearing door assembly and press the countershaft into the bearing pn 6304 Use the bearing s inner race as the press point Make sure your countershaft is perfectly vertical before pressing it in damage to threads could incur if not vertical Remove assembly from press Apply thread Red thread lock to the countershaft retainer nut pn 37141 and torque to 45 55 ft Ibs A ial Countershaft Assembly Pressed In 2 Take the mainshaft assembly with the clutch end facing down Make sure the split securing segments are still in place and place the mainshaft in the press supported vertically Now take the bearing door assembly and place it on to the mainshaft over the ratchet hub pn 308 6 Once the mainshaft is parallel with the countershaft and the gears mesh start pressing using the ratchet hub pn 308 6 as the press point Slow
13. ructions Softails Dynas and FLT FLHs are all different configurations and require a different order and method to accomplish the various steps WITH ANY DRIVETRAIN RELATED PROJECT THE FIRST STEPS THAT YOU WANT TO TAKE ARE TO REMOVE THE SEAT AND DISCONNECT THE BATTERY FOR YOUR SAFETY Start with draining your transmission and primary lubricants Refer to your Factory Service Manual for your drain plug locations Now remove the saddle bags if applicable floorboards foot controls and the exhaust system Hemove your starter Remove your entire primary unit including outer primary primary chain clutch and inner primary Use ToolB 56 Inner Race Service Tool to pull the race off of the mainshaft This needs to be done to remove gearset Loosen and remove the transmission side cover at this time Remove the clutch cable from the side cover The side cover and ball and ramp assembly will not be re used in the BAKER Factory 6 Kicker Barmove THE TRANSMISSION DIPSTICK AT THIS TIME YOU CAN NOT REMOVE THE GEARSET WITH IT INSTALLED Remove the transmission top cover Use your top cover gasket per the Factory Service Manual to act as a pad to rest the shifter pawl on while removing your gearset 1 16 6 pt socket you need to loosen the nylock jam nuts on both the countershaft and Using a 1 mainshaft before you remove the gearset from the case A good trick is to stand with you right foot on the rear brake pedal while trying to loos
14. ur Factory Service Manual using the supplied top cover gasket pn 34917 06 F gt AN CABLE TYPE KICKER COVER INSTALLATION pn 678 M P B R K Refer to your Factory Service Manual to remove your clutch cable from your side cover ball and ramp assembly 1 Place the side cover gasket on the two 10mm dowels pn 16583 00 on the bearing door assembly 2 While making sure the ratchet gear pn 310 56K is still retained by the kicker crank gear place the side cover on to the two 10mm dowels pn 16583 00 While holding the cover in place take the nine supplied 5 16 18 x 1 1 4 SHCS pn 73496 with 5 16 washers pn 6100 and apply blue thread lock to the threads Now torque the fasteners to 13 16 ft Ibs 156 192 in lbs 3 Remove the six fasteners holding the ball and ramp cover on Remove the ball and ramp cover and gasket at this time as well 4 Install the supplied clutch throw out rod at this time through the pinion gear quill 5 Thread your clutch cable into the side cover Loosen the clutch cable adjustment all the way so there is maximum cable exposed in the side cover 6 With the cable fully extended in the side cover take the supplied ball and ramp assembly and slide it over the cable Install the clutch cable ferrule pn 3094 DS SC and seat the cable Install the ball and ramp assembly with outer ramps tab in the 2 o clock position Now place the ball and ramp cover plate with gasket back into position
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